Browse Topic: Fastening

Items (253)

A Combined X-Ray CT and Mechanistic Characterization of Bearing Failure Mechanisms in Bolted Composite Components

F-0077-2021-16897

5/10/2021

ABSTRACT

Fulghum, Ethan, Kariyawasam, Supun, Saathoff, Caleb, Lua, Jim, Cui, Xiaodong, Xiao, Jian

The Innovative Blade Attachment for the new H145 Bearingless Main Rotor

F-0076-2020-16456

10/5/2020

With the market introduction of the EC135 the bearingless main rotor (BMR) as a novel main rotor system was put into series production. Since then a chain of interconnected research programs led to the next generation of BMR. It now enhances the qualities of the H145 regarding the aspects of useful load, comfort of ride, purchase and maintenance cost as well as operational features. The design targets definition and their implementation by innovative solutions are summarized hereafter. The focus is put on the modular design of the main rotor system which is realized by an integrated flexbeam and control cuff assembly and a separate rotor blade joined together by a bolted connection using flat laminate lay-up instead of fiber loops. A detailed view is given on the development of the novel blade attachment from design considerations and manufacturing aspects over parametric subcomponent tests to full scale testing.

Emmerling, Stefan, Kuntze-Fechner, Gerald, Wedekind, Max

ARP5481A (Current)9/17/2020

This SAE Aerospace Recommended Practice (ARP) provides the recommended procedure for obtaining desired preloads in aircraft wheel tie bolts when mounting tires and assembling the wheel. It is generally referred to as the snug-angle bolted joint assembly procedure. It is also known as the “torque-turn” procedure in the heavy equipment ground vehicle industry.

A-5A Wheels, Brakes and Skid Controls Committee

A Communication-Free Human-Robot-Collaboration Approach for Aircraft Riveting Process Using AI Probabilistic Planning

2020-01-00133/10/2020

In large scale industries attempts are continuously being made to automate assembly processes to not only increase productivity but also alleviate non-ergonomic tasks. However this is not always technologically possible due to specific joining challenges and the high number of special-purpose parts. For the riveting process, for example, semi-automated approaches represent an alternative to optimizing aircraft assembly and to reduce the exposure of workers to non-ergonomic conditions entailed by performing repetitive tasks. In [1], a semi-automated solution is proposed for the riveting process of assembling the section barrel of the aft section to its pressure bulkhead. The method introduced a dynamic task sharing strategy between human and robot that implements interaction possibilities to establish a communication between a human and a robot in Human-Robot-collaboration fashion. Although intuitive, interacting with the robot constantly is still not natural for the worker as in the manual process no explicit communication between both workers is needed. In this work a communication-free Human-Robot-collaboration solution is presented. The method developed not only enables sharing assembly missions by dividing tasks based on skills, but also offers the possibility of decision making to the robot. In this context, off-the-shelf Artificial Intelligence planning tools are used to model the work-flow of the human as well as the task of the robot handling alongside possible uncertainties yielding while perceiving the environment or the activity of the human.

Rekik, Khansa, Müller, Rainer, Hoffmann, Jörg, Vette, Matthias

In-Process Hole and Fastener Inspection Using a High-Accuracy Laser Sensor

2020-01-00153/10/2020

Electroimpact has produced a new in-process inspection system for use on drilling and fastening systems. The system uses a high-accuracy, non-contact, laser system to measure the flushness of installed fasteners. The system is also capable of measuring part normality and providing feedback to the machine for correction. One drawback to many automatic inspection systems is measurement error. Many sources of measurement error exist in a production environment, including drilling chips, lubrication, and fastener head markings. Electroimpact’s latest system can create a visualization of the measured fastener for the operator to interpret. This allows the operator to determine the cause of a failed measurement, thus reducing machine downtime due to false negatives.

Luker, Zachary, Stansbury, Erin

2019 'Create the Future' Manufacturing/Robotics/Automation Category Winner: The HPCI® Joining Gun

TBMG-3544011/1/2019

Low Cost Reconfigurable Jig Tooling and In-Process Metrology for High Accuracy Prototype Rotorcraft Wing Assembly

