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The E7000 riveting machine installs NAS1097KE5-5.5 rivets into A320 Section 18 fuselage side panels. For the thinnest stacks where the panel skin is under 2mm (2024) and the stringer is under 2mm (7075), the normal process of riveting will cause deformation of the panel or dimpling. The authors found a solution to this problem by forming the rivet with the upper pressure foot extended, and it has been tested and approved for production.

A frame-clip riveting end effector has been developed for installing 3.97mm (5/32) and 4.6mm (3/16) universal head aluminum rivets. The end effector can be mounted on the end of a robot arm. The end effector provides 35.6 kNt (8000 lbs) of rivet upset. Rivets can be installed fifteen millimeters from the IML. The clearance allowed to rivet centerline is 150 millimeters. The riveting process features a unique style of rivet fingers for the universal head rivet. These fingers allow the rivet to be brought in with the ram. This differentiates from some styles of frame-clip end effectors in which the rivet is blown into the hole. The paper shows the technical components of the end effector in sequence: the pneumatic clamp, rivet insert and upset. The end effector will be used for riveting shear ties to frames on the IML of fuselage panels.

The Electromagnetic Bolt Inserter (EMB) is a new tool that combines functions that on previous machines were performed by two tools, a bolt inserter followed by an EMR. By combining the operations of two tools in one the processing time for the wing spar is reduced. The tool incorporates quality checks for bolt length, stake height and bolt insert height.

Boeing has relied upon the 767 ASAT (ASAT1) since 1983 to fasten the chords, stiffeners and rib posts to the web of the four 767 wing spars. The machine was originally commissioned with a Terra five axis CNC control. The Terra company went out of business and the controls were replaced with a custom DOS application in 1990. These are now hard to support so Boeing solicited proposals. Electroimpact proposed to retrofit with a Fanuc 31I CNC, and in addition, to replace all associated sensors, cables and feedback systems. This work is now complete on two of the four machines. Both left front and right front are in production with the new CNC control.

A simple, open, post and index system is used for final alignment and joining of the fuselage and wings of a new passenger business jet. 19 manually actuated axes precisely move the wings, forward, and rear fuselage sections into position. Movement is accomplished with industrial jacking screws and positions recorded with precision linear potentiometers. Wing sweep, angle of attack, and dihedral are monitored and controlled. The axes positions are downloaded to data files for verification and data archiving. The Gulfstream G150 Join Cell's open architecture enhances access to fasten the main aircraft structure while maintaining flight critical geometry.

The Boeing Company (Renton Division) had a requirement for a 30,000 RPM spindle to provide improved surface finish when milling 2034 ice box rivets in hydraulic wing riveters. Electroimpact supplied an electrical spindle which fit into the same cylinder block as the hydraulic spindle. This was reported in SAE Paper #2000-01-3017. Boeing Renton has also now put Electroimpact 20,000 RPM electric drilling spindles into five wing riveting machines so now both spindles in the machine are Electroimpact electric spindles. The electric drill spindle features an HSK 40C holder. Both spindles are powered by the same spindle drive which is alternately connected to the drill and then the shave spindle.

Two spindles are discussed in this paper. The first spindle was installed on nine C-frame riveters on the 737/757 wing line at the Boeing Renton facility. Due to discontinuing the use of Freon coolant and cutting fluid, the C-frame riveters had difficulty shaving 2034 ice box rivets with the existing 6000 RPM hydraulic spindles. The solution was to install electric 30,000 RPM shave spindles inside the existing 76.2 mm (3 in.) diameter hydraulic cylinder envelope. The new spindle is capable of 4 Nm (35 in. lbs.) of torque at full speed and 110 kgf (250 lbs.) of thrust. Another design of interest is the Electroimpact Model 09 spindle which is used for 20,000 RPM drilling and shaving on wing riveting systems. The Model 09 spindle is a complete servo-servo drilling system all mounted on a common baseplate. The entire spindle and feed assembly is only 6.5″ wide.

Robotic gripper technology has been integrated into CNC riveting machines. Handling fasteners efficiently is critical in automated wing panel riveting. Computer controlled rivet gripper and collar gripper technology has been developed that demonstrates high reliability and decreased fastener cycle times