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Optimization of Automated Airframe Assembly Process on Example of A350 S19 Splice Joint

Airbus-Elodie Bonhomme, Pedro Montero-Sanjuan
Peter the Great St. Petersburg Polytechnic University-Sergey Lupuleac, Julia Shinder, Maria Churilova, Nadezhda Zaitseva, Valeriia Khashba
  • Technical Paper
  • 2019-01-1882
To be published on 2019-09-16 by SAE International in United States
The paper presents the numerical approach to simulation and optimization of A350 S19 splice assembly process. The main goal is to reduce the number of installed temporary fasteners while preventing the gap between parts from opening during drilling stage. The numerical approach includes computation of residual gaps between parts, optimization of fastener pattern and validation of obtained solution on input data generated on the base of available measurements. The problem is solved with ASRP (Assembly Simulation of Riveting Process) software. The described methodology is applied to the optimization of the robotized assembly process for A350 S19 section.

New Technologies for Airframe Structural Assemblies

LISI Aerospace-Mehdi Dahane
  • Technical Paper
  • 2019-01-1915
To be published on 2019-09-16 by SAE International in United States
With air traffic demand constantly increasing and several years of aircraft production in their backlog, major aircraft manufacturers are now shifting their focus toward improving assembly process efficiency. One of the most promising solutions, known as “One Side Assembly”, aims to perform the whole assembly sequence from one side of the structure (drilling, temporary fastener installation and removal, blind fastener installation, assembly control) and with a high level of integrated automation. Investments in robotic equipment, automation engineering and innovation are very active and automation capabilities have already increased a lot in the aerospace industry. As an example, drilling operations for large dimensions airframe are clearly moving from manual to automated. However, despite more and more clever and sophisticated robotics, the use of historical fasteners with two side installation method remains a strong limitation to innovative automated assembly sequences. A blind fastener which can provide the same mechanical characteristics than current structural fasteners, while providing automation friendly features and meeting cost objectives is a real “must have” for assembly process efficiency improvements. It is also full…

Point Precision Is Critical in Medical Motion Control

  • Magazine Article
  • TBMG-34815
Published 2019-07-01 by Tech Briefs Media Group in United States

The language used by suppliers of technology solutions aimed at precision engineering applications is vague and, in some instances, confusing. The use of traditional language and words such as precision and resolution without any degree of qualification are just meaningless. This article analyzes the concept of precision. It explores new language for defining submicron- and nanometer-level accuracy for motion control and details why new standards are required to indicate the real levels of precision that different motion control solutions can achieve.


Intelligent Motion Controls for Smarter Air Flow

  • Magazine Article
  • TBMG-34816
Published 2019-07-01 by Tech Briefs Media Group in United States

No longer a trend, automation has become the foundation in technology for manufacturing. This article addresses three areas that require new thinking and innovative approaches for next-generation cooling technology manufacturing: where intelligent motion controls are used, whether they increase product life and performance, and what they protect.


Key Factors to Consider When Designing a Smart Factory

  • Magazine Article
  • TBMG-34638
Published 2019-06-01 by Tech Briefs Media Group in United States

In recent years, the emergence of Industry 4.0 has been steadily transforming the manufacturing sector into an ultra-high-tech industry. Innovative smart technologies such as robotics, artificial intelligence (AI), robotic process automation (RPA), the IoT, sensors, and machine vision are powerful tools that many companies are starting to integrate into both their manufacturing techniques and business practices.


Vision Sensors in Factory Automation

  • Magazine Article
  • TBMG-34577
Published 2019-06-01 by Tech Briefs Media Group in United States

There are a number of ways to extract data from a production line. In factory automation, sensors are used in work cells to gather data for inspection or to trigger other devices. These sensors fall into multiple categories – photoelectric, fiber optic, proximity, ultrasonic, and vision are the most common.


Changing the Automation Conversation

  • Magazine Article
  • TBMG-34407
Published 2019-05-01 by Tech Briefs Media Group in United States

With advancements in manufacturing processes and materials, components in many industries are more precise with a new level of complex shapes. There is significant demand to create parts and assemblies that perform better, last longer, and cost less to make. Manufacturers are increasingly focused on robotics or other automated systems to produce, assemble, and inspect these components. The new generation of robotic manufacturing cells incorporates advanced metrology sensors that enable them to perform tasks more accurately and with greater versatility. These robotic cells are typically referred to as Metrology Enhanced Automation (MEA).


MELD exploits plastic deformation of metals with non-melt AM process

SAE Truck & Off-Highway Engineering: April 2019

Matthew Borst
  • Magazine Article
  • 19TOFHP04_07
Published 2019-04-01 by SAE International in United States

Additive manufacturing (AM) has been a catalyst in improving speed and efficiency during the product development process. However, the technology has been limited in the size and materials available to be produced. MELD Manufacturing believes it has the remedy for these limitations, and it has garnered numerous accolades for its patented MELD process, including the 2018 “Create the Future” award in the Robotics/Automation/Manufacturing category. The design contest is produced by Tech Briefs Media Group.

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A High Reliable Automated Percussive Riveting System for Aircraft Assembly

Shanghai Jiao Tong University-Yunfei Fan, Long Yu, Qingzhen Bi, Yuhan Wang
Shanghai Top NC Tech Co. Ltd.-Yilian Zhang
Published 2019-03-19 by SAE International in United States
Percussive riveting is a widely used way of fastening in the field of aircraft assembly, which used to be done manually. Nowadays, replacing the traditional percussive riveting with automated percussive riveting becomes a trend worldwide, which improves the quality of riveting significantly. For the automated riveting system used in aircraft assembly, reliability is of great importance, deserving to be deeply researched and fully enhanced. In this paper, a high reliable automated percussive riveting system integrated into a dual robot drilling and riveting system is proposed. The riveting system consists of the hammer part and the bucking bar part. And both parts have been optimized to enhance the reliability. In the hammer side, proximity switches are fully used to detect the state of rivet insertion. In the bucking bar side, a reliable step height measurement system is integrated to measure the exposed shank length of the rivet before riveting and the upsetting head height after riveting. Meanwhile, a reliable method is proposed to calibrate the measurement system. By measuring the exposed shank length of the rivet…
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Automated Surface Preparation of Embraer’s Commercial Jet Fuselage for Painting Process

Embraer-Rogerio Scafutto Scotton
Encore Automation-Karl Schuknecht
Published 2019-03-19 by SAE International in United States
The surface preparation of the fuselage prior to painting is largely done manually in the Aerospace Industry; utilizing scrubbers, sanders, chemicals, and manlifts resulting in safety and ergonomic issues without delivering a consistent result. The automation of the process employing robots, vision systems, machine movers, and automated process equipment provided the following benefits: Improved Safety and ErgonomicsReduced exposure to hazardous materials and working conditionsImproved Consistency and QualityImproved Production Capabilities and Reduced Labor CostsReduced Material UsageLess weightLower environmental risksLower costThis paper will describe the equipment used and the process changes required to automate the surface preparation process, then discuss the benefits that were realized.
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