Multi-Head Drill-Fill Layout for Pulsed Rivet Assembly
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Solution Overview
Problem
Current manufacturing systems for assembling large structures like commercial aircraft are complex and costly, with low throughput due to the need for manual or robotic drilling and fastening of thousands of rivets, taking 10 hours or more to complete a riveted assembly.
Innovation Solution
A multi-head drill and fill machine with a bifurcated backbone and actuator groups that pulse longitudinally to align and operate on a panel, allowing simultaneous drilling, rivet insertion, and squeezing, significantly increasing the speed and efficiency of the fabrication process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If traditional robotic systems with three dimensional positioning capability and multiple tool systems are used, then positioning precision and automation extent are improved, but device complexity and cost increase significantly
Solution Approach 1:
The system divides the panel processing into multiple sequential pulse positions (first pulse position through sixth pulse position), with each position performing specific operations (drilling, rivet insertion, squeezing). This segmentation allows simple actuators to perform complex tasks through temporal and spatial division of labor, avoiding the need for complex robotic heads with multiple tool systems.
Solution Approach 2:
The system uses periodic pulsing action where the panel is sequentially positioned at different pulse positions (first, second, third, fourth, fifth, sixth pulse position) and operations are performed at each position. This periodic action transforms a complex continuous operation into a series of simple periodic steps, reducing device complexity while maintaining automation.
2Manufacturing precision
If individual drilling and fastener insertion operations are performed sequentially, then manufacturing precision is maintained, but productivity remains low at 5-7 fasteners per minute
Solution Approach 1:
The system merges multiple operations (drilling, rivet insertion, rivet squeezing) into a single integrated pulse sequence. At each pulse position, multiple actuators work simultaneously on different rivets at different stages of the process. This merging of operations into a coordinated pulse sequence dramatically increases productivity while maintaining precision through the structured sequence.
Solution Approach 2:
The system maintains continuous useful action by overlapping operations across multiple pulse positions. While rivets are being squeezed at one position, drilling and insertion operations continue at other positions in the sequence. This continuous overlapping execution eliminates idle time and maximizes throughput while preserving manufacturing precision through the structured pulse sequence.
3Adaptability or versatility
If a common robotic head with automated tool changers is used to accommodate differing fastener sizes, then adaptability is improved, but device complexity and cost increase
Solution Approach 1:
The system applies local quality by having different actuators specialized for different operations (drilling actuators, rivet insertion actuators, squeezing actuators) positioned at different pulse positions. Each actuator is optimized for its specific function rather than using a universal tool system. This specialization provides adaptability for different fastener sizes while reducing overall device complexity.
Solution Approach 2:
The system uses dynamic reconfiguration where the panel is moved to different pulse positions to access different actuators specialized for different operations. This dynamic positioning approach provides versatility for different fastener requirements without requiring complex automated tool changers, as the system adapts by changing the panel position rather than the tooling.
Data Source
AI summary
A manufacturing system employing a bifurcated backbone having an upper plate and lower plate, with a longitudinal slot between the upper and lower plate. A plurality of actuator groups are mounted longitudinally adjacent the slot. A carrier supports a panel for longitudinal translation into the slot and the carrier is configured to pulse longitudinally in the slot relative to the plurality of actuator groups during a sequence of fabrication operations by the plurality of actuator groups on the panel.