Automated Installation of Difficult to Access Fasteners in Aircraft Assemblies

Fastening applications in military aircraft present unique challenges. Often times these aircraft designs are governed by considerations beyond manufacturability. This sometimes precludes the use of traditional automated fastening equipment for some assemblies. Lockheed Martin –Operations Technology identified these limiting challenges on one of their larger production assemblies and collaborated with PAR Systems to find novel solutions. Lockheed Martin Operations Technology performed the initial task breakdown to identify the various steps in the process and make an initial risk evaluation of each. Lockheed and PAR performed a mutual risk analysis and identified a series of Proof of Concept studies and demonstrations. PAR and Lockheed started with creating a minimal viable solution for automated fastening and layered on subsequent additional process feasibility and process development steps, until all the functional steps were proven individually. Subsequent integration efforts identified all requirements needed to make a fully automated fastening system. This allowed for an iterative design cycle approach that strategically burned down risk while keeping initial investments low.
Key challenges addressed were fastening in areas where access was limited, handling varying and inconsistent grip lengths, fastening assemblies that contain a large variety of unique fasteners, clearing sealant bleed in from fastener holes and countersinks, applying sealant to fasteners, and removing temporary fasteners. This range of tasks was accomplished by designing interchangeable and cost-effective end effectors, that all worked from a common base end effector. This allowed these tasks to be completed in one work cell using common motion platforms. Some processes required the development of novel approaches, and the TRL of these new processes were matured through iterative studies. The end result is the build and testing of a full complement of production ready end effectors for implementation in a future system.
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