Criteria

Display:

Results

Viewing 1 to 30 of 19612
Technical Paper
2014-09-30
Armin Förg, Moritz Wolter, Matthias Kreimeyer, Markus Lienkamp
Introduction & problem description Profoundly new commercial vehicle concepts for improved transport efficiency, better TCO and decreasing environmental impact are a key issue in current research. Although being showcased more and more as first concept studies and prototypes by OEMs these new concepts do hardly find their way into public traffic. Beside their non-conformance to today's legislation another reason is manufacturers being cautious and reserved when it comes to new concepts that require far-reaching changes in engineering and methods of production. In the context of sensitive markets manufactures can't afford low volume vehicle concepts that in addition include a lot of exclusive components and interfaces i.e. extra investments and engineering efforts. In order to pave the way for radical innovation in commercial vehicle concepts, manufacturers need to be able to analyze new concepts on their compatibility with the existing product portfolio and if necessary redesign their product architecture to avoid unmanageable overflow of variance.
Technical Paper
2014-09-30
Rajendra Vivekananda Hosamath, Muralidhar Nagarkatte
All top ranking automobile companies in the world believe in single world “Quality” and maintaining quality standards is a philosophy, a belief in which we live, a task which cannot be put aside for another day .To achieve the world class quality standards Divgi-Warner meticulously follows a highly effective tool known as Quality System Basics (QSB) QSB helps Divgiwarner to preserve integrity of commitment to achieve manufacturing excellence. This case study covers the Quality System Basics implementation experience of DivgiWarner Pvt. Ltd. India, one of the BorgWarner's plant based in Pune and Sirsi, India. A quality System basic consists of following 10 Key elements to establish world class quality. 1. Fast Response  Lessons Learned  Practical Problem Solving  8-D 2. Control of Non-Conforming Product 3. Verification Station 4. Standardized Operations  Work Place Organization – The 7 Wastes  Standardized Work Instructions – SOS  Operator Instructions – JES 5. Standardized Operator Training 6.
Technical Paper
2014-09-30
Venkatesan C, Faustino V, Arun S, S Ravi Shankar
The automotive industry needs for sustainable seating products which offer good climate performance and superior seating comfort. The safety requirement is always a concern for current seating systems. The life of the present seating system is low and absorbs moisture over a period of time which affects seat performance (cushioning effect). Recycling is one of the major concern as per as polyurethane (PU) is concern. This paper presents the development of an alternative material which is eco-friendly and light in weight. Thermoplastic materials were tried in place PU for many good reasons. The newly developed material is closed cell foam which has better tear and abrasion resistance. It doesn’t absorb water and has excellent weathering resistance. Also it has got better cushioning effect and available in various colours. Because of superior tear resistance, we can eliminate upholstery and reduce system level cost. The development involves testing and characterization of the materials, making of prototypes and validations.
Technical Paper
2014-09-16
Yanbin Yao
Drilling plays a significant process in the aircraft manufacturing. This paper develops a robot automatic drilling system for processing the titanium alloy, aluminum alloy and laminated composites component of aircraft. The accurate robot drilling system is comprised of ABB IRB6640-235 robot, drilling end-effector, end-effctor control system and vision system. Experimental results show that the system absolute location precision is within 0.3mm, and the drilling efficiency can be up to four holes per minute. The drilling efficiency and quality of the aircraft component can be increased immensely by the developed robot automatic drilling system.
Technical Paper
2014-09-16
Eric Barton, Dan Hasley, Joey Jackson
This presentation is a case-study describing the implementation of a Fastening Automation system at Center Industries, a Tier-2 Aerospace supplier, to assemble the Boeing 737 panels outsourced to them by a Tier 1 supplier, due to rate increases. The presentation will focus particularly on the implementation of new automation equipment for fastening of the panel assemblies as well as the related CAD/CAM software; it will outline the challenges faced by Center Industries and the contributions of key project partners to overcome them. From the Tier 2 supplier perspective, doing this level of automation for the first time; how do they take paper-2D part drawings, tribal knowledge of the process at the Tier 1, and relatively little automation experience in-house, and produce first-time quality product, meeting delivery dates at expected rate? Aerospace panels are expensive components with very tight manufacturing tolerance requirements that do not provide room for error, or scrap. The audience will hear from key members of the launch team and learn what tools and methods were used to overcome these challenges resulting in a successful conclusion.
