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Manual drilling and Lockbolt installation in carbon fiber structures is a labor intensive process. To reduce man hour requirements while concurrently improving throughput and process quality levels BROETJE-Automation developed a gantry positioning system with high performance multi-function end effectors for this application. This paper presents a unique solution featuring fully automated drilling and Lockbolt installation (inclusive of automated collar installation) for the vertical tail plane (vertical stabilizer) of large commercial aircraft. A flexible and reconfigurable assembly jig facilitates high access of the end effectors and increases the equipment efficiency. The described system fulfils the demand for affordable yet flexible precision manufacturing with the capacity to handle different aircraft model panels within the work envelope.

The iGantry concept focuses on cost effective production of aircraft subassemblies. This development is supportive of customer requirements: increasing rivet cycle rates; elimination of dedicated holding fixtures; simplification of workpiece loading and unloading; and saving floor space in production. This paper discusses the design of the assembly cell and demonstrates the process performance during the production flow.