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Rexroth HNC 100 servo hydraulic
controller. The HNC integrates
an SSI linear scale, load cell, and
a Rexroth servo solenoid valve.
This configuration provides fine
position control with seamless
transition between position and
force control.
According to Karagias, the
servo axis provides exceptional
control over panel position, and
the Rexroth HNC controller
imparts several important
system benefits, namely:
• Reducing the statically
indeterminate problem to a
determinate one, allowing flexible
wing panels to move as if they are
a rigid part.
• Controlling distribution of
force imparted upon the wing
accuracy compared to manual and
earlier automated systems.”
Interim stage:
install panels to wing
substructure with manipulators
After the wing panels are
produced, they must be moved to
the wing-structure jigs. Because the
largest panel is up to 111 feet long,
the huge scale creates a big material
handling problem.
To meet this challenge, an Airbus
team of Alan Ferguson, Allan
Ellson, and Jim Rowe of Airbus
called upon Theodore Karagias of
Electroimpact. Karagias headed an
Electroimpact team — comprised
of Charles Hopper, Remco Spiker,
Laurence Durack and Matt
Kerschbaum — to devise a solution.
Instead of cranes, Electroimpact
created an array of six coordinated
servo hydraulic arms that engages
the panel along its entire length.
According to Karagias handling a
wing panel with multiple support
A close up view of E4380 machine and Stage 00 jigs.
panel to control the panel’s
shape and how it is presented
to the wing structure.
• Simplifying system level PLC logic
and position control instructions.
• Allowing direct access to all
critical system components and
providing servo control via the
SSI port using analog and digital
I/O, ProfiBus, and CANbus
fieldbuses, regardless of PLC scan
rates or network speeds.
When put to the test, the wingpanel
manipulator successfully
loaded its first A380 wing panel.
“It took a lot of teamwork to create
this system,” notes Karagias. “And
thanks to great collaboration, the
pieces just fit together beautifully.”
Stage 01:
wing-structure assembly
After the wing panels are loaded
in the Stage 01 jig, two operations
are performed: 1) fastening the
wing panels to the rib-andspar
structure, which requires
automated drilling, bolting,
and positioning employing
Electroimpact’s HAWDE machine;
and 2) attaching the undercarriage
reinforcement through the
lower wing skin, which uses
Electroimpact’s GRAWDE system.
HAWDE
Based on previous successes,
Airbus approached Electroimpact
to automate wing-panel
fastening to the wing structure.
Traditionally, this task is
done by drilling, bolting and
positioning the panels manually.
Automating the process meant
overcoming several challenges
with unique solutions.
“The basic challenge was how to
transport equipment from jig to jig
between port and starboard wings,
while accommodating necessary
manual work on all vertical
levels,” says Ryan Haldimann of
Electroimpact’s HAWDE team. “In
effect, the machine tool needed to
be transported along Y (vertical)
and X (horizontal) directions of
travel, similar to a tool head in a
gigantic CNC machine.”
As a solution, the Electroimpact
team of six headed by Rick Calawa
created the HAWDE machine — a
portable unit that can travel
around a panel section by using
elements integrated into each
jig. To give workers access all
around the wing structure, the
jig incorporates “flip” flooring.
Each flip floor consists of a small
platform for worker access, which
is pivoted up when the completed
wing is removed. A single jig uses
150 flip floors, each employing
a Rexroth hydraulic cylinder
for smooth, reliable actuation.
Ultimately, four jigs will be in use,
requiring 600 Rexroth cylinders.
Because Electroimpact is
responsible for both the jig and the
HAWDE unit, an unprecedented
level of integration was achieved.
Right from the initial concepts, all
mobile elements of the machine
were integrated into the jig. To
move the 7000-lb machine from
jig to jig, a transporter crane is
used. Level-to-level movement
employs an elevator that is capable
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