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A closing of the gap between the unit costs of composite parts and those of the competing metal parts as demanded by the market for years can best be achieved through use of automated systems. A unique automation solution for the production of composite parts is the Continuous Composite Preforming System (CCPS) by BROETJE-Automation (BA). This system permits the automated, continuous production of 3D shaped and curved composite profiles such as those requiredfor the frames and stringers of modern aircraft. At present such components can only be produced in a very time-intensive sequential manual or semi-automated process. The newly developed system provides a fully automated preforming process for curved profiles to ensure a cost efficient solution for composite frame production.

For the past ten years, international Aerospace production is asking for flexible and production optimized machinery including IT-Integration packages for streamlining machine tool efforts into aircraft production. As one answer of these questions, a new innovative robot cell has been developed for drilling and fastener insertion in the inner structure of aircraft parts consisting of composite, titanium and aluminum. The new robot cell is based on a scalable 840D system configuration. The required absolute path planning and positioning accuracy force us to integrate our developed compensation methods in the 840D control system. This solution demonstrates how standard robots equipped with a matured control, compensation and off-line programming strategy by an innovative Aerospace solution supplier resulted in a highly flexible and cost-efficient light weight automation response.

Recent changes in the aircraft production process forces us, as a supplier of aircraft assembly equipment, to design innovative and modular manufacturing equipment that complies with modern specifications. This is especially true of composite manufacturing processes in combination with new materials that are now under development. In some applications, the potential for optimizing existing manufacturing processes (e.g. Prepreg-technology) as related to quality improvements and cost reduction has reached their limit. Using optimized production processes like preforming and resin infusion could allow one to achieve considerable benefits. This paper describes the latest development of a robot cell for dry fiber placement. Our customer's application required a completely new type of end-effector and an extension of the proven high accuracy robot positioning system.

This paper describes the application of an automated process for installing dome-type pressure bulkheads into the rear section of widebody airplanes by use of a new CNC-controlled multi-axis drilling and two-piece fastener installation machine. The system basically consists of a DNC/CNC drilling and fastening machine and an assembly jig for the aircraft rear section. The workhead performing the drilling, sealant application and fastener installation travels on a circular ring around the fuselage section. The required counteraction force for installing the interference fit fasteners is provided by the support system, which works on the inner side of the fuselage. The purpose of the unit is to provide an automatic system with the goal of increasing the consistency of the quality of assembly by simultaneously reducing cost.