Technical Paper
2014-09-16
Lucas Irving, Svetan Ratchev, Atanas Popov, Marcus Rafla
The replacement for the current single-aisle aircraft will need to be manufactured at a rate more than double that of current production. Production rate can be increased by reducing the processing time for assembly operations. This paper presents research that was applied to the build philosophy of the leading edge of a laminar flow European wing demonstrator. The aim was to implement determinate assembly for the rib to bracket assembly interface. By optimising the diametric and the positional tolerances of the holes on the two bracket types, and ribs, determinate assembly was successfully implemented. The bracket to rib interface is now secured with no tooling or post processes other than inserting and tightening the fastener. This will reduce the tooling costs and eliminates the need for the local drilling, de-burring and re-assembly of the bracket to rib interface, reducing the cycle time of the operation. The self-indexing components mean that the there is more flexibility as to what point in production the bracket can be attached to the rib.
Technical Paper
2014-09-16
Jason Rediger, Joseph Malcomb, Craig Sylvester
A new portable floor drilling machine, the 767AFDE, has been designed with a focus on increased reach and speed, ease-of-use, and minimal weight. A 13-foot wide drilling span allows consolidation of 767 section 45 floor drilling into a single swath. A custom CNC interface simplifies machine operations and troubleshooting. Four servo-driven, air-cooled spindles allow high rate drilling through titanium and aluminum. An aluminum space frame optimized for high stiffness/weight ratio allows high speed operation while minimizing aircraft floor deflection. A vacuum system, offline calibration plate, and transportation dolly complete the cell.
Technical Paper
2014-09-16
Joshua Norman, Cesar Moreno, Zhiyu Wang, James Mann, Christopher Saldana
Vibration/modulation-assisted machining processes offer potential for enabling more efficient processing of aerospace alloys. While benefits of these processes have been well documented, sources for the improvements are not well understood. This study explores the nature of energy dissipation during conventional and modulation-assisted machining by characterizing effects of controllable process parameters on chip formation in aerospace alloys. Simultaneous force and tool position measurements are used to show that the processing response in modulation-assisted machining can be described by empirically derived process models. These models accurately predict plastic dissipation over a range of modulation conditions and configurations, including in cases where energy expenditure decreases with the application of modulation. These observations suggest that the underlying plastic response in modulation-assisted machining at low frequency is analogous to that of conventional machining with a time-varying component.
Technical Paper
2014-09-16
Samuel Baha II
Hybrid (bolted/bonded) joining is becoming one of the innovative joining processes for light weight structures in the transport industry, especially in the aerospace industry where weight reduction and high joining requirements are permanent challenges. Combining the adhesive bonding with the mechanical joining -riveting for instance- can lead to an enhancement of the properties of the joint compared to the wide established riveting, as a result of a synergistic load bearing interaction between the fastener and the adhesive bondline. The influence of the rivet installation process on a hybrid joint regarding the joint stress state, the change of the bondline thickness as well as its effects on the joint performance and load transfer are some of the factors that drive the users to a better understanding of the hybrid joining process. This paper deals therefore on one hand with the numerical simulation of the rivet installation process in an adhesively bonded joint to understand the phenomena occurring during the installation process and on the other hand with the investigation of the load transfer depending on the joint parameters.
Technical Paper
2014-09-16
Peter B. Zieve, Osman Emre Celek, John Fenty
The E7000 riveting machine allows fast and efficient installation of NAS1097KE5-5 rivets in fuselage panels. For the thinnest stacks, where the panel skin is 2mm and the stringer is 2mm, the normal process of installing rivets will cause deformation of the panel or dimpling. The dimpling is caused by uneven interference, significant under the formed rivet tail on the stringer side and much less on the skin panel side. Due to the large number of these thin stacks on A320 Section 18 it was important to find a solution to keep the panel flat. We found a solution by forming the rivet with the pressure foot extended. The upper buck is held 0.4mm above the panel work plane surface. This reverse flexes the panel upon upset and evens out the rivet interference. The panel stays flat. More than one hundred A320 Section 18 side panels have been produced with this technique. There was a concern of head gapping between the rivet and the countersink but meticulous inspection showed that this does not occur.
Technical Paper
2014-09-16
George Nicholas Bullen
Constant swirls of innovative ideas are starting to push composites and hybrid metal-composite components for use in an ever expanding circle of products. Recent discoveries of Graphene/Au composites have invigorated innovations for its application to aerospace and space products. Attributes such as a low CTE, stiffness, and light weight attract other manufacturers of smaller products to use composites for enhanced performance and durability. The uses and economics of composites is an enormously broad subject. Examples of composite materials will be described in this presentation and paper to provide samples of applications selected for their far reaching potential to enhance product performance. Examples will also be presented to explain the application of carbon based composites where the product performance or application would not be possible without special materials. This presentation and paper will also describe emerging materials such as graphene and some of its applications to enhance the performance of current technologies It is easy become enamored with the composite big parts built for trains, planes, automobiles, ships, and wind turbine blades.
