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外文翻译--A320机翼盘区使用的水平铆钉注射器的设计 英文版.pdf

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外文翻译--A320机翼盘区使用的水平铆钉注射器的设计 英文版.pdf

PaperNumber2007013783HorizontalRivetInjectorDesignUsedonA320UpperPanelChristopherBuchheit,PeterZieveElectroimpact,IncCopyright©2007SAEInternationalABSTRACTThispaperwillcoverthedesignofthehorizontalrivetinjectoruseontheSA2LVERdesignatedforstage0productionofAirbusA320UpperWingPanels.TheinjectordesignisintendedtodecreasecycletimesandincreasereliabilitywhilenotreducingthefunctionalityoverpreviousrivetfeeddesignsusedbyElectroimpact.Specificrivethandlingmethodsanddesignfeatureswillbereviewedandtheirresultoncycletimeandreliabilitydiscussed.INTRODUCTIONTheSA2machineisthelatestintheLowVoltageElectromagnetRiveterfamilyorLVER.ThisfamilyisaseriesofwingpanelfasteningmachinesdesignedhasbeenimplementedforproductionoftheAirbusA320throughA380wingskinpanels.ThenewlyimplementedSA2machineincorporatesmanymajordesignrevisionsintendedtoincreaseproductivityandreliability.Oneofthesemajorrevisionsinvolvesthespecificprocessusedtomovetherivetslugfromthefeedtubetothepanel.Thispaperwillreviewthespecificsoftherivetinjectorithasimprovedbothreliabilityoftherivetingprocessandincreasedproductivitybydecreasingcycletimes.BACKGROUNDLVERBASICSSomedetailsonhowtheelectroimpactfasteningmachineworkswillbenecessaryinunderstandingthebenefitsofthenewinjectoroverthepreviousdesign.TheLVERisafamilyofpurposebuilt5axismachinesdesignedtoaccuratelyfastenaverticallyorientedwingskinandstringer.seeFigure1TheLVERsuseapairofactuatedfasteningtablesthatdriveforwardtorigidlyclampthewingandstingertogetherbetweentwoclampingfeetsosubsequentdrillingandfasteningcanbecarriedoutwithoutdefectsbetweenthestringerandwingpanel.Theskinsidefasteningtablecarriesthemajorityoftheworktoolswhicharecarriedonamovableaxisallowingthetransferorshuttlebetweentoolswhileremainingclamped.Hereisadescriptionoftherivetfasteningcycle.ClampupandmeasurethestackthicknessShuttletodrillspindle–drillholeShuttletoEMR–Insertrivet,checkrivetlengthandformrivetShuttletoshavespindle–ShaveskinsiderivetheadflushtopanelUnclampandmovetonextfastenerpositionPREVIOUSRIVETGRIPPERPreviousdesignsfortransferringtherivetfromthefeedtubestothepanelhaveutilizedapneumaticgripperlocatedonthefrontoftheEMR.InadditiontherivetfeedpathincludedaFigure1TheSA2machineintheAirbusfactoryinBroughton,UKNov.2006showingtheverticalorientationofthewingskinFigure3DiagramofthemajorcomponentscomprisingtherivetinjectordropdownchutecalledtheUturnwhichwaslocatedonthesideoftheclampingfoot.Thischuteonlylineduptotherivetgripperwhiletheshuttletablewasatthedrillposition.Thisoftenresultedinadelayinthecyclewherethedrillhadcompleteddrillingtheholebuttherivethadyettoreachtherivetgripper.Thisdelaywasespeciallyapparentinthinstacksandsmalldiameterrivetswheredrilltimewasatitsminimum.THESOLUTION–ANEWRIVETINJECTORThenewinjectordesignsolutionwouldincorporateareductionofthefrequencyofadjustmentsandtheeliminationofdelaysinthecycleduetoafixedfeedpositionaswellasnotremovinganyfunctionalityfromtheoriginaldesigns.Firstthesolutiontothefixedfeedpositionrequiredthenewsystemtobelocatedonthemovingportionoftheshuttletable.Second,theadjustmentswouldbeeliminatedwithabuiltinorpassivealignmentfeatures.Theoutcomeofthedesignprocesswasreplacingthepneumaticgripperwithasimplespringloadedrivetfingers,andreplacingtheUturnwithanewrivetinjector.Theinjectorsjobistotransfertherivetfromthefeedtubestotherivetfingers.Therivetfingersreplacedthepneumaticgripperfrompreviousmachinesandareverysimilartodesignsusedonotherfasteningmachines.Theonlychangeisthatthefingersholdarivethorizontalinsteadofvertical.ThepurposeoftherivetfingersaresimplytoholdarivetdirectlyinfrontoftherivetdiesowhentheEMRdrivestowardthepanel,therivetisinsertedintothepreparedhole.TheentiredevicehasnopneumaticsorelectronicsandonlyreliesonspringstoholdtherivetandsimpleslotscutintotheEMRdriverforalignment.TherewaslittledesigneffortputintothisassemblyonlyamatteroffittingittotheexistinghardwareontheendoftheEMRdriverbearing.Themajorityofthedesignwentintothenewrivetinjectorwhichhadtofeedahorizontalrivetintotherivetfingers.TherivetinjectorispositionedinaspaceunderneaththeEMRbutabovethesealantinserter.TheItalsohadtobebehindtheclampingfootbutfarenoughforwardtominimizethetraveloftheEMRwhichalsoimpactedcycletimes.seeFigure2withtheInjectorastheblueandblackrectangleLeftofcenter,thesealantinserterthelongblackrectangleatananglebelowcenterandtheclampingfootthesilvershapetouchingthewingpaneljustabovecenterThedecisionwastohangtheinjectorunderneaththeEMRbyapairofsupportlegswhichreacharoundtheoutsideoftheEMRanddowntotheinjector.seeFigure3ThereforetheinjectormoveswiththeshuttletableaxisbuthasafixedzaxistowardandawayfromthewingpanelpositionontheEMR.Whenitcomestimetofeedarivet,theEMRmovestothefeedpositiononitsZaxisandwaitsfortheinjectortoplacearivetintherivetfingers.Thefeedtubesblowtherivettoachamberintheinjectorlocatedabout75mmbelowtherivetfingers.ThislocationisashighaspossibleyetstillallowingtheEMRtopassoverthetopduringtheformingprocess.ThischamberisjustslightlyFigure2Theskinsideprocesstoolsandclampingfoot.Therivetinjectoristhebluerectangleleftofcenter.Figure4Diagramoftherivetchambershowingtherivetgripedbetweenthestoppinandgripbarlargerthenthe1/4rivetandiscompletelyenclosedatthistimebythecover.Next,theentranceofthechamberisblockedoffwithapopupstopperpin.Oncethestopperpinisextended,thenthegripbarwouldpinchtherivetaxiallybetweenthestopperpinandthegripbar.seeFigure4Nowthattherivetiscaptured,thecoverretractsleavingthechamberopenfromthetopandtwosides.Next,thetowerextends,translatingtherivettherequired75mmtotherivetfingers.seeFigure5Oncethere,thespringloadedrivetfingersgriptherivetontwosides.Nowthegripbarandstopperpinretractandthetowerlowers,leavingtherivetinthefingersreadytobefedintothewingpanel.Thewholeprocesstakesabout0.92secondsandcanbedonewhiletheshuttletableismovingsothereisnolongeradelayintherivetcycle.DESIGNFEATURESAxialRivetGrippingOneofthemajordesignaspectsoftherivetinjectoristheaxialgrippingoftherivet.Thisfeatureactuallyhelpstoeliminatenearlyallofthealignmentrequirementsbetweentheinjectorandrivetfingerbyallowingsomeflexibilityandtolerancetomisalignment.Ifboththeinjectorandfingersheldtherivetonthesides,therivetwouldbeoverconstrainedduringthetransfer.Thiswouldrequireatightalignmentbetweenthetwoassemblies.Grippingtheendsoftherivetreleasesthisoverconstrainingproblem.Itispossiblethataloosealignmentwouldcausetherivettobemishandledwhereitwoulddroporcausedtobetippedinthefingers.Inadditiontheaxialgrippingalsopushestherivettowardtherivetdiesettingafixeddistancefromtherivetdietotheendoftherivet.Thisisopposedtosettingthefixeddistanceonthepanelsideoftherivet.Puttingthesetdistanceonthediesidereducesthelengthofthefingerssincewealwaysknowwheretheendoftherivetwillbelocated.Inaddition,thisreducesthechanceofmarkingtheshankoftherivetbecausethefingersdontneedtoslidedownthelengthoftherivetbeforecontactingtherivetdie.PlasticOnlyContactSpecialconsiderationshavebeengiventorivetmarkingwiththenewrivetinjector.Toreducecycletimestherivetisblownthroughthefeedtubsatveryhighspeeds.Atthesespeedswhenevertherivetcontactsametalsurface,asmallmarkontheendoftherivetisproduced.Thismarksimplyaremovaloftherivetcoating,morethenagougeorscratch,butthereissomeconcernwiththelongtermproblemsassociatedwithmarkedrivets.Thereforeanysurfacetherivetcancomeincontactwithismadeofplasticandarealleasilyreplaceable.AirVentsIntheprocessoftestingtherivetinjectorwediscoveredaneedtoincreasetheairflowthroughthefeedtubes.Therivetistransferreddownthefeedtubesusingcompressedair.IncreasingthespeedoftheairintheFeedtubesalsoincreasedthespeedofthetransferredrivet.Howevertherivettravelingathigherspeedbouncedofftheendoftherivetchamberfartherandfartherastheairspeedwasincreased.Theresultwasaincreaseincycletimesduetolongersettlingtimes.Tofixthisproblem,longventswerecutintotherivetchamber.ThissolutioncompletelystoppedallrivetFigure5Diagramoftherivetinjectorintheraisedpositionbouncebacknomatterhowfasttherivetwastraveling,byallowinglargeamountsofairtopassaroundtherivetholdingitagainsttheendoftherivetchamber.DoubleRivetCheckOccasionallytworivetswindupinthefeedtubesatthesametime.Theresultisasituationwhereitisunknownwhichrivetisthecorrectforthepreparedhole.Acheckfortworivetsispreformedbythestopperwhenitextendstoblocktherivetchamber.Therivetchamberhasbeensizedtoonlyallowonrivetinthechamber.Bybeinglongerthanthelongestrivetbutshorterthan2timestheshortestrivet.Thatifmorethenonerivetwasfedthenthestopperpinwontbeabletoreachtheendofitstravel.Thistriggersanautomaticpurgecyclewheretherivetchamberisopenedup,alltherivetsareblownoutofthesystem,andanewrivetisfed.CONCLUSIONOneofthemajorgoalsoftheSA2projectwastodecreaserivetcycletimesoverpreviousmachines.ItwasclearthatpartofthesolutiontothisrequiredtheoldrivetgripperandUturnassemblieshadtobereplaced.InNovember2006theSA2machinebeganproductionofA320upperwingskinsinBroughton,UKforAirbus.SincethentheSA2machineregularlyachieves10cyclesperminuteandupto12rivetsperminuteinspeedtests.Previousmachinesachievednomorethen8.5rivetsperminute.Thiswaspartlyachievedbydecreasingtherivetfeedtimefromabout2.50secondsonpreviousmachinetoabout1.82secondsfortheSA2machine.Inaddition,toa.68secondimprovementtherivetfedisalwaysthecorrectlengthbecausetherivetisbasedontheactualstackmeasurementandnotprefedbaseduponthepreviousfedrivet.Lastlymaintenancedowntimedowntimeduetotherivetfeedhardwarehasbeenreducedfromapproximately1hrspermachinepermonthto0.25hrspermachinepermonth.REFERENCES1.07ATC208RH2–AutomatedRivetingCellforA320WingPanelsHolden,RayandPaulHayworth2007CONTACTAuthorChristopherBuchheitUniversityofPortland2001ElectroimpactInc,Seattle,WAChrisBelectroimpact.com

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