2019-01-18779/16/2019

Reconfigurable tooling frames consisting of steel box sections and bolted friction clamps offer an opportunity to replace traditional expensive welded steel tooling. This well publicized reconfigurable reusable jig tooling has been investigated for use in the assembly of a prototype compound helicopter wing. Due to the aircraft configuration, the wing design is pinned at both ends and therefore requires a higher degree of end to end accuracy, over the 4m length, than conventional wings. During the investigation some fundamental issues are approached, including: Potential cost savings and variables which effect the business case. Achievable Jig accuracy. Potential sources of instability that may affect accuracy over time. Repeatability of measurements with various features and methods. Typical jig stability over 24hrs including effects of small temperature fluctuations. Deflections that occur due to loading. The cost benefit of reusable tooling in a low volume prototype scenario is examined followed by the design of the jig and location features to enable the accurate build and certification documentation to be completed. A prototype 4m test jig comprising of commercially available components and bespoke machined ‘pick-ups’ is presented. Hardware and measurement process cost modelling is documented along with results for the positional and center-line concentricity setting accuracy that was achieved using a Leica AT901 laser tracking system. Subsequent measurements over a 24hr period are also discussed along with potential sources of deviation in jig accuracy over time and with an applied load.

Crossley, Richard J., Ratchev, Svetan

Simulation of Aircraft Assembly via ASRP Software

2019-01-18879/16/2019

ASRP (Assembly Simulation of Riveting Process) software is a special tool for assembly process modelling for large scale airframe parts. On the base of variation simulation, ASRP provides a convenient way to analyze, verify and optimize the arrangement of temporary fasteners. During the assembly of airframe certain criteria on residual gap between parts must be fulfilled. The numerical approach implemented in ASRP allows to evaluate the quality of contact on every stage of assembly process and solve verification and optimization problems for temporary fastener patterns. The paper is devoted to description of several specialized approaches that combine statistical analysis of measured data and numerical simulation using high-performance computing for optimization of fastener patterns, calculation of forces in fasteners needed to close initial gaps, and identification of hazardous areas in junction regions via ASRP software.

Zaitseva, Nadezhda, Pogarskaia, Tatiana, Minevich, Olga, Shinder, Julia, Bonhomme, Elodie

Optimization of Automated Airframe Assembly Process on Example of A350 S19 Splice Joint

2019-01-18829/16/2019

The paper presents the numerical approach to simulation and optimization of A350 S19 splice assembly process. The main goal is to reduce the number of installed temporary fasteners while preventing the gap between parts from opening during drilling stage. The numerical approach includes computation of residual gaps between parts, optimization of fastener pattern and validation of obtained solution on input data generated on the base of available measurements. The problem is solved with ASRP (Assembly Simulation of Riveting Process) software. The described methodology is applied to the optimization of the robotized assembly process for A350 S19 section.

Lupuleac, Sergey, Shinder, Julia, Churilova, Maria, Zaitseva, Nadezhda, Khashba, Valeriia, Bonhomme, Elodie, Montero-Sanjuan, Pedro

New Technologies for Airframe Structural Assemblies

2019-01-19159/16/2019

With air traffic demand constantly increasing and several years of aircraft production in their backlog, major aircraft manufacturers are now shifting their focus toward improving assembly process efficiency. One of the most promising solutions, known as “One Side Assembly”, aims to perform the whole assembly sequence from one side of the structure (drilling, temporary fastener installation and removal, blind fastener installation, assembly control) and with a high level of integrated automation. Investments in robotic equipment, automation engineering and innovation are very active and automation capabilities have already increased a lot in the aerospace industry. As an example, drilling operations for large dimensions airframe are clearly moving from manual to automated. However, despite more and more clever and sophisticated robotics, the use of historical fasteners with two side installation method remains a strong limitation to innovative automated assembly sequences. A blind fastener which can provide the same mechanical characteristics than current structural fasteners, while providing automation friendly features and meeting cost objectives is a real “must have” for assembly process efficiency improvements. It is also full of challenges for aerospace fasteners industry. Many research and development activities are on-going to remove fasteners from the equation of aerospace structure assemblies, but we will consider in this article that fasteners will remain a good solution for many years from now, which is shared by a lot of professionals and which doesn’t mean that nothing will change.

Dahane, Mehdi

Joining Gun Bonds Metal and Plastic in Seconds

TBMG-346126/1/2019

The connection of plastics and metals poses a challenge due to the different physical properties of the two materials. All conventional joining options, such as bonds using adhesives or rivets, have their disadvantages — adhesives need time to harden, which delays further processing, and plastics can be easily damaged during riveting. Furthermore, both adhesive bonding and riveting require additional materials that increase production costs.

High Strength Elevated Temperature Bolting Practice

ARP700C (Current)5/3/2019

This SAE Aerospace Recommended Practice (ARP) provides general information on the design and installation of threaded fasteners in high strength and high temperature applications in propulsion systems. Some of the more common definitions of fastener terminology are also provided.

