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The joining and assembly of barrel sections of large aircraft is always cumbersome. Any means to ease this task are welcome. In recent years The Boeing Co. has invented and licensed their “Flex-Track” system. But however flexible this approach may be, double curved surfaces, large variations of cross-section radius and issues with vacuum cup fixture are problems to be dealt with. Zhejiang University in Hangzhou, China has developed a new, innovative circumferential splicing system in cooperation with Broetje-Automation, Germany. There is a unique, time-saving setup technology and self-stepping actuation for a one up 360° splicing operation. The process endeffector is based on standard, state of the art components in use for large fastening systems. Features are high speed servo drilling spindle with HSK 32 drill chuck holder, tool changer, vacuum chip removal, reference hole detection and correction, surface normality alignment, pressure foot clamp-up, countersink control.

SCALE is a modular, non-contact, in-line measurement system. It measures the diameter of the countersink directly after the drilling, the amount and distribution of sealant in the open hole, and the head height of the fastener as well as pressed out sealant (cf. Figure 1). The system is fast and reliable and the out coming information is reliable and trustworthy. Until now the system could not measure the inner diameter of the hole. The reason for this is that it is not possible to detect the inner diameter with a camera that looks only at the top of the component. But as our customers make the request to us, we decided to develop an optical hole probe system which is fully integrated in the auto fastening process. We think that a mechanical system cannot fulfill the customer expectations in terms of reliability, low maintenance, precision and speed. Only a non-contact system can measure permanently safe and fast the inner diameter of holes.

For decades optical camera systems have been used by Broetje-Automation to locate pilot holes and find product orientation on NC-controlled positioner systems. Measurement tolerance requirements were and are in the range of +/− 0.2 mm. Recent developments enhance the sensor technology function from pure hole detection to new features like Fastener Head Height Measurement and Countersink Diameter Measurement. While head height measurement has to go 3D by enhancing the planar sensors to head protrusion measurement, the Countersink measuring tolerances are much smaller than “simple” hole detection, in fact require more than a magnitude tighter tolerances. This paper will present how Broetje-Automation solved the issue of a 20 plus fold accuracy increase, the 3D capability of the one eyed camera and all accompanied by a more robust evaluation software.

Industrial robot applications are going to reduce cost in capital investment and enhancing the capability. A new concept of drill technology is successfully running in composite trailing edge manufacturing for drilling 5/8\mi holes in Composite/Aluminum stacks in IT8 quality. This article characterizes the special features of drilling of CFRP/Titanium and Aluminum stacks. Simplified theoretic models will show how CFRP/Titanium stacks should be machined without scratches and burn marks contacting carbon. Low axial forces and smart chip removal technology are the main characteristics of the drilling tool technology, optimized to reach IT8 quality in one shot operation.