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the center. Ribs cross the spars,
extending from the leading to the
trailing edges of the wing.
Custom-built Electroimpact HAWDE machine speeds wing-panel production.
The E4380 wing panel machine attaches stringers to the skin in the Stage 00 cell.
for Airbus’s manufacturing
team in Broughton, U.K., and
for its prime contractor for
wing-assembly automation
tools, Electroimpact, Inc.
Focusing on the design and
manufacturing of quality aircraft
assembly tooling, Electroimpact
is known for its engineering
culture — nearly 70% of its
250 employees have an engineering
degree. Engineers in charge of a
program are empowered to take
total responsibility, including
vendor selection. For the Airbus
programs, Electroimpact choose
to work with Bosch Rexroth for its
best-in-class hydraulic and linearmotion
solutions and applications
expertise, as well as Bosch
Rexroth’s distributor, Pacific Power
Tech, based in Seattle.
Stages of wing construction
“The assembly process is
done in two stages,” explains
Electroimpact’s Ben Hempstead.
“For the initial stage, which Airbus
calls Stage 00, Electroimpact
provided four lines of fixtures
for building up the upper and
lower wing panels. This is a highly
automated process in which
riveting-bolting machines traverse
the panels attaching stringers to
the skin. Virtually no manual labor
is required in this cell.
Next, the panels are moved to the
structural wing-assembly process.
The huge size of a completed
panel — up to 111 feet long and
weighing 8,818 pounds — poses
a big problem. “Using cranes
doesn’t work,” says Electroimpact’s
Ted Karagias. “The wing
panels are distorted when
suspended from the cranes.”
Panels, which consist of an
aluminum alloy skin reinforced
by stringers, are then attached
to this framework.
The panels are produced
concurrently in a separate
operation. First, skins are formed
to the proper curvature. Stringers
are made to fit that contour, then
are attached to the skin to ensure
proper shape and strength by the
E4380 machines in the Stage 00
cell. The A380’s upper wing uses
the largest single skin, which is
111 feet long.
The completed panels are then
moved to the structure for
assembly. After being loaded into
a jig, the panels are positioned,
drilled, countersunk, riveted or
bolted with titanium lockbolts
onto the pre-drilled framework.
The entire process is both labor
and automation intensive,
especially at this scale — a complete
“wing box” takes weeks to produce,
which, even so, is very fast by
industry standards.
Construction of the A380’s wings
presented several large challenges
HAWDE unit automatically drills holes
during the Stage 01 wing process without
the quality and speed compromises of
manual operations.
Stage 00 E4380 machine positioned over panel fixture.
Close-up of the rotated head of the
HAWDE CNC drilling machine used in
Stage 01 .
machines. Our design goal was
to enable one operator to set up,
load NC tapes, verify accuracy,
and configure the fixtures.”
For the Airbus A380 panelproduction
facility, Electroimpact
built four machine lines, each
with two machines for upper and
lower surface panels. Each line
includes three fixtures, where four
panels are loaded. The jigs hold
the components in accurate form
and location while the automated
machines drill, rivet, and bolt
the components together. Sealant
is applied to the components
during the jig load. No temporary
fasteners are used.
Thus after fastening, the wing
panel assemblies are complete.
No interim operations are needed
to clean and deburr. The oneup
assembly process reduces
handling damage and positioning
inaccuracies (datum errors).
The machines can install rivets
and bolts in diameters of 1⁄4
to 1⁄2 inch, with a stack range
up to 2.5 inches. Automated
cold working, hole probing,
countersink sealing, and collar
installation are all included.
Achieving high-accuracy goals
was possible, because the machines
and fixtures used many highly
accurate linear axes employing
Rexroth linear guides and ball
screws. Machine accuracy is a
function of deflections of welded
and machined components.
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