E-25 General Standards for Aerospace and Propulsion Systems

Axiomatic Design of a Reconfigurable Assembly System for Aircraft Fuselages

2019-01-13593/19/2019

Modern aerospace industry develops assembly process lines for new aircraft which is produced on a single production line while shortening production times by new technologies. Production processes are developed with systems such as lightweight fixtures, reconfigurable tools, automated part positioning, automated scanning countersink control, automated riveting, robotic measurement etc. These systems provide the necessary flexibility for aircraft fuselage and wing assembly projects. Aerospace manufacturers invest in assembly lines in order to increase production rates and meet growing customer demands. Most of the investments are allocated to state-of-the-art robots for drilling and riveting, sealing, coating and painting applications, in addition to material handling, carbon fiber layup and different types of machining operations. In this study, an assembly system design methodology is developed by using axiomatic design principles in order to propose a solution to design complexity for aircraft fuselage structures assembly. Framework of design methodology is shaped based on system design methods, academic research, industry requirements and industrial case studies. Axiomatic design and reconfigurability principles integrated to developed methodology. Holistic and hierarchical design approach is demonstrated. Aircraft fuselage panel assembly case study is carried out for better understanding of how the methodology is applied. It has been shown in the study that the methodology transforms the reconfigurability requirements into a flexible and scalable system. This study can be used as a reference guide to assembly system design not only for aerospace industry but also whole assembly systems in different industry branch.

Celek, Osman Emre, Yurdakul, Mustafa, Ic, Tansel

Automatic Drilling and Fastening System for Large Aircraft Doors

2019-01-13463/19/2019

Electroimpact has developed a system for drilling and fastening of cargo door structures which efficiently addresses many of the manufacturing challenges that such parts present. Challenges to door automation include 1) the presence of an inner skin that must be processed, in addition to the outer skin, and 2) a stiff frame structure, which makes the clamping and drilling processes that are typical to automated fastening machines very unforgiving of any errors in workpiece positioning. In this case, the manufacturing cell was to be installed in an existing facility with very limited ceiling height, further complicating the system and process design. New methods were devised to solve these problems, and the solutions found will likely have utility in future applications.

Bigoney, Burton

Improved Briles Rivet Forming Using High-Speed Force Feedback and Improved Die Geometry

2019-01-13773/19/2019

Electroimpact and Kawasaki Heavy Industries (KHI) have produced a new riveting process for the forming of Briles type rivets in Boeing 777 and 777X fuselage assemblies. The Briles rivet is typically used for fuselage assembly and is unique in that it has a self-sealing head. Unlike conventional headed rivets such as the NAS1079, this fastener does not require aircraft sealant under the head to be fluid tight. This unique fastener makes for a difficult fastening process due to the fact that interference must be maintained between the hole and fastener shank, as well as along the sides of the fastener head. Common issues with the formed fasteners include gapping under the fastener head and along the shank of the fastener. Electroimpact has employed a host of different technologies to combat these issues with Briles fastening. First, Electroimpact’s patented “Air Gap” system allows the machine to confirm that the head of the rivet is fully seated in the countersink prior to forming. If the fastener head is not seated prior to forming then there is no chance of reliable formed fastener quality. Second, Fanuc pressure control is used to control the forming process. Pressure control allows the machine to form the fastener, following a “force path” using a load cell as the feedback device. Third, specialized upper die geometry was developed to improve fastener head seating during fastening. By changing the pressure profile on the head, these dies help to eliminate gapping under the fastener head.

Stansbury, Erin C., Yano, Fuminori, Haworth, Paul

Flexible All Electric Riveter

2019-01-13333/19/2019

A new style of all electric riveting machine has been developed with saddle hoppers that does not require a track between the hoppers and the fingers. This enables feeding square rivets without difficulty. The upper ram has a bent knee which allows the rivet fingers to be brought up to the hopper and rotated 30 degrees rather than the rivet sliding down a track, which minimizes jamming that occurs with some fasteners in the track, and increases reliability. A mixture of fasteners can be loaded side by side in the hoppers, increasing flexibility. The rivet feeding is accomplished by bringing the rivet fingers to the hopper. The machine uses a power drawbar to change out different rivet fingers. A small industrial robot is incorporated into the machine to complete different sized coupons and also complete small assemblies. In larger machines larger robots or CNC positioners can be used to scale up the use of the machine.

Zieve, Peter B.

