Fluid flow systems often require orifices to control pressure drop or flow rate. These orifices are often retained in bolted housings that require seals and introduce potential leak points into the system.

Processing CSeries Aircraft Panels

2013-01-214909/17/2013

Bombardier faced new manufacturing process challenges drilling and fastening CSeries* aircraft panels with multi-material stacks of composite (CFRP), titanium and aluminum in which Gemcor responded with a unique, flexible CNC Drivmatic® automatic fastening system, now in production at Bombardier. This joint technical paper is presented by Bombardier, expounding on manufacturing process challenges with the C Series aircraft design requirements and Gemcor presenting a unique solution to automatically fasten CFRP aft fuselage panels and aluminum lithium (Al Li) cockpit panels with the same CNC Drivmatic® system. After installation and preliminary acceptance at Bombardier, the CNC system was further enhanced to automatically fasten the carbon fiber pressure bulkhead dome assembly.

Barton, Eric, Rummell, Thomas, Grenier, Daniel

E7000 High-Speed CNC Fuselage Riveting Cell

2013-01-215009/17/2013

Electroimpact has recently produced a high-speed fuselage panel fastening machine which utilizes an all-electric, CNC-controlled squeeze process for rivet upset and bolt insertion. The machine is designed to fasten skin panels to stringers, shear ties, and other internal fuselage components. A high riveting rate of 15 rivets per minute was achieved on the first-generation E7000 machine. This rate includes drilling, insertion, and upset of headed fuselage rivets. The rivets are inserted by a roller screw-driven upper actuator, with rivet upset performed by a lower actuator driven by a high-load-capacity ball screw. The rivet upset process can be controlled using either position- or load-based feedback. The E7000 machine incorporates a number of systems to increase panel processing speed, improve final product quality, and minimize operator intervention. The upper riveting head includes automatic tool changers for drills and upper anvils, both designed with very fast tool changes as a

Stansbury, Erin C., Bigoney, Burton, Allen, Reese

Body Join Drilling for One-Up-Assembly

2013-01-229609/17/2013

Over 1,200 large diameter holes must be drilled into the side-of-body join on a Boeing commercial aircraft's fuselage. The material stack-ups are multiple layers of primarily titanium and CFRP. Due to assembly constraints, the holes must be drilled for one-up-assembly (no disassembly for deburr). In order to improve productivity, reduce manual drilling processes and improve first-time hole quality, Boeing set out to automate the drilling process in their Side-of-Body join cell. Implementing an automated solution into existing assembly lines was complicated by the location of the target area, which is over 15 feet (4 meters) above the factory floor. The Side-of-Body Drilling machines (Figure 1) are capable of locating, drilling, measuring and fastening holes with less than 14 seconds devoted to non-drilling operations. Drilling capabilities provided for holes up to ¾″ in diameter through stacks over 4.5″ thick in a titanium/CFRP environment. Using high precision servo control, each

Assadi, Michael, Martin, Christopher, Siegel, Eliot, Mathis, Dennis

Guide for Rivet Selection and Design Consideration

J492_201304 (Historical)04/16/2013

Fasteners Committee

LED Chains

TBMG-1609203/01/2013

Universal’s (Nashville, TN) new family of Signa® LED chains makes it simple to design signage with high lumens, consistent color, superior reliability, and an installer-friendly module fastening system. Offering high-efficiency 80- and 100-lumens-perfoot options, these new LED chains allow you to maximize the number of feet of letter channeling per single 60W power supply while still providing high lumen performance. Universal also offers 60W 12-volt Class 2 LED drivers to power these LEDs in a variety of applications. The RoHS-compliant LED chain also features a wide operation temperature range of -40°C to +60°C.

Aerospace Engineering 2012-12-12

12AERD121212/12/2012

Joining metal/composite structures The interference-fit bolted joining of hybrid metal/composite can greatly improve the fatigue life of such joints, according to Chinese researchers.

Fastener Inserts

TBMG-1491610/01/2012

Ongoing efforts to increase fuel efficiency, tactical mobility, and payload capacity in aerospace design have driven engineers to find numerous ways to reduce mass through the extensive use of lightweight materials such as composites, aluminum, and plastics. Use of these lightweight materials can create other issues, however, such as finding safe and reliable ways to fasten assemblies that provide complete assurance of joint integrity under the severe conditions of shock, vibration and thermal cycling common in aerospace applications.

Measurement Method for Evaluating Normal Direction of Surface for Digital Drilling and Riveting

2012-01-186009/10/2012

A method of noncontact laser distance measurement is proposed for the digital drilling and riveting of complex surface. By means of measurement resulting from locating devices, the normal direction of measured region on curved surface is evaluated. The posture of end-effector fixed on the end of industrial robot is adjusted to feed along the evaluated normal direction. The datum plane for calibration is derived using the least square plane fitting method. The position and posture of locating devices are calibrated on the basis of the distances between locating devices and datum plane. The normal direction of measured area is derived from the distances measured by locating devices. A numerical example illustrates the correctness of the proposed method. The method can be used for positioning and attitude-adjusting for digital manufacturing and assembly.

