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The use of CNC automatic fastening on large aircraft structures requires a process-oriented approach. Included in that process are factors related to the parts and assemblies, tooling, machine control data, as well as the automated fastening machine itself. ...This paper summarizes some challenges and solutions that occurred during the production implementation of such a CNC assembly process for very large aircraft structures.

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.

On CNC Machines, drilling holes under perfect condition is possible. For drilling holes into titanium, composite and aluminum stacked materials the specific cutting condition can be selected. ...When drilling holes in the final assembly, CNC machine tools cannot be employed due to sizes and accessibility. Power Feed Units or Automated Drill Units ADUs are very handy, flexible and depending upon the jig extremely rigid. ...In the mind-set of the fourth industrial revolution, this article presents a completely new approach in the ADU Technology, while the benefits in the capability of CNC machine tools are now available on ADUs likewise. The benefits of using individual cutting condition for every layer in composite/metal stacked material, the worldwide online-process and -data monitoring, the improved tool-management and traceability, the remote diagnostic and improved cutting tool development functions will show a variety of extremely useful and new features.

A new Electronic Gantry Applied Drilling System has been developed and demonstrated which provides a CNC controlled, multi-axis drilling system to replace hand drilling and countersinking operations at Assembly Jig Stations.

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.

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.

This equipment is considered new technology for it's combination of features which include: CNC positioning, sealant installation, drilling of multiple hole diameters in a single cycle, domenut installation, as well as the capability of varying hole spacing for alternate domenut needs.

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 process integrates a Laser Tracker to check and align a floor grid assembly; a two spindle, CNC controlled, gantry drilling system to drill the floor grid assembly; a manual work area for the installation of the fittings and other manual work tasks; and a material handling system to move the floor grid assembly through the system.

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.

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.

This method of assembly (prior to automatic fastening) uses a new generation, accurate CNC machine tool in conjunction with reconfigurable part fixturing techniques and specialized end-of-arm tools (end effectors).

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.

The system is controlled by a Siemens 840Dsl CNC which handles all process functions, robot motion, and executes software technologies developed for superior positional accuracy including enhanced kinematics, automated normality correction, and anti-skid correction.

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.

Both automatic (CNC) and semi-automatic (portable) orbital drilling were investigated. Damage in the vicinity of the holes was assessed by means of microscopic evaluation.

When conducting a trial, the CNC press was used to control insertion rate. Insertion force data was collected electronically by the CNC press controller. ...Insertion force data was collected electronically by the CNC press controller. After assembly each sample was leak tested using an air pressure test. Samples were then disassembled to search for and examined O-ring damage.