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The industry wide requirement of new highly flexible automated fastening systems in aircraft production has created the need for developing new fastening systems. This paper will focus on the development of the Frame Riveting Assembly Cell (FRAC) by BROETJE-Automation to meet this need. The new FRAC machine configuration is built for automated drilling and fastening of different aircraft type parts. It is highly flexible with a high speed positioning system mounted multifunction end effector. System travel is limited only by installed track length. The FRAC integrates well with conventional and reconfigurable automated fastening work holding tools.

Drilling of high-strength titan material and composites in combination creates complex challenges in order to achieve required productivity and quality. Long spiral chips are characteristically for the titan drilling process, which leads to e.g. chip accumulation, high thermomechanical load, surface damages and excessive tool wear. The basic approach is the substitution of today’s peck drilling as current solution to this problem and the implementation of a vibration assisted drilling, so called micro-peck-drilling-process, to generate a kinematic chip breakage in a significant more efficient way. To meet perfectly the requirements regarding rates, quality and automation level, Broetje-Automation as system integrator has investigated and developed the implementation of different alternative high-performance systems and methods to approach the optimal oscillation movement of the tool.

Resin transfer molding (RTM) is gaining importance as a particularly economical manufacturing method for composites needed in the automotive and aerospace industries. With this method, the component is first shaped with dry fiber reinforcements in a so-called “preforming process” before the mold is placed in a RTM tool, injected with resin and cured. In recent years, Broetje-Automation has been developing innovative product solutions that are specially designed for these preforming processes and suitable for industrial use. For the first time ever, Broetje’s Composite Preforming Cell (CPC) makes large-quantity serial production of complex and near-net-shape preforms for composite components using this RTM process possible. With the additional integration of the patented 3D Composite Handling System Broetje impressively demonstrates its service and product portfolio in the area of innovative composite manufacturing technology and its know-how as a complete system integrator.

The demand to produce aircraft structures with new materials, at acceptable investment levels, without restricting product quality or equipment reliability prompts suppliers and customers to think about new concepts for production processes. The manufacturing system in this paper, for a Fixed Trailing Edge Assembly Facility, combines traditional manual manufacturing processes with highly automated machinery. The introduction of a flow process, with moveable assembly jigs, enables high production rates with optimized operating times of the equipment. The system also provides the flexibility to handle different aircraft variants. This paper is intended to focus on the main aspects of the state of the art technology of the manufacturing system and shall explain the integration of such a system from the design phase to the operational launch in an actual aircraft program.

The demand of fulfilling continually increasing customer requirements forces suppliers to always improve their system solutions to be state of the art. The subject Project Management Approach explains the planning and realization of complete Integrated Assembly Lines for Aircraft structural parts and components. The paper will describe and focus on the main aspects of the state of the art technology in automated fastening, drilling and assembly processes to meet the required customer production and reporting criteria. Furthermore the paper will present existing production examples in support of the established project management process.

Within the current part production of carbon fiber parts a lot of manual work is included for sorting and kitting of automatic cut plies. This is required due to the high raw material costs and enables a good utilization of the materials. Automation of this non-value adding process will be a big benefit for the part production. The high variety of shapes and the different materials to be processed are complex boundary conditions, which are to be overcome. Broetje is in development of handling systems and automation solutions, which are used for a high variety of materials as well as for a high variety of shapes. These systems are meant to be an add-on for existing cutting tables as well as for fully integrated production systems with downstream automation equipment like draping hoods. Mayor challenges to overcome are safe gripping capabilities, detection of non-cut fibers, high variety of shapes, complex logistic management. These challenges are addressed with Broetje’s ASK solution.