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Accurately aligning and assembling large structures has traditionally been accomplished via fixed assembly tools and a skilled mechanic's eye. Advancements in measurement technology have facilitated the automation of the alignment process but its use has been limited due to difficulty in measuring and monitoring the join features during the alignment process. A newly developed method that combines the capabilities of Arc Second's IRGPS system along with Leica's Scanning Laser Radar technology provides an alternative means to automate the assembly and alignment of large complex structures.

The Flex Track Drill is a lightweight, portable, automated machine used to drill aircraft structure. It is a low cost option to traditional automation where large 4 or 5 axis machines are normally used. The Flex Track Drill utilizes two flexible rails vacuumed to the part. Mounted to the rails is a carriage that carries a drill spindle that is driven in two axes. The rails are designed to be stiff and accurate in one plane and flexible in the other. The rail design allows the system to self-normalize and simplifies part programming - the machine uses 2D flat pattern programs. The Flex Track Drill uses local index holes for reference and does not rely on “global” accuracy. Those reference holes can be drilled by hand using the supporting structure as a reference or can be machine drilled using a conventional NC (numerically controlled) machine.