Technical Paper
2014-09-16
George Nicholas Bullen
Rapid advances in cloud-based computing, robotics and smart sensors, multi-modal modeling and simulation, and advanced production are transforming modern manufacturing. The shift toward smaller runs on custom-designed products favors agile and adaptable workplaces that can compete in the global economy. This paper and presentation will describe the advances in Digital Manufacturing that provides the backbone to tighten integration and interoperability of design methods interlinked with advanced manufacturing technologies and agile business practices. The digital tapestry that seamlessly connects computer design tools, modeling and simulation, intelligent machines and sensors, additive manufacturing, manufacturing methods, and post-delivery services to shorten the time and cost between idea generation and first successful product-in-hand will be illustrated.
Technical Paper
2014-09-16
Janice Meraglia, Mitchell Miller
As part of a comprehensive counterfeit mitigation effort, the Defense Logistics Agency (DLA) has created a program of four initiatives including the requirement of SigNature DNA marking on microcircuits. The Agency’s efforts began prior to the National Defense Authorization Act of Fiscal Year 2012, Section 818. Also, in the April 26, 2013 memo from Under Secretary Frank Kendall, the Office of Secretary of Defense is clearly focused on “prevention and early warning,” as the “primary” defense against counterfeits. SigNature DNA marking is within the spirit and guidance set forth by both DLA and OSD. Section 818 compels government action and creates real liability for contractors. Among other provisions, Section 818 requires the government and contractors to establish “…policies and procedures to eliminate counterfeit electronic parts from the defense supply chain” and “…mechanisms to enable traceability of parts.” SigNature® DNA provides per part forensic traceability and can be implemented as part of a comprehensive inventory management system.
Technical Paper
2014-09-16
Joseph R. Malcomb
Automated countersink measurement methods which require contact with the workpiece are susceptible to a loss of accuracy due to cutting debris and lube build-up. This paper demonstrates a non-contact method for countersink diameter measurement on CFRP which eliminates the need for periodic cleaning. Holes are scanned using a laser profilometer. Coordinates for points along the countersink edge are processed with a unique filtering algorithm providing a highly repeatable estimate for major and minor diameter.
Technical Paper
2014-09-16
Zachary A. Collier, Steve Walters, Dan DiMase, Jeffrey M. Keisler, Igor Linkov
Counterfeit electronic components entering into critical infrastructure and applications through the global supply chain threaten the economy and national security. In response to the growing threat from counterfeits, the Society of Automotive Engineers G-19 Committee is developing AS6171. This aerospace standard is focused on testing facilities with a goal of standardizing the process of counterfeit detection. An integral part of the standard is a semi-quantitative risk assessment method. This method assigns risk scores to electronic components based on a number of relevant criteria, and places the components into one of five risk tier levels corresponding to an appropriate level of laboratory testing to ensure the authenticity of the component. In this way, the methodology aims at standardizing the risk assessment process and bases the identified risk as guidance for commensurate testing protocols. This paper outlines the risk assessment method contained within AS6171 and briefly explores other complementary efforts and research gaps within the G-19 and electronics community.
Technical Paper
2014-09-16
Pietro Ladisa, Gabriele Santonico
The marman interface is widely used in space applications to fit the spacecrafts to the launch vehicle, and it is the same interface that allows the assembly, integration, test and transport of the satellites (AIT). The satellites marman interfaces are usually designed for launch loads with related flight design safety factors and margins, but this is not always compatible with the handling and transport needings and environment. In particular some criticalities are evidenced during the transport of satellites, where they are mounted in the container in horizontal position therefore subjected to bending loads due to gravity and transport dynamic environment. The study deals with a finite element analysis approach in the calculation and verification of marman clamp bands used for spacecraft AIT operations, where in some chases the loads can be higher or more critical than during launch phases. The paper describes the details of modelling of the clamp band parts, the involved spacecraft launch vehicle interface ring and the MGSE interface.
Technical Paper
2014-09-16
Ryan Haldimann, Daniel Orf
Description: Utilization of a vision system to automate mobile assembly machines facilitating movement, placement and accuracy. Problem: To create a flat floor factory where machine tools used for assembly automation need to position rapidly and accurately while moving to multiple positions on the factory floor. Solution: The solution falls to two distinct modes, movement and placement, both of which use the same two-camera vision system. To automate movement, the vision system and a PLC are used to guide the mobile platform to each location with barcodes and optical guidelines placed on the factory floor. Accurate placement is accomplished using a floor resynchronization methodology which utilizes the vision system and miniature embedded targets to rapidly determine position. The combination allows for an early reconfigurable accurate system for a Lean manufacturing environment.