A High Reliable Automated Percussive Riveting System for Aircraft Assembly

2019-01-13353/19/2019

Percussive riveting is a widely used way of fastening in the field of aircraft assembly, which used to be done manually. Nowadays, replacing the traditional percussive riveting with automated percussive riveting becomes a trend worldwide, which improves the quality of riveting significantly. For the automated riveting system used in aircraft assembly, reliability is of great importance, deserving to be deeply researched and fully enhanced. In this paper, a high reliable automated percussive riveting system integrated into a dual robot drilling and riveting system is proposed. The riveting system consists of the hammer part and the bucking bar part. And both parts have been optimized to enhance the reliability. In the hammer side, proximity switches are fully used to detect the state of rivet insertion. In the bucking bar side, a reliable step height measurement system is integrated to measure the exposed shank length of the rivet before riveting and the upsetting head height after riveting. Meanwhile, a reliable method is proposed to calibrate the measurement system. By measuring the exposed shank length of the rivet before riveting, the riveting system can judge whether the rivet has been inserted into the hole and whether the length specification of the rivet is appropriate. By measuring the upsetting head height after riveting, the riveting system can realize online monitoring of riveting quality. All the above measures enhance the reliability of the riveting system. At last, an experiment is carried out, the result indicates that the automated percussive riveting system can conduct high-quality and reliable riveting.

Fan, Yunfei, Yu, Long, Zhang, Yilian, Bi, Qingzhen, Wang, Yuhan

Collaborative Robotic Fastening Using Stereo Machine Vision

2019-01-13743/19/2019

With typically over 2.3 million parts, attached with over 3 million fasteners, it may be surprising to learn that approximately two out of every three fasteners on a twin aisle aircraft are fastened by hand. In addition the fasteners are often installed in locations designed for strength and not necessarily ergonomics. These facts lead to vast opportunities to automate this tedious and repetitive task. The solution outlined in this paper utilizes the latest machine vision and robotics techniques to solve these unique challenges. Stereo machine vision techniques find the fastener on the interior of an aerospace structure and calculate the 6DOF (Degrees of Freedom) location in less than 500ms. Once the fastener is located, sealed, and inspected for bead width and gaps, a nut or collar is then installed. Force feedback capabilities of a collaborative robot are used to prevent part damage and ensure the nut or collar are properly located on the fastener. This type robot also opens up the possibility of interacting more closely with humans as fastening can be done simultaneously with other manual assembly processes. This paper outlines how automated fastening can be achieved using an end effector weighing less than 14kg by leveraging the capabilities of a collaborative robot and advanced machine vision techniques.

Haldimann, Ryan

Tolerance Management in a Semi-Automated and Collaborative Human-Robot Aircraft Riveting Process

2019-01-13733/19/2019

Large aircraft sizes with high precision requirements combined with complex joining tasks are typical challenges for aircraft production. To increase competitiveness and effectiveness, the automation of such production processes seems a viable solution for companies in the aircraft sector. When implementing automation, in order to handle small batch sizes and high variation while adhering to tight tolerances, the production equipment must meet high quality standards and flexibility requirements. To achieve the objectives above, tolerance management is essential: deviations are acceptable within limits, as long as they do not result in quality losses and expensive rework. For these reasons, all the interactions between the product, production process and production equipment used must be analyzed in detail. The importance of this analysis is evident in assembly where new technologies are used, such as (semi-)automation using Human-Robot-Collaboration. Despite its innovative value, this approach must be robust, within tolerances and have minimal deviations from the outset. However, current planning and optimization of deviations and tolerances lack properly developed methods and approaches. This paper proposes a method for securing and achieving proper tolerance in assembly processes: characteristic trees and tolerance chains are simple methods to make tolerance management more effective and attractive. The method combination promotes understanding of interactions and communication between all those involved in the development of products and the associated processes. The methods developed are validated using a semi-automated riveting process, with Human-Robot-Collaboration, to complete a joining process in the assembly of the aft section. In this scenario the pressure bulkhead is mounted to the section barrel by means of hundreds of rivets. The intention is to implement a semi-automated production process to improve ergonomics, increase process traceability and efficiency, and minimize rework while meeting tolerance requirements.

