1、Bullen R-416 George N. Bullen George N. Bullen Automated/ Mechanized Drilling and Countersinking of Airframes Automated/ Mechanized Drilling and Countersinking of Airframes Automated/Mechanized Drilling and Countersinking of Airframes The book guides airframe producers through a stepped approach for
2、 evaluating areas of airframe manufacture for applying automation, and provides a detailed description of the process for choosing, acquiring, and transitioning the right machinery for success. It offers a future state of airframe assembly and describes a vision for the next 10 to 15 years of airfra
3、me manufacturing. Readers from industry, government, and academia will use the information in the book to: Understand the evolution of automated/mechanized drilling and countersinking airframes. Access decision models and matrices to help evaluate the feasibility of applying automation/mechanization
4、 to any airframe. Gain access to a step-by-step procedure to select the right piece of machinery. Learn the necessary processes for testing and transitioning machinery to production. Assess and acquire data to evaluate the effect of the process. Choose and train the right individuals to manage and r
5、un the machinery. Conduct cost benefit analysis models. Make recommendations for maintenance and spares. Address socio-economic factors of reconfiguring a facility from hand to automated activities. No other book provides such detailed technical, economic, and social information about applying autom
6、ation to the single largest contributor to airframe cost. About the Author George “Nick” Bullen became president and CEO of Smart Blades, Inc. after retiring as technical fellow and principal engineer for Northrop Grumman. Smart Blades designs and develops wind turbine blades and modular factories f
7、or manufacturing them in situ.Mr. Bullen holds 16 U.S. and international patents for innovations related to manufacturing, mechanization, robotics, robotics control software, and nuclear testing/quality devices that are the basis for all current automated systems used to assemble airframes in the Un
8、ited States and Europe. He earned an MBA from Loyola Marymount University, a BSMG from Pepperdine University, an ASBA from Mesa College, and is finishing his PhD in decision sciences, engineering research.Automated/ Mechanized Drilling and Countersinking of Airframes 6326_Book.indb 1 4/11/13 4:49 PM
9、Other SAE books of interest: Care and Repair of Advanced Composites, Second Edition By Keith B. Armstrong (Product Code: R-336) Aircraft Maintenance: The Art and Science of Keeping Aircraft Safe By Bruce R. Aubin (Product Code: T-115) Mechanics Modeling of Sheet Metal Forming By Jwo Pan and Sing C.
10、Tang (Product Code: R-321) For more information or to order a book, contact: SAE International 400 Commonwealth Drive, Warrendale, PA 15096-0001, USA; Phone: 877-606-7323 (U.S. and Canada only) or 724-776-4970 (outside U.S. and Canada); Fax: 724-776-0790; Email: CustomerServicesae.org; Website: http
11、:/books.sae.org. 6326_Book.indb 2 4/11/13 4:49 PMAutomated/ Mechanized Drilling and Countersinking of Airframes By George N. Bullen Warrendale, Pennsylvania USA 6326_Book.indb 3 4/11/13 4:49 PM Copyright 2013 SAE International eISBN: 978-0-7680-7995-1 400 Commonwealth Drive Warrendale, PA 15096-0001
12、 USA E-mail: CustomerServicesae.org Phone: 877-606-7323 (inside USA and Canada)724-776-4970 (outside USA) Fax: 724-776-0790 Copyright 2013 SAE International. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, distributed, or transmitted, in any form or
