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specific wing rib part being produced.
The wing ribs are being run in
single-piece production quantities,
For the A380, Airbus made significant changes to its plant in Filton, UK, developing
an advanced wing rib manufacturing cell using Makino equipment.
26 Aerospace Engineering October 2003
Tech focus
dramatically reducing inventory
levels. The raw material cost of each
rib exceeds 15,000 euros (approximately
$16,000).
Only minimal staffing increases
were required for the wing rib
production facility to support the
additional A380 machining requirements.
This is due to the multi-machine
staffing capability of the Makino
Machining Complex automatic palletmm
with a tolerance of –0.08 mm/
+0.25 mm. “We feel that the Makino
machines can allow us to reduce to
0.8 mm with proven process capability,”
he said.
The Airbus A380 super jumbo jet
is intended to achieve a 25% reduction
in cost per seat and a 15%
improvement in fuel efficiency.
Patrick Ponticel
handling system. Two operators are
capable of loading and unloading the
parts, with the Makino cell control
software managing the machine
scheduling, the indexing of the pallets
to the machine, and the loading/
unloading station.
Airbus is holding tolerances of
±0.095 mm on the extremities of its
parts, according to Harland. This is
done with pocket thicknesses of 1.1
Drilling, installation of fasteners leaned out at Boeing
A new drill/insert fastener end
effector developed by J.F. Hubert
Enterprises, Brown Aerospace, and
Boeing is a good example of lean
manufacturing, eliminating as it does
several steps between hole drilling
and fastener installing.
The device is being used in an
aircraft fuselage for drilling an
aluminum stack-up of aluminum/
aluminum and aluminum-titanium
bulkheads. Most hols are 3/16- or
1/4-in diameter with controlled-depth
countersinks.
Capability requirements of the end
effector include:
• Burr-free drilling.
• Wet drilling (faying surface seal
present between skin and substructure
while drilling).
• Countersink depth control on single bit
for one-up, one-pass (burrless) operation.
• Interference-fit fastener insertion of
a Hi-Lok fastener in the current
process. (Freedom to transition to a
Monogram OSI one-sided fastener is
designed-in with a rapid change-out
module.)
The technology eliminates more
than half the steps previously required,
including manual deburring,
and generates “huge savings,”
according to the companies.
Crimping tool from Tyco is lightweight affair
Tyco’s micropneumatic
crimping tool
with tool
holders and
crimp heads.
A micro-pneumatic crimping tool from
Tyco Electronics that measures 5.75 in
long and has a mass of 1.5 lb is 50%
smaller and 35% lighter than the
company’s widely used 6-26 pneumatic
hand tool (it is not designed as
a replacement for the 6-26), allowing
for use in more ergonomically
challenging operations. Its small size
and negligible weight are well suited
for intricate crimping processes found
in airframe wiring installation and
repair situations.
Hand-actuated, it operates on air
pressure of 90 psi. The power unit is
compatible with the small tool holder
and adapters used on the 6-26 unit.
When used with compatible crimping
heads, it will typically crimp terminals
and splices to 26-14 AWG wire. In
some cases, as with AMP
SOLISTRAND terminals, the acceptable
wire range is 22-10 AWG.
The tool can be outfitted with a
double-action crimp head, a T-HEAD
crimper, or a straight-action crimp
head. It is designed to crimp many
types of terminals, splices, and
contacts including PLASTI-GRIP butt
splices and terminals, PIDG terminals
and splices, SOLISTRAND uninsulated
terminals and splices, AMPLIMITE size
20 and DF contacts, as well as
circular plastic connector contacts and
MATE-N-LOK contacts.
Micro-pneumatic hand tools are
general-purpose tools designed for
intermediate production volumes that
require more speed than unpowered
hand tools, but do not demand the
capacity of a semi-automatic
bench press.
Patrick Ponticel
Aerospace Engineering October 2003 27
Tech focus
Here are the steps in the previous
process:
1. Apply doublers on top of the
bulkheads.
2. Apply skins over the doublers.
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