Mueller, Rainer, Vette-Steinkamp, Matthias, Schirmer, Leonie, Masiak, Tobias

Collaboration in a Hybrid Team of Human and Robot for Improving Working Conditions in an Aircraft Riveting Process

2019-01-13723/19/2019

Aircraft production is facing various technical challenges, such as large product dimensions, complex joining processes, and organization of assembly tasks. Overcoming such challenges, as well as maintaining low tolerances and small batch sizes, is often difficult to achieve whilst retaining economic viability. ZeMA believes that a semi-automated approach is the most effective way to optimize aircraft section assembly. This can be achieved with a semi-automated riveting process for solid rivets, using Human-Robot-Collaboration in combination with an intuitive Human-Machine-Interaction operating concept. In the assembly of aircraft structures - in this scenario the aircraft aft section - the pressure bulk head is mounted to the section barrel. Two operators work collaboratively in uncomfortable, non-ergonomic positions, yet of course have to maintain exacting quality standards. In order to improve this process, a dynamic task sharing strategy between human and robot according to their respective skills, with due consideration given to ergonomic factors is proposed. The ideal solution involves placing a robot inside the section barrel. The robot’s workspace is expanded by mounting it on top of a lifting unit so that it can position the anvil properly. In the meantime, the human performs the more complex tasks of inserting the solid rivets and operating the riveting hammer from outside the section barrel. In order to carry out the assembly tasks efficiently, the following components must be implemented: Human-Robot-Collaboration based on natural and intuitive interaction possibilities, and smart mixed reality devices for communication between human and robot in the hybrid team. By implementing a modular control system for configuration and operation of the assembly station with a variety of interaction possibilities, human and robot can perform the collaborative riveting process more efficiently than human operators alone. Additionally, due to the high forces and vibrations applied by the riveting hammer, a process-specific tool has been developed to prevent damage to the robot system. The implementation of natural and intuitive interaction within the Human-Robot-Collaboration achieves operator acceptance, improves ergonomics and therefore effectively optimizes aircraft production. The results are part of the European Union’s Horizon 2020 research and innovation program, and present semi-automation as shown in the HRC riveting process.

Mueller, Rainer, Vette-Steinkamp, Matthias, Kanso, Ali, Masiak, Tobias

High Strength Elevated Temperature Bolting Practice

ARP700B (Historical)8/23/2018

E-25 General Standards for Aerospace and Propulsion Systems

Enabling Lower Cost Assembly using Hybrid Additive Manufacturing

F-0074-2018-12808

5/14/2018

ABSTRACT Any power-driven transportation vehicle is a complex system, composed of numerous assemblies, sub-assemblies and components encompassing various mechanical, structural, electrical and computer systems for its operation. Depending on the mode of transportation, be it land vehicles, sea vessels, aircraft or spacecraft, each application has its own set of challenges in its development and production. The need for improved part performance along with reduced manufacturing cost is a driver for technological innovations in both design and manufacturing processes. This paper focuses on an innovative way of achieving cost and performance improvements for structural assemblies using Additive Manufacturing (AM) in a hybrid approach. The hybrid AM process discussed in this paper is a combination of AM with existing manufacturing processes in the fabrication of a single part or assembly. The discussion of this approach will be in the context of engine components and a variety of fastening applications within rotary aircraft.

Rizza, Gregory, Kamal, Manish

Advanced Techniques For The Fabrication Of Airframe Structures Using Innovative Friction Stir Welding (FSW) Technology

F-0074-2018-12804

5/14/2018

ABSTRACT One of the alternative method for welding method is a friction stir welding (FSW), which was developed in 1991 at TWI (The Welding Institute) in the United Kingdom, initially especially for joining aluminum and its alloys [1]. This process consists in joining of materials in solid state, which eliminates the problems resulting from melting the material and its re-solidifying, such as, hot cracking, residual stresses and distortion created during conventional welding. In this process, the heat which plasticized the material is provided by rotating tool consisting of shoulder and pin. This tool penetrates into the base material and then moves along the welding line. As a result of the friction between tool and joining materials is generated a sufficient amount of heat allowing on mixed the base material and create FSW joint. Among the most important advantages of using the FSW method should be listed: relatively easy automatization (it is often possible to use conventional CNC machine), lower residual stresses in the welded joints and their very good mechanical properties (often exceed the mechanical properties of welded or riveted joints). Project FAST_FSW (Advanced techniques for the Fabrication of Airframe STructures using innovative friction stir welding (FSW) technology) is realized within consortium between PZL Mielec and research partner Czestochowa University of Technology. The main objective of the FAST_FSW Project is to develop friction stir welding technology to aircraft design and manufacturing for introduce fasteners free, lighter weight and lower cost aerostructures.