13、by any means without the prior written permission of SAE. For permission and licensing requests, contact SAE Permissions, 400 Commonwealth Drive, Warrendale, PA 15096-0001 USA; email: copyrightsae.org; phone: 724-772-4028; fax: 724-772-9765. ISBN 978-0-7680-7646-2 SAE Order Number R-416 DOI 10.4271/
14、R-416 Library of Congress Cataloging-in-Publication Data Bullen, George N. Automated/mechanized drilling and countersinking of airframes / by George N. Bullen. pages cm Includes bibliographical references. ISBN 978-0-7680-7646-2 1. Rivets and riveting, Aircraft-Automation. 2. Airframes-Design and co
15、nstruction- -Automation. 3. Drilling and boring machinery-Automation. 4. Manufacturing processes-Automation. 5. Fasteners. I. Title. TL671.5.B85 2013 629.1342-dc23 2013002026 Information contained in this work has been obtained by SAE International from sources believed to be reliable. However, neit
16、her SAE International nor its authors guarantee the accuracy or completeness of any information published herein and neither SAE International nor its authors shall be responsible for any errors, omissions, or damages arising out of use of this information. This work is published with the understand
17、ing that SAE International and its authors are supplying information, but are not attempting to render engineering or other professional services. If such services are required, the assistance of an appropriate professional should be sought. To purchase bulk quantities, please contact: SAE Customer
18、Service Email: CustomerServicesae.org Phone: 877-606-7323 (inside USA and Canada)724-776-4970 (outside USA) Fax: 724-776-0790 Visit the SAE International Bookstore at books.sae.org 6326_Book.indb 4 4/11/13 4:49 PMDedication To my wife, Natalie, for her support and patience, and Joe Wardell, who was
19、my right arm through the long days and nights of design, development, and transition to production. 6326_Book.indb 5 4/11/13 4:49 PM6326_Book.indb 6 4/11/13 4:49 PMvii Table of Contents Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii Acknowl
20、edgments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xv Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 End Notes 16 Reference .16 Chapter 1 Historical Perspective: Why Airframes Have Holes . . 17 1.1 Introduction
21、 .17 1.2 The Airframe 18 1.3 Aluminum 19 1.4 Rivets.20 1.5 Assembly Tooling 23 1.6 Titanium 24 1.7 Hand Tools and Drills.25 1.8 Composites28 1.9 Tooling and Composites.30 1.10 On-Assembly Drilling32 References 36 Chapter 2 Airframe Manufacturing Cost Drivers . . . . . . . . . . . . 37 2.1 Introducti
22、on .37 2.2 Why Reduce Cost? .38 2.2.1 The Value Price Profitability Index Commercial .40 2.3 Defining Cost 41 2.4 Identifying Manufacturing-Related Costs43 2.4.1 Efficiency 44 2.4.2 Effectivity46 2.4.3 Impact 47 2.4.4 Cost Contributors Assessment 51 2.5 Summary .52 References 54 6326_Book.indb 7 4/1
23、1/13 4:49 PMviii Table of Contents Chapter 3 Incentives and Disincentives to Automate . . . . . . . . 55 3.1 Introduction .55 3.2 Military Automation Disincentive 57 3.2.1 The Means of Production 57 3.2.2 Parceled Application 59 3.2.3 Specific Use 60 3.2.4 Time Horizon 60 3.2.5 Politics 61 3.2.6 Con
24、trolled Profit62 3.2.7 Restricted Sales .62 3.2.8 No Competition 63 3.3 Military Producers Incentives to Automate 64 3.3.1 Affordability .64 3.3.2 Enlightenment .64 3.3.3 Complexity 65 3.3.4 Multiyear Buys .65 3.3.5 Quality 65 3.3.6 Marketing .66 3.3.7 Access.66 3.4 Commercial Disincentives .67 3.4.
