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The ONCE robotic drilling system utilizes a mass produced, high capacity industrial robot as the motion platform for an automated drilling, countersinking, and hole inspection machine for the skin to substructure join on the F/A-18E/F Super Hornet wing trailing edge flaps (TEF). Historically, robots have lacked the accuracy, payload capacity, and stiffness required for aerospace drilling applications. Recent improvements in positional accuracy and payload capacity, along with position and stiffness compensation, have enabled the robot to become an effective motion platform. Coupled with a servo-controlled multifunction end effector (MFEE), hole locations have successfully been placed within the specification's +/-0.060″ tolerance. The hole diameters and countersinks have proven to be very accurate, with countersink depth variation at 0.0025″ worst case.

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.