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A small, lightweight end effector drill and rivet machine has been developed. The system is capable of installing fasteners in areas that have previously been inaccessible to automatic fastening machines. The unique lower ram system is so small that it can reach through access openings to drill and install fasteners. The system incorporates sensors, a fiber-optic camera system and electronic measurement devices to provide statistical process control data (SPC) for the installed fasteners. An automatic fastener feeding system provides the correct diameter and grip length fastener to the machine. Fastener information is either stored in the part program or is determined by the machine measurement system. The mechanical functions of the system, the machine controls, and the communications between the automatic drill and rivet end effector and the robotic system are discussed. The fully automatic system is mounted on a Jomach 16 Robot.

Rapid Prototyping is a group of advanced technologies for converting designs from computer representations directly into solid objects without human intervention. These technologies are generally referred to as computer automated fabrication. The first rapid prototyping process was developed in the late 1980’s and since that time several other competing processes have been developed. Each process is unique and has benefits above other processes. As a potential user of these technologies, it is important to understand each process and realize the advantages and limitations that each may provide. This technical paper will present each of these technologies and discuss how they operate and their appropriate applications. The reader will gain exposure to the rapid prototyping technologies currently on the market as well as an understanding of the fundamental principles involved in rapid prototyping.

The two basic methods of process improvement are discussed. The continuous and methodical Japanese system for improvement called KAIZEN is presented along with the typical U.S. approach to improvement called Innovation. The two contrasting methodologies are discussed individually and then are combined to form a strategy for improving the aerospace manufacturing process. The Kaizen of continuous improvements in part fixturing and the innovations of new automatic riveting techniques are combined to provide a tool for survival in the ever increasing competitive aerospace fastening business. The process of transition from today to the future not only means changes in equipment and methods but also changes in people and management. An integrated approach to managing the elements of change is presented. The paper tries the “what is necessary” and the “how to implement” strategies into one comprehensive concept called PROGRESS.

The CNC controlled automatic riveting work cell represents the latest State-Of-The-Art in automatic fastening machines and support hardware. The work cell contains a unique designed knee type drill and rivet machine that has a sixty inch throat depth, four position upper head and sixteen thousand pounds of upset force. The machine is equipped with dual drill spindles, one for drilling and one for deburring. The knee style machine was developed for fabricating tubular assemblies which are fed into the throat of the machine over an eight inch square lower knee. A CNC controlled four axis positioning system presents the part to the machine for riveting. Support systems include an automatic fastener feed system and a vacuum chip collection system. The work cell is controlled by an Allen Bradley series 9/290 enhanced CNC processor. The paper presents each individual system and it's role as part of the total CNC duct riveting work cell.

A drill and rivet machine with a unique dual lower ram has been designed and built. The dual lower ram assembly consists of two horn shaped rams that are mounted at ninety degree angles to one another. Both rams remain operational at all times. When one ram is in place in the front of the machine the other ram is pivoted out to the side of the machine. Each ram has a unique horn shape and carries its own offset lower anvil assembly. The unique horn design allows the ram to reach into high curvature leading edge parts. The operator can select either ram so that a complete ship set of high curvature parts can be produced by the machine with no other tool changes required.

Fasteners are currently being fed into automated installation machines by a variety of different devices. Once fed, the fastener often travels to the machine's installation point via a track or feed tube. Some tracks and tubes keep the fastener oriented while others allow the fastener to tumble and reorient it at the machine head. Fastener escapements, shuttles, tracks, blow tubes and injectors are all part of the overall system. Fastener grip length selection and fastener inspection devices add to the overall complexity of feeding systems. The technical paper discusses the theory and operation of each of the fastener feeding devices including; hoppers, magazines, cassettes and vibratory bowls. Support systems are covered and methods to optimize fastener feed times are presented.

A compact, portable, fully automated rivet installation system for a fraction of the cost of large stationary systems is presented. Hand assembly is still being done in many areas where automated equipment could be used to improve quality and productivity. One such application is minor subassemblies such as clips, brackets etc. that often have fewer than ten or twelve rivets. The system presented is fast, reliable, self contained and can process a wide range of parts. Operation of the system and application of each style of “C” frame are discussed.

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. The four function rivet head contains a drill spindle, a sealant applicator, a rivet insertion station and a camera unit. The unique lower ram will allow the machine to fasten high curvature parts as well as flat panels with minimal changes. The fastener feed system utilizes a bank of vibratory bowls that feed fasteners through a single feed tube. The fasteners are allowed to tumble and then are aligned prior to insertion into the anvil fingers. Countersunk fasteners as small as -4-3 will be fed by the system. The system will be used by Raytheon Aircraft Corporation to produce body panels and wing parts for the JPATS Program (Joint Procurement Aircraft Training 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 seven axis of control; the five common axis of X, Y, Z, Alpha, and Beta plus lower ram position and tool position on the knee style lower ram. The six function rivet head contains a pre-drill spindle, a rotary spin dimple spindle, a final drill spindle, a sealant applicator, a rivet insertion station and a rivet shave spindle. The unique lower knee style ram will allow the machine to fasten small radius high curvature parts as well as flat panels with minimal changes. The fastener feed system utilizes a bank of vibratory bowls that feed fasteners through a single feed tube. The fasteners are allowed to tumble and then are aligned prior to insertion into the anvil fingers. Countersunk fasteners as small as -4-3 will be fed by the system.