25、1 Geopolitical Local.67 3.4.2 Geopolitical Global .68 3.4.3 Labor .68 3.5 Commercial Incentives 69 3.6 Summary .70 References 71 Chapter 4 Types of Drill/Countersink Automation . . . . . . . . . . . 73 4.1 Introduction .73 4.2 Motion74 4.2.1 Size .75 4.2.2 Machine Types .76 4.2.3 Tools and Parts .80
26、 4.2.4 Integration Level I 81 4.3 Action 81 4.3.1 End Effector81 4.3.2 Dust Collection .84 4.3.3 Coolant85 4.3.4 Tool Changer.85 4.3.5 Vision System 85 4.3.6 Inspection .85 4.3.7 Integration Level II86 6326_Book.indb 8 4/11/13 4:49 PMix Table of Contents 4.4 Controller .86 4.4.1 Human Machine Interf
27、ace .86 4.4.2 V olumetric Compensation Algorithm87 4.4.3 Integration Level III .87 4.5 Calibration 88 4.6 Sustainability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 4.7 Summary .89 References 90 Chapter 5 Considerations Before Replac
28、ing Hand Drilling with Mechanization or Automation . . . . . . . . . . . . . . . . . . 91 5.1 Introduction .91 5.2 Before the Decision to Automate .93 5.2.1 Feasibility Analysis .93 5.2.2 Cost Benefits Analysis 100 5.3 “Go-Ahead” Decision Criteria.105 5.4 Summary 105 Chapter 6 How to Choose the Righ
29、t Automation . . . . . . . . . . . 107 6.1 Introduction 107 6.2 Three Donts108 6.2.1 Needs 109 6.2.2 Affordability 110 6.2.3 Complexity .112 6.3 References112 6.4 Requirements Document .113 6.4.1 General Information114 6.4.2 System Summary 114 6.4.3 Functional Requirements .114 6.4.4 User Impacts 11
30、4 6.4.5 Performance Requirements114 6.4.6 Additional System Requirements 115 6.4.7 Equipment and Software115 6.4.8 Security 115 6.4.9 Location 115 6.5 Summary 116 References .117 Chapter 7 Steps to Installation . . . . . . . . . . . . . . . . . . . . . . . . . 119 7.1 Introduction 119 7.2 Mapping th
31、e Existing Process .120 7.2.1 Part Placement 122 7.2.2 Trim .124 7.2.3 Finished Hole Size .124 6326_Book.indb 9 4/11/13 4:49 PMx Table of Contents 7.3 Mapping the New Process 125 7.4 Requirements Document .126 7.4.1 Identify Stakeholders and Define Stakeholder Needs .126 7.4.2 Categorize System Requ
32、irements 127 7.4.3 Interpret and Record Requirements 128 7.4.4 Sign Off 128 7.5 Platform Specification128 7.6 Request for Proposal.129 7.6.1 Introduction 130 7.7 Manufacturing Readiness Level Consideration 132 7.8 Performance Measurement Tools 133 7.9 Factory Acceptance 133 7.9.1 Basic Process Contr
33、ol System 134 7.9.2 Hazard .135 7.9.3 Instruments .135 7.9.4 Process Risk.135 7.9.5 Safety Instrument Function .136 7.10 Installation and Test 136 7.11 Summary136 References .137 Chapter 8 Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 8.1 Introduction 139 8.2 Unique Tes
34、ts140 8.2.1 Impact Avoidance Test141 8.2.2 Aluminum Tape Ink Dot Test 143 8.2.3 Compression Deflection Test 146 8.2.4 Drill Routine Conformance Test147 8.2.5 Countersink Depth Test.147 8.2.6 Machine Subroutines .148 8.2.7 Final Full Function .149 8.2.8 Demonstration 149 8.3 Volatile Organic Compound
35、s .150 8.4 Summary 151 References .152 Chapter 9 Transition to Production . . . . . . . . . . . . . . . . . . . . . . 153 9.1 Introduction 153 9.2 TTP Document and Transfer of RAA .154 9.3 TTP Technology Readiness Levels .155 9.3.1 TRL 4 155 9.3.2 TRL 5 156 9.3.3 Combined TRL/MRL 156 6326_Book.indb
36、10 4/11/13 4:49 PMxi Table of Contents 9.4 TTP Manufacturing Readiness Level .156 9.4.1 MRL 4 Material Solutions Analysis, Milestone A .157 9.4.2 MRL 5 Technology Development, Milestone B .157 9.5 TTP and Product Delivery Team Composition and Selection 158 9.6 TTP Document159 9.6.1 TTP Final Hole Co
37、unt and Cost Benefits Analysis 161 9.7 TTP Risk Identification and Assessment 162 9.7.1 Technology and Industrial Base 163 9.8 Validation of System to Production Requirements: Exit Criteria166 9.9 Summary 166 References .167 Chapter 10 Training . . . . . . . . . . . . . . . . . . . . . . . . . . . .
