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The ever increasing use of composites for aircraft components presents opportunities for new ways to process these parts. There are myriad benefits for use of composites in achieving aircraft performance goals. However, composites come with unique challenges as well. Some of these challenges impact the ability to produce accurate parts. Traditionally, such parts have been trimmed only while clamped in dedicated rigid tools that secure the part in the nominal shape. This results in significant investment in tooling design, production, maintenance, storage and, handling. As an alternative, PaR has developed its Adaptive Manufacturing System that incorporates a Robotic Fixture and Precision Motion Machine with an Integrated Process Head. The Robotic Fixture allows the entire family of parts to be managed with one fixture that remains within the machine footprint.

The massive size of the A380 Trailing Edge Spar structure and challenges associated with its construction made it well suited for automation. PaR Systems, Inc. worked with Airbus UK on a pair of gantry systems each 55 meters long to provide the drilling, fettling and coldworking needs required for the Trailing Edge Spar. The processes and sequences for constructing the spar structure were further enhanced by flexible database driven software that improved productivity.

This paper covers issues related to the installation, testing, and production implementation of a large-scale automated wing drilling/fastener installation system. Emphasis is placed on describing the production process, foundation requirements, axes alignment, calibration, testing and implementation. Description will include key hardware features such as the multi-function end effector and spindle end effector. The objective is to convey the complexity of implementing this system as well as reviewing the lessons learned from this experience.

This paper describes the application of an automated machine tool system used in the assembly process of a military aircraft wing torque box, manufactured by The Boeing Company. Traditional approaches to the wing assembly production involve manual framing, drilling, and installation steps. This program first introduced an automated drilling system during the Engineering/Manufacturing Development phase of this project. In a continuous search to optimize the wing assembly process, Boeing decided to go beyond this level of automation. The idea was to introduce an automated system to drill, ream, countersink, inspect holes, seal prior to fastener insertion, and install various types of fasteners. This paper will examine and outline the production constraints that lead to the requirements of the automated system. System capabilities as they apply to the wing production requirements are presented. The current and proposed assembly techniques are described.