Luty, Grzegorz, Wronska, Agata, Andres, Jacek, Galaczynski, Tomasz

Influence of the Friction Coefficient in Self-Pierce Riveting Simulations: A Statistical Analysis

05-11-02-00135/8/2018

In this work, optimal modeling parameters for self-pierce riveting (SPR) were determined using a factorial design of experiments (DOE). In particular, we show statistically how each of the calibrating parameters used in modeling the SPR process through nonlinear finite element modeling can drastically change the geometry of the joint. The results of this study indicate that the degree of interlock, which is a key feature of a sound joint, is largely influenced by the friction between the die and bottom sheet as well as the friction between the rivet and top sheet. Furthermore, this numerical study also helped elucidate the role of friction in SPR and sheds light on how coatings with diverse friction coefficients can affect material deformation and ultimately structural integrity of the joint.

Moraes, J.F.C., Jordon, J.B.

Residual Stresses and Plastic Deformation in Self-Pierce Riveting of Dissimilar Aluminum-to-Magnesium Alloys

05-11-02-00155/8/2018

In this work, the complex relationship between deformation history and residual stresses in a magnesium-to-aluminum self-pierce riveted (SPR) joint is elucidated using numerical and experimental approaches. Non-linear finite element (FE) simulations incorporating strain rate and temperature effects were performed to model the deformation in the SPR process. In order to accurately capture the deformation, a stress triaxiality-based damage material model was employed to capture the sheet piercing from the rivet. Strong visual comparison between the physical cross-section of the SPR joint and the simulation was achieved. To aid in understanding of the role of deformation in the riveting process and to validate the modeling approach, several experimental measurements were conducted. To quantify the plastic deformation from the piercing of the rivet, micro hardness mapping was performed on a cross-section of the SPR joint. The FE model showed very strong correlation to the experimental hardness mapping results suggesting the nonlinear model captured the plastic deformation with high accuracy. To measure the elastic residual stresses in the SPR joint, neutron and x-ray diffraction mapping techniques were conducted and in general, the FE model correlated well to the trends and magnitudes of the elastic stresses. While some error occurred in between the model and the neutron and x-ray diffraction results, the numerical approach developed in this study shows potential as a tool for understanding SPR behavior as well as optimizing the process parameters.

Moraes, J.F.C., Jordon, J.B., Brewer, Luke N., Fay, Brian J., Bunn, J.R., Sochalski-Kolbus, Lindsay

Improving Working Conditions in Aircraft Productions using Human-Robot-Collaboration in a Collaborative Riveting Process

2017-01-20969/19/2017

Assembly processes in aircraft production are difficult to automate due to technical risks. Examples of such technical challenges include small batch sizes and large product dimensions as well as limited work space for complex joining processes and organization of the assembly tasks. A fully automated system can be expensive and requires a large amount of programming knowledge. For these reasons, ZeMA believes a semi-automated approach is the most effective means of success for optimizing aircraft production. Many methods can be considered semi automation, one of which is Human-Robot-Collaboration. ZeMA will use the example of a riveting process to measure the advantages of Human-Robot-Collaboration systems in aircraft structure assembly. In the assembly of the aircraft aft section the pressure bulkhead is mounted with a barrel section using hundreds of rivets. This assembly process is a non-ergonomic and burdensome task in which two humans must work cooperatively. The alleviation of such work can be achieved by using a collaborative scheme between operator and robot system. This approach uses dynamic task sharing between the operator and robot based on their skills and the process requirements. This is demonstrated by placing a robot inside section 19 on top of a lifting unit to position the counter holder while the human does the more complex task of inserting the rivet and operating the rivet tool. Using dynamic task sharing and an intuitive control system, ZeMA aims to assist the operator with a collaborative robot and assistance system to improve the manufacturing quality as well as ergonomics for the human during the overhead riveting process. The results are part of the European Union's Horizon 2020 research and innovation program at ZeMA and will present needs-based automation shown in the HRC riveting process.

Mueller, Rainer, Vette, Matthias, Geenen, Aaron, Masiak, Tobias

777X Control Surface Assembly Using Advanced Robotic Automation

2017-01-20929/19/2017

Fabrication and assembly of the majority of control surfaces for Boeing’s 777X airplane is completed at the Boeing Defense, Space and Security (BDS) site in St. Louis, Missouri. The former 777 airplane has been revamped to compete with affordability goals and contentious markets requiring cost-effective production technologies with high maturity and reliability. With tens of thousands of fasteners per shipset, the tasks of drilling, countersinking, hole inspection, and temporary fastener installation are automated. Additionally and wherever possible, blueprint fasteners are automatically installed. Initial production is supported by four (4) Electroimpact robotic systems embedded into a pulse-line production system requiring strategic processing and safeguarding solutions to manage several key layout, build and product flow constraints. Commonality amongst the robots was desired to allow each to effectively address any of the commodities which range from small fairings to very large empennage and leading edge assemblies that required the automation to work its way around from the upper to lower surface. Multi-function end effectors enable processes to be completed in one pass from initial hole preparation to installed fastener. Advanced safety systems are utilized which include programmable laser scanners on the robots and tooling that are automatically configured based on the present tooling. Operator access and part flow through the cell are paramount, driving the design of a flush floor rail system and the ability to operate robots in dual zones, further driving the requirement for flexible cell processing and safeguarding techniques.

