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Electroimpact developed an end effector for Airbus UK, Ltd. for use on a Kuka KR350 robot provided by Airbus UK. The end effector is referred to as the DDEE (Drill and Drive End Effector), and incorporates four main functions. The end effector pushes up on a wing panel with programmable pressure, drills a hole with a servo-servo drill, inspects the hole with a servo ball-type hole gauge and then drives a pin-tail style lockbolt into the hole. The end effector is being used as part of a development and feasibility study for incorporating automation into the wing panel manufacture process.

McDonnell Douglas Aircraft in St. Louis, MO manufacturers various transport and fighter military aircraft such as the C-17 and the F/A-18. With shrinking military budgets and increased competition, market forces demand high quality parts at lower cost and shorter lead times. Currently, a large number of different fastener types which include both solid rivets and interference bolts are used to fasten these assemblies. The majority of these fasteners are installed by hand or by using manually operated C-Frame riveters. MDA engineers recognized that in order to reach their goals they would be required to rethink all phases of the assembly system, which includes fastener selection, part fixturing and fastener installation methods. Phase 1 of this program is to identify and to develop fastener installation processes which will provide the required flexibility. The EMR fastening process provides this flexibility.

The incorporation of split mandrel coldworking into a single- station, automated wing assembly machine advances the technical quality of automated production. Coldworking innovations, including the CMX process and new puller unit development, combined with new clamp-up technology, have eliminated the need for manual dissasembly and deburring, both costly and time consuming procedures. These advances in automation are illustrated in the development of a next-generation automated unit created for wing production of the Airbus A340-600 wide-body program. This paper describes the implementation of new fastener and coldworking technology that led to the development of this automated manufacturing system.