38、 . . . . . . . 169 10.1 Introduction .169 10.2 Who to Train.171 10.2.1 Operator.171 10.2.2 Design Engineer 177 10.2.3 Manufacturing Engineer .180 10.2.4 Quality Assurance 182 10.2.5 NC Programmers .183 10.2.6 Cost Center Managers .183 10.2.7 Tooling 184 10.3 Summary .184 References .185 Chapter 11 M
39、aintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187 11.1 Introduction .187 11.2 ComplexityNew Normal 188 11.3 Impact Prevention 191 11.4 Predictive Maintenance .192 11.4.1 Maintenance Integration .192 11.5 Prognostic Health Monitoring196 11.6 Maintenance .196 11.6.1 Autonomo
40、us .197 11.6.2 Breakdown.198 11.6.3 Improvement.198 11.6.4 Periodic Maintenance .198 11.6.5 Certification198 11.7 Buying Maintenance 198 11.8 Troubleshooting 199 11.9 Summary200 References .201 6326_Book.indb 11 4/11/13 4:49 PMxii Table of Contents Chapter 12 Social Impact of Automation . . . . . .
41、. . . . . . . . . . . . 203 12.1 Introduction .203 12.2 Pacifying the Human Capability-Machine Experience .204 12.2.1 The Social Concept of Operations .206 12.2.2 Data Compilation .212 12.3 Perception of Ubiquitous Automation.212 12.4 Safe, Secure, and Ethical Automation .213 12.4.1 Safety .213 12.4
42、.2 Security .214 12.4.3 Ethical Application of Automation 214 12.5 Management of Automated Systems 215 12.6 Organizations215 12.7 Customers.216 12.8 Summary .216 12.8.1 Communication 217 12.8.2 Participation .217 12.8.3 Consultation .217 12.8.4 Training .217 12.8.5 Support .217 References .218 Chapt
43、er 13 Future State of Airframes and Automation Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219 13.1 Introduction .219 13.2 Economics.220 13.3 Manufacturing Exodus221 13.4 Exit the Autoclave 225 13.5 Automation or Labor .227 13.6 Fastener Alternatives .229 13.7 Summary .
44、230 References .233 Appendix A Automated Machine Suppliers for D/C of Airframes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237 About the Author . . . . . . . . . . . . . . . . .
45、 . . . . . . . . . . . . . . . . . . . . . 245 6326_Book.indb 12 4/11/13 4:49 PMxiii Preface This book has been written to guide airframe producers through the challenging process of applying automation to perform drilling and countersinking (D/C). Automated D/C is the application of specialized Num
46、eric Control (NC) machinery to D/C a finished hole “one shot” 1for insertion of the fasteners that hold the airframe together. Applying automation replaces the traditional hand methods for D/C. A chapter-by-chapter description will be provided to define the steps necessary to successfully apply auto
47、mation for D/C holes. There can be well over 100,000 holes that need to be drilled and countersunk in a modern military fighter/attack airframe and more than 2,000,000 in a large commercial airframe. Large commercial and military airframes can exceed three million holes. The large number of holes an
48、d the hand method for D/C drives cost, quality, schedule, complexity, and safety. Sixty-five percent of the cost of airframe assembly is derived from D/C of holes by hand. Eighty-five percent of the quality issues and eighty percent of the lost time injuries are the result of the hand process for D/
49、C. Therefore, the focus of this book will be the area of greatest return on investment (ROI) for the airframe producerautomation of D/C. Numerous attempts have been made to automate the fastener installation and sealing process, with limited success. The investment, complexity, processes, and operation of fasteners have not made their application economically viable as an option to replace the hand operation, in most cases. Examples exist, but they are limited to off-line assembly operations or are rare in on-assembly applications. There are some signs that
