Multi-Head Riveting Line With Pulsed Panel Positioning
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Solution Overview
Problem
Current manufacturing systems for assembling large structures like commercial aircraft are costly and complex, with low throughput due to the need for highly complex robotic systems and manual drilling and fastening processes, which can take several hours to complete a riveted assembly with thousands of rivets.
Innovation Solution
A multi-head drill and fill machine with actuator groups, each comprising a drill, rivet feeder, and squeezer, aligned for sequential operation on a panel, supported by a bifurcated backbone, allowing for pulsed positioning and simultaneous operation across multiple actuators to rapidly drill and fill rivets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional robotic systems with three dimensional positioning capability and multiple tool systems are used, then positioning precision and operation versatility are improved, but device complexity and cost increase significantly
Solution Approach 1:
The system divides the riveting operation into multiple sequential actuator stations (drilling station, fastener installation station, bucking station) arranged in a linear sequence. Each station performs a specific function, eliminating the need for complex robotic heads with multiple tool systems while maintaining operational versatility.
Solution Approach 2:
The invention transitions from three-dimensional robotic positioning to a linear one-dimensional sequence of actuator stations. The panel moves through a fixed linear sequence of operations rather than requiring complex spatial positioning, simplifying the system architecture while maintaining capability.
2Manufacturing precision
If individual drilling and fastener insertion operations are performed sequentially by robotic systems, then operation precision is maintained, but productivity decreases to only 5-7 fasteners per minute
Solution Approach 1:
Multiple actuator stations (drilling, fastener installation, bucking) are merged into a single integrated system that processes multiple rivets simultaneously as the panel moves through the sequence. This combines multiple operations into one coordinated system, dramatically increasing throughput while maintaining precision through controlled sequential activation.
Solution Approach 2:
The system enables continuous processing by having multiple actuator stations operate in sequence as the panel moves through them. Rather than completing one rivet entirely before starting the next, the system continuously progresses through multiple rivets in parallel stages, eliminating idle time and maximizing productivity.
3Reliability
If complete riveted assemblies with several thousand rivets are produced using traditional systems, then assembly quality is ensured, but production time extends to 10 hours or more
Solution Approach 1:
The panel is pre-positioned on a carriage that moves it through the sequence of actuator stations. The drilling, fastener installation, and bucking operations are preliminarily arranged in a fixed linear sequence, allowing the system to process thousands of rivets rapidly without compromising quality through controlled sequential execution.
Solution Approach 2:
The system uses periodic activation of actuator stations as the panel moves through them in rhythmic sequence. Each station activates at specific intervals corresponding to panel position, enabling rapid cyclic processing of multiple rivets while maintaining consistent quality through standardized periodic operations.
Data Source
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Figure 4
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. (Fig. 4)