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The presented paper introduces the new software complex aimed at simulation of the riveting process as applied to aircraft parts. The software complex implements the novel mathematical model based on minimization of the potential energy. The paper gives the detailed description of the mathematical model and particularizes the main features of the software. The physical and numerical tests aimed at validation of the software are also described in the paper.

Looking at ways to improve assembly techniques and cut lead times for serial and future programs, Airbus' research and technology team launched a project some years ago to evaluate greater automation of sub-components or final assembly lines. The idea was to develop a new type of machine or ‘robot’ that could be attached to fuselage sections using suction cups, and walk along it while drilling and installing fasteners. A camera inside the robot takes a snapshot to work out its position on the part, so that it knows where to drill or install what. Once a fixed working area is complete, the robot moves itself into a new position and starts the process again until the whole surface is covered. Three companies - Alema, MTorres and Serra - were approached to develop prototype robots along the same basic principles, although each was asked to follow a slightly different specification to test a range of options, such as weight, size and positioning.

Novator's patented orbital drilling technology is now well known for its ability to drill holes with high quality and finish in a single operation. By using orbital drilling, the need to disassemble the parts in order to remove the burrs is eliminated. A fully implemented orbital drilling process makes it possible to reduce the drilling time by 50%. Dry drilling makes coolant obsolete and reduces environmental hazards. To exploit the advantages of orbital drilling, Airbus started a project with Novator a few years ago in order to develop a Portable Orbital Drilling Unit to be used in the final assembly lines in Toulouse and Hamburg. This lightweight, portable system, called Twinspin PX3, is a CNC controlled unit allowing for a continuous radial offset adjustment of the cutting tool. Based on this innovative process, it makes it possible to produce not only cylindrical holes but also conical holes or more complex shaped holes.

This paper describes the development and application of new self-removable temporary fasteners for orbital junction. These low size temporary fasteners made of aluminum are easily automatically destructible by drilling and have been deployed into our automatic robot on final assembly line. The major benefit of these new temporary fasteners is then the possibility to be integrated into an automatic assembly process. The R&D team of the Final Assembly Line unit at Airbus - Toulouse, has conducted this project in cooperation with LISI Aerospace.

This paper describes the ‘Measurement-Assisted Assembly’ activities led by the Final Assembly Line unit at Airbus - Toulouse. These activities are meant to eliminate some of the problems associated with the conventional process of locating and positioning large airframe sub-assemblies during the final assembly process, like fuselage-to-fuselage or wing to fuselage junctions. All these activities include laser or photogrammetry subsystems, computer-aided measuring systems, Best-Fit optimization software, specific Graphical User Interface. The combination of these technologies offers: jigless assembly, faster assembly process, rework and waste reduction and many more advantages.

In order to be more competitive, aerospace industries have to continually improve product's cost, quality and cycle time. One way to perform all three at once is to manage product's variations, as variations are responsible for waste, rework and delay. There are only three ways to reduce product's variation: improve manufacturing capability, improve assembly capabilities and manage assembly sequence. Generally, variation reduction programs tackle only manufacturing capabilities. Unfortunately this solution is by far the most expensive one. We propose in this article to reduce variation first by selecting best assembly sequences or eliminating assembly tools and only after if there is no other way by reducing manufacturing capabilities. With this aim, we have defined an assembly analysis method. This method studies for each assembly sequence how variations are flowed from part to part through the assembly joints.