Technical Paper
2014-09-16
Ralf Schomaker, Richard Pedwell, Björn Knickrehm
As a result of the increasing use of fibre reinforced plastic (FRP) components, exceeding more than 50% of the overall structural weight of a modern commercial aircraft, manufacturers are facing new challenges – especially with regards to the achievement of significant build rates. One challenge is the larger variation of the thickness of FRP components compared with metal parts that can normally be manufactured within a very narrow thickness tolerance bandwidth. The larger thickness variation of composite structures has an impact on the shape of the component and especially on the surfaces intended to be joined together with other components. As a result, significant gaps between the components to be assembled could be encountered. However, from a structure mechanical point of view, gaps can only be accepted to a certain extent in order to maintain the integrity of the joint. Any exceeding of the permissible gap height requires corrective measures, therefore. Today’s state of the art technologies to close gaps between FRP structures comprise shimming methods using liquid, solid or peelable shims.
Technical Paper
2014-09-16
Yvan Blanchard
Today, the design of complex composites structures is managed by taking into account both engineering and basic manufacturing constraints, as ply shape and continuity. But in order to optimize the laminate, it is strongly advised to also take into account material and process constraints, as the machine limitations in the case of automated manufacturing use. A new innovative software technology has been developed to include engineering, material and process specifications, to help designers and NC programmers to optimize the final layup program in terms of structural properties and productivity. A typical aerospace case studies will be presented to highlights these software capabilities.
Technical Paper
2014-09-16
Rainer Mueller, Matthias Vette, Andreas Ginschel, Ortwin Mailahn
Innovative production technologies for large part components Prof. Dr. -Ing. Rainer Müller, Dipl.-Wirtsch.-Ing.(FH) Matthias Vette M.Eng., Andreas Ginschel M.Sc. , Dipl.-Ing. Ortwin Mailahn Zentrum für Mechatronik und Automatisierungstechnik gGmbH Gewerbepark Eschbergerweg Gebäude 9 66121 Saarbrücken Germany Phone: +49 (0) 681 85787-544 E-Mail: a.ginschel@mechatronikzentrum.de Abstract Large part components are mostly assembled manually at fixed position assembly. There is a high demand of automated reconfigurable assembly systems. One reason is to reduce this people intensive work. Another reason is to cope with the rising variety of aircraft or wind turbine generator systems. The project “IProGro” is government funded by the European Union .The objective of the project is to develop innovative production technologies for large part components, which offer high flexibility. On one hand this flexibility is reached by a reconfigurable automated fixture for the components on the other hand by assistance systems, which guide the staff and provide information during the assembly process.
Technical Paper
2014-09-16
Helen Lockett, Sarah Fletcher, Nicolas Luquet
The installation of essential systems into aircraft wings involves numerous labour-intensive processes. Many human operators are required to perform complex manual tasks over long periods of time in very challenging physical positions due to the limited access and confined space. This level of human activity in poor ergonomic conditions directly impacts on speed and quality of production but also, in the longer term, can cause costly human resource problems from operators’ cumulative development of musculoskeletal injuries. These problems are exacerbated in areas of the wing which house multiple systems components because the volume of manual work and number of operators is higher but the available space is reduced. To improve the efficiency of manual work processes which cannot yet be automated we therefore need to consider how we might redesign systems installations in these congested areas to better enable operator access and reduce production time. This paper describes a recent study that applied design for assembly and maintainability principles and CATIA v5 computer aided design software to identify small design changes in a congested wing area.
Technical Paper
2014-09-16
Samira Keivanpour, Christian Mascle, Daoud Ait Kadi
The End of Life phase of Aircraft is a relatively complex phase in life cycle of this product. The retired Aircrafts need to be parked in a certain conditions. The valuable parts are disassembled and the rest of them are dismantled. Materials are separated and upgraded, waste is burned or deserted and toxic materials restrained or incinerated. All of these activities should be performed in an ecologically right manner; however, collectively produced added values for all stakeholders need to be considered. This paper aims to provide a conceptual framework for value chain analysis of Aircraft recycling process in the context of sustainable development. The value chain related to recycling aircraft at the end of life was chosen to generate an in-depth analysis of a value chain, considering environmental and socio-economic concerns. The value chain framework for recycling of fleets is identified. The key processes with environmental and social impacts are determined. The decision making process along the value chain and the policy framework including codes, regulations and standards are addressed.
