A Novel Smart Installation System for Airframe Production

ABSTRACT: The installation of EDDIE BOLT fasteners in aerospace assembly is a time consuming process requiring multiple inspections of 100% of the installation of thousands of fasteners per aircraft. After installation, the fastener is inspected multiple times to ensure proper installation, including both nut swaging, grip length, and thread protrusion length. For the F-35 program, the installation and inspection of Eddie bolt assemblies is challenging in some aircraft locations, requires significant manual labor, and dramatically impacts system affordability. Creare"s novel solution to combine the installation and inspection steps for Eddie bolt installations is our Smart Installation System (SIS). Our SIS enables the operator to install, inspect, and record inspection data in a single step and it will dramatically reduce the cost of Eddie bolt installations across the military aircraft programs by eliminating the secondary inspection step and it will enhance the"digital thread"for each produced aircraft. During the Phase I project, we will assemble the proof-of-concept SIS, complete inspection testing on a relevant Eddie bolt installation, and design the prototype for tool integration. During Phase II, we will complete the system design, fabrication, testing, and transition the technology to F-35 production. BENEFIT: Proper fastener installation is a fundamental manufacturing process used in everyday construction and military systems. The ability to safely, efficiently, and conveniently join two parts together using fasteners that are installed to critical specifications is common in a wide variety commercial and military products. The commercial applications of our innovation include large-scale manufacturing, automotive, construction, and the commercial aerospace industries.