DU, ZhaoCai, YAO, Yanbin

Thermoplastic Reflector Design for Robust Optical Performance

2012-01-026604/16/2012

A headlamp reflector has many performance requirements. Principal among these is the need to deliver a compliant beam pattern while withstanding a severe heat environment. In serving this requirement, the reflector must reliably secure the light source (bulb filament) relative to the optical prescription (facets) of the reflector. Traditionally, achieving this performance requirement has been challenging since the reflector elements which are designed to deliver stable and reliable optical performance, are the same elements which must also withstand thermal stresses and adjustment-related static stresses within the reflector. The integrity of these optical elements may also be limited by surface sink, especially in the bulb fastening and attachment locations. The current work describes the design of a reflector bracket through which these forces can be minimized and accommodated while delivering robust optical performance. Improved Optical performance of the reflector is presented by

Tankala, Triloka, TK, Poovanna, p, Arunachala, Bloomfield, Russell, Wilson, James

Bosses-Good & Bad

1069611/18/2011

Protolabs shows you what makes a good or a bad boss on injection molded products.

Flexible LED Assembly for Automotive Signal Lighting

TBMG-1428311/01/2011

A build-out-of-the-box approach to turn, tail, and stop lighting applications on vehicles significantly reduces engineering and development costs. With recent improvements to Snap LED, an automotive LED assembly, the need for retesting and screening is removed, which can save users on operational costs, reduce equipment and manpower needs, speed production, and improve finished goods yields. The LED assemblies can be shaped to any contour, allowing users to create more innovative and streamlined designs. SnapLED's solder-less clinch fastening technology is a formable metal substrate designed for ease of design and installation.

Technical Improvements to the ASAT2 Boeing 777 Spar Assembly Cell

2011-01-270710/18/2011

Electroimpact and Boeing are improving the efficiency and reliability of the Boeing 777 spar assembly process. In 1992, the Boeing 777 spar shop installed Giddings and Lewis spar machines with Electroimpact Inc. EMR(1) (Electromagnetic Riveting) technology. In 2011, Electroimpact Inc. began replacing the original spar machines with next generation assembly machines. The new carriages incorporate a number of technical improvements and advancements over the current system. These technical advancements have facilitated a 50% increase in average cycle rate, as well as improvements to overall process efficiency, reliability and maintainability. Boeing and Electroimpact have focused on several key technology areas as opportunities for significant technical improvements.

Hogan, Scott, Haworth, Paul, Rediger, Jason, Wilkes, Richard

Automated Coaxial Squeeze Riveter

2011-01-277410/18/2011

Electroimpact has developed a new automated squeeze riveting process. This process utilizes an innovative coaxial riveting head design in which the drill spindle and rivet driver share a common servo axis, with a simple toggle mechanism to switch which tool is active. This system has been optimized for the installation of headed solid rivets which can be automatically installed without the need for additional process tools beyond the drill and driver. By optimizing for the requirements of these rivets, Electroimpact has been able to eliminate much of the complexity typically seen on automated fastening equipment, resulting in an unprecedentedly simple and cost-effective design.

Allen, Reese

Pulse Motion Line

2011-01-260910/18/2011

The demand of fulfilling the continually increasing customer requirements forces suppliers to always improve their system solutions to be state of the art. The discussed Pulse Motion Assembly Line for complex 160° Aircraft Structures features the combined drilling and fastener installation in 160° closed complex aircraft structures and in parallel, the use of robots and workers in different cells. The equipment described herein fulfills high precision manufacturing under economic constraints using state-of-the-art accuracy improving realignment methods for robotics. The system provides ultimate flexibility to handle different aircraft panels and types. The paper is intended to describe and focus on the main aspects of the state-of-the-art technology in automated fastening and drilling process to meet the important customer production criteria. Furthermore, it shall explain the integration by presenting the process with a current example in production.

Neugebauer, Lutz

Grommet Hole Reinforcement and Lightning Strike Protection in Composite Structural Assembly

2011-01-261010/18/2011

Aircraft design and assembly challenges include provision of hole protection from lightning strike in fastened joints, especially in the vicinity of fuel tanks or electrical services. Installation of interference fit fasteners helps minimize the effect of lightning strike and also enhances the durability and load transfer ability of the joint. However, these are known to cause laminate damage during installation which can degrade the fastener system performance. Use of a pre-installed expanded grommet into the hole prior to installing interference fit fasteners has been shown to greatly enhance the effectiveness of the joint as well as the conductivity of electrical current into the structure to minimize arcing or plasma discharge at the fastener in the event of lightning strike. The Fatigue Technology (FTI) GromEx® system provides such hole protection for fastener installations into composites, allowing for the installation of interference fit fasteners without detrimental impact to

Reid, Len, Ransom, Joy, Wehrmeister, Mark

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