Mir, Ryan, DeVlieg, Russell

Fully Automated Off-Line Cartridge Filling Station

2017-01-21009/19/2017

A fully automated off-line cartridge filling station has been commissioned to support the new Boeing SAL production cell. The filing station uses automated fastener feed technology that is typically found on the machines themselves. Incorporating this technology off-line in place of the traditional manual handling processes extends the benefits of automation beyond the main manufacturing cell. A single operator is able to keep up with the demand of eight production fastening machines while maintaining the highest levels of accuracy and quality. Additional benefits to this application of automation include reduction of the operators exposure to risks associated with manual handling and repetitive tasks.

Boad, Carter L.

EMR with High Reliability for Retrofit of E4100 Riveting Gantry Machines

2017-01-20999/19/2017

Electroimpact has retrofitted two E4100 riveting gantry machines and two more are in process. These machines use the EMR (Electromagnetic Riveter) riveting process for the installation of slug rivets. We have improved the skin side EMR to provide fast and reliable results: reliability improved by eliminating a weekly shutdown of the machine. In paper 2015-01-2515 we showed the slug rivet injector using a Synchronized Parallel Gripper that provides good results over multiple rivet diameters. This injector is mounted to the skin side EMR so that the rivet injection can be done at any position of the shuttle table. The EMR is a challenging application for the fingers due to shock and vibration. In previous designs, fingers would occasionally be thrown out of the slots. To provide reliable results we redesigned the fingers retainer to capture the finger in a slotted plastic block which slides along the outside diameter of the driver bearing. The various size fingers are pinned to the block in such a fashion as to allow rotation and clamping on the rivet. The clamping action is provided by opposing wave springs. The design of the fingers and clamping unit are shown in detail. This improvement in the injector (already reported), combined with an improved finger design, has provided unprecedented reliability and rivet rate.

Zieve, Peter B., Gray, Troy, Wright, Christopher

Power RACe

2017-01-20939/19/2017

Ever increasing process applications inspire us, as suppliers of aircraft, structural-assembly, and equipment to design innovative and modular, manufacturing cells in compliance with modern specification. The result is the new highly flexible Aerospace application specific robot identified as “POWER RACe”. This paper describes how benchmarks for flexible automated drilling and fastening are being achieved with the Power RACe technology platform.

Dillhoefer, Thorsten

Combination of Experimental and Computational Approaches to A320 Wing Assembly

2017-01-20859/19/2017

The paper is devoted to the simulation of A320 wing assembly on the base of numerical experiments carried out with the help of ASRP software. The main goal is to find fasteners’ configuration with minimal number of fastening elements that provides closing of admissible initial gaps. However, for considered junction type initial gap field is not known a priori though it should be provided as input data for computations. In order to resolve this problem the methodology of random initial gap generation based on available results of gap measurements is developed along with algorithms for optimization of fasteners' configuration on generated initial gaps. Presented paper illustrates how this methodology allows optimizing assembly process for A320 wing.

Lupuleac, Sergey, Zaitseva, Nadezhda, Petukhova, Margarita, Shinder, Julia, Berezin, Sergey, Khashba, Valeriia, Bonhomme, Elodie

Automatic Tool Change System for Stringer Side Rivet and Bolt Anvils on a D-Frame or C-Frame Fuselage Fastening Machine

2017-01-20809/19/2017

Manually changing stringer-side tooling on an automatic fastening machine is time consuming and can be susceptible to human error. Stringer-side tools can also be physically difficult to manage because of their weight, negatively impacting the experience and safety of the machine operator. A solution to these problems has recently been developed by Electroimpact for use with its new Fuselage Skin Splice Fastening Machine. The Automatic Tool Changer makes use of a mechanically passive gripper system capable of securely holding and maneuvering twelve tools weighing 40 pounds each inside of a space-saving enclosure. The Automatic Tool Changer is mounted directly to the stringer side fastening head, meaning the machine is capable of changing tools relatively quickly while maintaining its position on the aircraft panel with no machine operator involvement. Additionally, since the tools are all contained within an interlocked enclosure, this system reduces the required frequency of tool recalibration which also saves time and increases productivity. Other features of this system include machine crash protection, tool interface automatic blow off, and tool RFID.

