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Flex Track Drilling systems are being used increasingly in aerospace applications providing low cost, highly efficient automated drilling systems. Certain applications like circumferential splice drilling on large size airplane fuselages require multi spindle flex track systems working in tandem to meet production efficiency requirements. This paper discusses the development of a multi spindle flex track drilling system for a circumferential splice drilling on the 777 airplane. The multi spindle system developed uses a variety of flex track carriages attached to the flexible vacuum tracks to allow for offset or wide inside drilling. Segmented machine programmes allow these multiple machines to be deployed on the same circumferential splice on the airplane providing the multi spindle system. Interfacing of the multiple spindles is achieved by a custom OEM interface using a single screen thereby ensuring simplicity of operation.

With the recent development of a multi spindle flex track drilling system for aerospace applications, the challenges of testing and implementation on existing airplane programmes require unique technical methodologies and solutions. This paper discusses the technical approach, problems encountered and methodologies/solutions used to successfully implement a multi spindle flex track drilling system for circumferential splice drilling on the 777 airplane. The multi spindle system uses varieties of flex track carriages attached to flexible vacuum tracks for wide inside drilling. The hardware and software challenges encountered during the interfacing of the multi spindles are discussed as well as the complex problem of indexing and locating all detailed components of the splice accurately and with high repeatability.

Drilling fastener holes in large assemblies is traditionally accomplished through the use of large machine tools in order to obtain the accuracies required for the assembled part. Given recent advances of machine design and machine controller compensation, the accuracy of the motion platform can be corrected if the machine is repeatable. This coupled with the use of a vision system or touch probe to compensate for assembly variations, permit the use of smaller, more portable drilling systems. These smaller, more portable machine tools allow for lean manufacturing techniques to be incorporated into build processes, utilize less floor space, and in many cases are less costly than larger, permanent machine tools. This paper examines the feasibility of utilizing a small 5-axis, portable, drilling system for drilling the side panel skins on the F/A-18 E/F forward fuselage.

Lightweight and flexible automated drilling machines are becoming more common in aerospace industry to address the increase in demand for low cost assembly solutions. Successful production implementation of the Flex Track system has been accomplished by matching applications with appropriate design features. Following the concept of small lightweight machines, which rely on local accuracy and sacrifice stiffness and shear mass, the Flex Track tackles problems on a detail level. This paper describes how the evolutionary progress of the Flex Track drilling system has and continues to address the increase in demand for low cost automated drilling systems.