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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.

Previous work has greatly reduced this error through the use of secondary scales and a mathematical model of the robot deflection running on a CNC controller. Further research improved upon this model by accounting for linear deformation of each robot link regardless of position.

Very large multi-axis CNC machines offer a special challenge for efficient and accurate machine compensation. Aerospace applications demand tight tolerances, but conventional compensation methods become expensive for large machines.

The machine was originally commissioned with a Terra five axis CNC control. The Terra company went out of business and the controls were replaced with a custom DOS application in 1990. ...Electroimpact proposed to retrofit with a Fanuc 31I CNC, and in addition, to replace all associated sensors, cables and feedback systems. This work is now complete on two of the four machines. ...Both left front and right front are in production with the new CNC control.

Each of the 7 axes is enhanced with secondary position encoders and the entire system is controlled by a Siemens 840Dsl CNC. The CNC handles all process functions, robot motion, and executes software technologies developed for superior dynamic positional accuracy, including enhanced kinematics.

It is often the case that while a CNC is used for positioning control, another secondary controller is used to perform the fastener upset. ...In the new process, it has been possible to combine the control of the upset process with the machine CNC, thus eliminating any separate controllers. The fastener upset force profile is controlled throughout the forming of the rivet by using a closed loop force control system that has a load cell mounted directly behind the stringer side forming tool.

With the addition of secondary feedback, high-order kinematic model, and a fully integrated conventional CNC control, robotic technology can now compete on a performance level with customized high precision motion platforms.

A custom CNC interface simplifies machine operations and troubleshooting. Four servo-driven, air-cooled spindles allow high rate drilling through titanium and aluminum.

A short list of the changes made to the machine includes a new CNC, new motors, scales, spindles, and new technologies such as laser tracers and normality sensors.

The predominantly auto-generated programs are executed on a single Siemens CNC that controls two Electroimpact-enhanced Kuka 6 axis robots. This paper documents the system design including the specification, applicable technologies, descriptions of system components, and the comprehensive system integration.

To accomplish this a CNC controlled electromagnetic interface was developed, capable of pulling with 0-3400 pounds. This electromagnetic safety base releases when impact occurs from the sides or during downward motion (5 sided crash protection), and it retains all riveting and bolting functionality.

In larger machines larger robots or CNC positioners can be used to scale up the use of the machine.

The system is controlled by a Siemens 840Dsl CNC which handles all process functions, robot motion, and executes software technologies developed by Electroimpact for superior positional accuracy including enhanced kinematics utilizing a high-order kinematic model.

Integrated wing major assembly cell with manual assembly jigs and large CNC wing drilling machines. Twenty-three other manual work stations. New technology developments implemented include: A new high-curvature nosepiece on the robot end effecter to enable accurate drilling and countersinking on the LE Spar D-Nose section.