Merluzzi, James, Bahr, Isaac

Automated Riveting of C-130J Aft Fuselage Panels

2017-01-20759/19/2017

Electroimpact and Lockheed Martin have developed an automated drilling and fastening system for C-130J aft fuselage panels. Numerous design and manufacturing challenges were addressed to incorporate the system into Lockheed Martin’s existing manufacturing paradigm and to adapt Electroimpact’s existing line of riveting machines for manufacture of these legacy aircraft parts. Challenges to automation included design of a very long yet sufficiently rigid and lightweight offset riveting anvil for fastening around deep circumferential frames, automated feeding of very short, “square” rivets in which the length is similar to the head diameter, creation of part programs and simulation models for legacy parts with no existing 3d manufacturing data, and crash protection for the aircraft part from machine collisions, given the uncertainties inherent in the model and the unique geometry of the aircraft parts. Additional challenges were overcome in integrating the system into Lockheed Martin’s existing manufacturing methodology, while avoiding disruption to ongoing production activity and delivery schedules. Innovative and novel solutions to all of these problems were found and implemented. The result is successful automation of the drilling and riveting work on the aft fuselage, with corresponding improvements in manufacturing quality and production cost, and development of new technology that will have application in future automation systems.

Bigoney, Burton, Huddleston, Nicholas

CPAC Bulkhead Riveting System

2017-01-20749/19/2017

Ever increasing process applications inspire us, as suppliers of aircraft, structural-assembly, and equipment to design innovative and modular, manufacturing cells in compliance with modern specifications. The result is the new flexible C-Frame Panel Assembly Cell (CPAC) Bulkhead riveting System. This paper describes how benchmarks for flexible automated drilling and fastening are being achieved with the CPAC.

Dillhoefer, Thorsten, Erdinc, Fatih

Development of Axial Force Testing System for Wheel Bearing

2017-01-25229/17/2017

The actual installed conditions of 1st, 2nd and 3rd generation of wheel bearing were introduced. The theoretical factors of the axial fastening force for the axle (or CVJ bolts) and nuts were analyzed and the requirements for building up a precise axial force test system were given out. Four testing plans were discussed for the requirements. Based on the cases, the axial force test system was built up, and the axial force test was successfully carried out for the front wheel bearing of a car.

Wen, Chao, Zhang, Lu, Luo, Tong, Huang, Dejie, Liu, Yu

Drilling Material Stacks: Can it be both automated and affordable?

SN-00016/26/2017

Automating a manufacturing process often comes with substantial investment or sustained operational costs of complex subsystems. But, by reducing complexity and using technologically mature components, it is possible to develop viable scaled and robust automated solutions. For the past several years, aerospace manufacturers have endeavored to automate manufacturing processes as much as possible for both production efficiencies and competitive advantage. Automating processes like drilling, fastening, sealing, painting, and composite material production have reaped a wide range of benefits; from improving quality and productivity to lowering worker ergonomic risks. The results have improved supply chains from small component manufacturers all the way up to airframe assemblers. That said, automation can be very expensive, and difficult to introduce when a product is anywhere beyond the beginning of its life cycle. In this Solution Notes, engineers address those two challenges with a mix of off-the-shelf systems and specially developed SCADA for a low-cost automatic system that can accurately drill aluminum stacks.

Reliability Analysis of a Rotorcraft Transmission Bolted Connection

F-0073-2017-12155

5/9/2017

ABSTRACT Reliability analysis of a rotorcraft transmission bolted connection using actual service records data is the focus of this paper. The analysis is conducted for two different bolt materials used in the gearbox to evaluate the difference in reliability. As part of a continued operational safety bolt preload assurance check, the bolted connection between the spiral bevel ring gear and first stage sun gear undergoes a periodic field inspection: the inspection is said to have failed if the application of a prescribed torque to the nut causes the entire bolt assembly to spin. Reliability analysis employs a two-parameter Weibull probability density function to model the life of the bolted connection, with parameters derived using the Maximum Likelihood Estimator method. Results for each bolt type are discussed and an observation is made as one possible explanation for disparity in reliability levels for the two different bolt materials which is supported by direct measurement of bolt tension at initial assembly. As a result of the findings in this paper, recommendations for future work, including modification of the bolted connection assembly procedure, is discussed.

R., James, Rodriquez, Steven, Pilkington, Lawrence