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The multiple axis flexible CNC riveting cell consists of three major systems: a multi-axis part positioner, a multiple head drill and rivet machine and a multi-bowl rivet feed system. ...The multiple axis flexible CNC riveting cell consists of three major systems: a multi-axis part positioner, a multiple head drill and rivet machine and a multi-bowl rivet feed system. The CNC positioner has six axis of control; the five common axis of X, Y, Z, Alpha, and Beta plus tool position on the lower ram.

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. ...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.

Computer numerical control (CNC) robotic machining has demonstrated the capability to manufacture large, unique shapes, which are utilized for fabrication of industrial molds and tooling for composite parts. .... × 9.5 ft.) can be machined from low-density materials by 7-axis CNC robots operating from parallel tracks. This capability demonstrated that rapid prototyping is possible via both limited production and full production tooling/molds being machined from surface and/or solid computer models. ...By employing large CNC robots, tooling for the identical design developed and tested in the computer, may be manufactured with a very high degree of accuracy.

The assembly work has been accomplished using Gemcor CNC Drivmatic systems. These systems have performed reliably since their initial installation in the late 1960's, but have recently begun to show their age.

Each line consists of three fully automated CNC controlled flexible fixtures placed end to end serviced by two E4100 CNC assemble machines.

Improvements in CNC controlled machines, called Positioners, and tooling, called End Effectors, have enabled the assembly process to pass from, two people, to robots working on opposite sides of a panel. ...Working in a cell where a Cell Controller interfaces with the Positioner’s CNC and the Rivet Feed System’s PLC, and a Host computer interfaces with design computers containing CADICAM data, the APAC System, Automated Panel Assembly Cell, becomes a flexible, low cost solution for the assembly of virtually all components for assembly.

Machining and turning centers take center stage Makers of CNC machining equipment are incorporating more and better functionality into their products so users cope better with processing challenges such as those posed by tough new grades of aerospace materials.

The Flexible Lateral Seam Riveting system (FLSR) proposed by Gemcor will be able to automatically, under CNC and tracer control, rivet both lateral and radial joints without the use of dedicated and fixed machine track systems.

There have been attempts to automatically move the panels, skins and bulkheads using CNC equipment. There have been other attempts to move the riveting head itself; however the basic premise has been a two sided fastener.

The aero structure sourced to Center Industries has tight manufacturing tolerances & quality requirements without room for error or scrap whereby Drivmatic® fastening with CNC positioning and offline part programming was the feasible approach. The CNC automatic riveting and part programming technology detailed in this paper provided a technical solution to meet the challenges Center Industries faced as a new supplier for aircraft panel assemblies. ...The automation technology integrated for the skin to stringer & skin to window frame fastening were two GEMCOR G12 five-axis CNC All-Electric fastening systems coupled with a Cenit offline part programming system. This joint solution served as a launch vehicle for Center Industries to efficiently supply the full rate of fuselage panel assemblies for a large volume commercial aircraft program without having any automatic riveting experience.

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

These techniques rely on using three-dimensional CAD data in the form of wing surface models stiffener (stringer) models fastener maps The introduction of a new CNC wing riveting machine necessitated the re-programming of Airbus A320, A321, A330 and A340 wing panel assemblies.

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.

They were installed on two production CNC riveters to provide improved edge tracing of longerons and drill/countersink control. The optical tracer uses video techniques to maintain a constant edge distance for fastener locations.

Use of today’s advance 3-Dimensional CAD systems coupled with the high accuracy of CNC machines enables the success of the determinate assembly approach for aircraft tooling. This approach provides the aircraft manufacturer significant lead-time reductions while at the same time it supports enhanced system flexibility.

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.

TOPASE today has a series of identical C.N.C. machines each capable of complete panel assembly in one operation. This includes installation of rivets, double headed slug rivets and two piece fasteners.

This paper presents a case of CFRP/Ti6Al4V drilling on a CNC machine where productivity must be increased. A comparison is made between the current regular process and the MITIS drilling process.

Drilling of aircraft wings to the tolerances demanded by laminar flow requires machines with the stiffness and accuracy of a CNC machine while having the flexibility and envelope of an articulated arm. This paper describes the development and evaluation of high accuracy automated processes to enable the assembly of a one-off innovative laminar flow wing concept.