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Equivalent system mass (ESM) was defined in 1997 as an integral part of the Advanced Life Support project metric. It is particularly suited to comparing technologies that differ in mass, volume, power, cooling, and crew time during the early phases of a program. In principle, ESM can also be used to compare technologies that differ in other parameters. In practice, the necessary data is generally not available, and this limits this application. ESM has proven to be a useful tool. Like any tool, its strengths and weaknesses must be understood. This paper documents the history, capability and methods used in connection with ESM.

This paper details the Electroimpact Cartridge Feed Auto Select (CFAS) System, the Electroimpact Cartridge Filling Station (CFS) and the implementation of these systems on today&’s factory floors. Problems inherent in handling tens of thousands of fasteners per workpiece have traditionally been an Achilles Heel to many aerospace-manufacturing cells. The CFAS system moves the job of sorting through bulk fasteners to the stand alone offline CFS. With the bulk feeding process offline, problems such as contaminated fastener lots get taken care of before they ever get to a fastening machine. Modular briefcase sized coiled tube magazines store and distribute fasteners to automated riveting and bolting equipment via the CFAS rack. Cartridges captively hold 500 to 3,000 fasteners from 1/8” to 3/8” diameters and are length independent which allow a small number of cartridges to work with a large array of overall fasteners.

Large diameter, tightly toleranced fastener patterns are commonplace in aerospace structures. Satisfactory generation of these holes is often challenging and can be further complicated by difficult or obstructed access. Bespoke tooling and drill jigs are typically used in conjunction with power feed units leading to a manual, inflexible, and expensive manufacturing process. For 777X flap production, Boeing and Electroimpact collaborated to create a novel, automated solution to generate the fastener holes for the main carrier fitting attachment pattern. Existing robotic automation used for skin to substructure assembly was modified to utilize extended length (up to 635mm), bearing-supported drill bar sub-assemblies. These Long Assembly Drills (LADs) had to be easily attached and detached by one operator, interface with the existing spindle(s), supply cutting lubricant, extract swarf on demand, and include a means for automatically locating datum features.