New Technology for Fully Automated One Side Assembly

With more than 10 000 aircrafts in their order backlog Aircraft manufacturers focus on automated assembly is of critical importance for the future of efficient production assembly. Moreover to obtain maximum benefit from automation, it is necessary to achieve not only an automated assembly cell, but also a real breakthrough in fastener technology. The optimum solution, known as “One Side Assembly”, performs the whole assembly sequence from one side of the structure using an accurate robot arm equipped with a multifunction end effector and high performance fasteners. This configuration provides an efficient and flexible automated installation process, superior to current solutions which are typically, large scale, capital intensive systems, which still require operators to complete or control the fastener installation.

The search for a technological breakthrough in this domain has been targeted for more than 15 years by many aircraft manufacturers.

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In order to develop a new technology, LISI AEROSPACE & KUKA SYSTEMS combined their expertise, to produce a NEW system capable of performing the following processes in a fully automated configuration: pre-assembling, drilling, automatic fastener feeding and sealant integration, fastener installation and assembly control.

This innovative solution became a success through enhancement of a mature barrel multifunction end-effector, with a proven track record for assembly in commercial aircraft and the introduction of a new generation of high performance structural blind fasteners (OPTIBLIND^TM) coupled with a Temporary Fastener (CLY^TM62) solution from our automated assembly range.

This presentation will describe the technology developed, and focus on the new technical performances of these new technologies.