Technical Paper
2014-09-16
Lutz Neugebauer
The demand of fulfilling continually increasing customer requirements forces suppliers to constant improve their system solutions to be state of the art after entry into service. The subject Production Optimization via Efficiency Software explains the optimization of Automated Fastening Machines and Systems as well as Assembly Lines for Aircraft structural parts and components used in the production. The paper will describe and focus on the main aspects of improving the system through put rate by using software based analyzing tools without investing in new equipment. The software tool focuses on machine functionalities as well as work organizational issues in the production.
Technical Paper
2014-09-16
Thomas G. Jefferson, Svetan Ratchev, Richard Crossley
The paper presents a flexible assembly cell concept design for wing structure assembly. A leading Aircraft Manufacturer is planning to increase rate to meet future demand. The current static system restricts the deployment of new technologies and production ramp-up requires additional fixtures which require large investment and long lead times. The aim is to allow production rates to be increased or decreased as demand requires, thereby reducing the requirement for extra fixtures. Improvements in metrology and tooling systems means a flexible system may now be feasible. The proposed system concept allows implementation of new technologies as they become viable. This research focusses on developing conceptual designs of the system architecture. Axiomatic Design (AD) is a design methodology that maps requirements to physical elements. AD principles are used to produce a decoupled cell design that meets the requirements of flexible production and new technology introduction. Designs are presented as DELMIA models and factory layouts.
Technical Paper
2014-09-16
Santiago Droll
In contemporary industries the demand for very accurate robots is continuously growing. Yet, robot vendors are limited in the achievable accuracy of their robots, as they have no means to provide a direct end-effector feedback. Therefore most approaches aim to evaluate an accurate model of the system, thus providing compensation factors to correct the paths. Models, however, are unable to represent the real physical system in a sufficient manner for path correction. The non-linearities in robotic systems are difficult to model and the dynamics are very fast. A better approach is therefore to use direct end-effector position and orientation feedback from an external sensor. The measured data can directly be compared to the nominal data from the path interpolator. Hence, they are not dependent on the kinematic robot model. The residual errors can be used to calculate correction values for the individual robot joints, thus providing a fast path correction algorithm. In this paper such a method is discussed, implemented and tested.
Technical Paper
2014-09-16
Ruiqiang Lu
With the development of many new technologies in aircraft manufacturing area and the increasing competition of the global market, aircraft manufacturing enterprises have to reduce the total production time and increase the cost-efficiency, with the consideration of high speed response to the changes inside enterprises or in the environment. Production planning and scheduling is a significant process in manufacturing, especially for complicated part or component processing. This paper proposes an agent based multi-objective optimization approach for production planning and scheduling based on genetic algorithms. It aims to minimize the total production cost and simultaneously reducing the emission released during production, and the delivery time and equipment constraints are satisfied as well. The new approach is employed into a workshop for aircraft engine blade manufacturing. Exprimental results show that a group of Pareto optimal solutions are gained, which can be provided to the enterprise decision maker to select according to different actual conditions.
Technical Paper
2014-09-16
Karl-Erik Neumann, Robert Reno
Practical and Portable Automated Machining The utilization of new materials and tightening of desired tolerances has driven the advancement of Practical and Portable Automated Machining. Increased demand in volume within the aerospace industry not only requires minimizing the amount of manual operations, but also applying automation inside existing manual fixtures. In the past, manual labor, with drastic limitations on achievable accuracies, has been utilized in areas that machine tools cannot either access or the limited amount of work does not justify the expense of additional machines. Assemblies requiring critical hole alignment or drilling through stack materials often are difficult to achieve using manual operations. The solution is a practical and very portable machining unit that is small enough to fit into otherwise difficult areas and is lightweight enough to be either moved into position by small machines or quickly disassembled/assembled with each subassembly capable of being positioned manually.
Technical Paper
2014-09-16
Richard Kingston
This project presented in this paper is the result of a package of work undertaken as part Manufacturing Technology Centre's Core Research Project programme and backed by MTC members Airbus, GKN, Spirit, Rolls-Royce and Hexagon Metrology. The Metrology Assisted Robotic Automation (MARA) project is MTC's attempt to tackle the issue of industrial robot positional & path accuracy and builds on some of the principals exhibited on commercially available metrology guidance systems. To date, commercially available metrology guidance systems are only capable of performing static correction of a single robot point position. The MARA solution described in this paper details a software development that uses data captured from a metrology device, namely a Leica T-Mac system, and performs a dynamic correction of, not only, a single robot point position but also a dynamic correction of the robot path to accuracies better than +/-0.2 mm.
Viewing 1 to 30 of 19612

Filter

  • Article
    1237
  • Book
    54
  • Collection
    12
  • Magazine
    798
  • Technical Paper
    8351
  • Standard
    9160
  • Article
    9160