Riveting Technologies for Aerospace Manufacturing Automation

Active Panel Protection is standard on all Gemcor heads, providing protection against tipped or damaged fasteners, chips in the drilled hole, wrong hole size, or a broken drill. This feature is always active, without adding additional cycle time, and has been proven to almost eliminate scrapping panels.

Gemcor offers a number of manual, semi-automatic, fully automatic CNC and robotic positioning solutions to aid operators in fastening airframe assemblies.

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Pendulum Head Fastening System

High Quality at an Economical Price

Our patented, Gemcor all-electric roller screw technology is offered in a simple, low-cost platform that can be used in a multitude of different fastening applications. The pendulum system provides high quality installed fasteners, quick fastening rates and unmatched reliability, creating higher productivity for airframers around the world.

 

Capable of installing a variety of fasteners, including interference-fit pins, the system’s unique upper head design incorporates a high-speed drill spindle with optional straight down sealant and buck positions.

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Features
  • All-electric operation with 3 position head
  • Custom-sized C-frame for any application
  • 2- or 3- position upper head
  • Up to 3″ (75mm) upper tooling clearance
  • High-speed pendulum transfer
  • Variable, high-speed drill spindle, 3,000 - 18,000 rpm
  • Fixed pressure foot
  • 20,000lbs (9,000kg) maximum upset force
  • 100 to 1,000 lbs (45-450kg) clamp force
  • Touch screen operator station, mounted to swing arm overhead pendant
  • Very simple maintenance and alignment
Options
  • Drill / seal / buck
  • Drill / buck with straight down camera
  • Head-mounted, manual or automatic bin-hopper ARS
  • Floor-mounted cassette feed ARS
  • 900 - 9,000 rpm electric spindle
  • Peck-type sealant applicator
  • Normality sensors
  • Retractable resilient pressure foot
  • High clamp for pin insertion
  • Semi-automatic overhead positioning system
  • Full CNC positioning system
  • Height-adjusting table support system
Rotary Head Systems

Our Gemcor all-electric, rotary upper head has a plethora of benefits

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Increased flexibility

With six major and six mid positions, the rotary head offers tremendous flexibility in an economical package.

 

Improves throughput

The rotary head configuration maintains three spindles and three upper anvils, eliminating the need for an automatic tool changer - and the related changing time. Three tool groups [drill/buck] make it possible to change up to three diameters/styles of fastener automatically without pulling off the panel for a manual tool-change, significantly improving throughput.

 

A range of speed choices

One, two or three constant-torque, variable-speed motors can be supplied in a high speed configuration (primarily for aluminum work) or a low-speed, high-torque configuration (for titanium or composite).

Simple, operator-configurable set up

Our rotary head can run any type of fastener - from a 4-headed rivet in either force or position upset mode, to a large-diameter, fuel-tight, fatigue-rated slug fastener. It also reliably inserts interference-fit pins, such as Lock-bolts or HiLoks.

 

Protection against panel damage

Active Panel Protection is standard on all Gemcor all-electric heads, providing protection against tipped or damaged fasteners, chips in the drilled hole, wrong hole size, or a broken drill. This feature is always active, without adding additional cycle time, and has been proven to almost eliminate scrapping panels.

 

No zero backlash gearbox

Our rotary head system’s cartridge drive provides direct rotary drive to the dial plate, eliminating the need for a zero backlash gearbox.

 

High Speed Linear Head
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This upper head utilizes a “high-speed, linear, electric motor” for the toggle head transfer, affording very fast cycle times - up to 19 fasteners per minute! Gemcor’s patented roller screw technology is used in the lower ram to provide fastener upset.

Three position transfer head

The upper head assembly features a three-position transfer head, including an auto vision resync camera, drill spindle, and toggle buck.
 

Two ways to apply sealant

Sealant can be applied using a “peck”-type applicator, through the pressure foot bushing or using a straight-down sealant position in the head as a 4th position.

Precision

A Fischer/Precise spindle with vector drive ensures precision whether drilling aluminum alloy, titanium or carbon composites.

Protection against panel damage

 

Simple changeovers

The automatic tool changer utilizes HSK40-type tool holders. A rivet injector auto changer, with up to five stations, provides easy, automatic changeover from one fastener style to another. Combining the automatic functions of both the tool changer and injector changer creates ability to change up to five diameters of fasteners, automatically, without pulling off the panel, significantly improving throughput.

High Upset Force Linear Head

Up to 40,000lbs of upset force!

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With ability to install up to 14 fatigue-rated, fuel-tight slug rivets, utilizing up to 40,000lbs (18,200kgs) of upset force, the this head is capable of installing fasteners in the most demanding wing fastening or wing related fastening applications.

 

Patented, roller-screw technology drives the straight down buck assembly and lower ram, facilitating a multitude of slug fastening processes including squeeze, squeeze/squeeze, pogo, and others.

 

Highly-precise control over the driven buck assembly and lower ram provides simple, operator-configurable setups, with ability to reliably installing any type of fastener, including interference-fit, 2-piece fasteners, such as Huck Lockbolts or HiLoks.

Other features:
  • High-speed, linear, electric-servo-motor transfer
  • 4-position transfer head with vision resync camera, drill spindle, shave spindle and straight down buck
  • Automatic tool changer
  • 2 Fischer/Precise spindles for precise drilling and shave functions
Protection against panel damage

Active Panel Protection is standard on all Gemcor all-electric heads, providing protection against tipped or damaged fasteners, chips in the drilled hole, wrong hole size, or a broken drill. This feature is always active, without adding additional cycle time, and has been proven to almost eliminate scrapping panels.

Fully Automatic CNC Work Positioners
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With more than two hundred (200) Computer Numerically Controlled (CNC) positioners installed, we are well versed in supplying CNC positioning systems for even the most exacting of requirements. From a simple 3-axis up to an 8-axis system, we’ll find the most efficient and economical approach to your application.

G12 5-Axis Work Positioner

The G12 positioner provides “X”, “Y”, “Z”, “A” and “B” motion to position the panel and normalize fastener locations with the pressure foot bushing. “Y”, “Z” and “A” axes movements are generated within the pedestals, enabling horizontal or vertical floor-level panel loading. The G12 positioner is light weight, eliminating the need for a special foundation.

G14 5-Axis Work Positioner

Our new, lighter weight G14 is quickly and easily installed on most standard factory floors, without the need for special foundations. With a highly-flexible, in-process, adaptive controls systems, the G14 meets exacting aerospace specifications with minimal hard tooling, allowing for quick changeover and reconfiguration for many different present and future applications. “X”, “Y”, “Z”, “A” and “B” axis motion positions the panel and normalizes fastener locations with the pressure foot bushing.

G86 5-Axis Work Positioner

The G86 combines a unique, low center of gravity with weight reduction technologies to provide rapid travel, high accuracy, and impressive positioning repeatability. The system offers a modular frame design, resulting in faster field assembly and greater manufacturing flexibility for growth to accommodate various future fastening programs.

G2000 7-Axis Work Positioner

The G2000 combines the G86 positioner enables 180˚ fastening of half fuselage super panels with an extra minor C-frame mounted in place of a straight lower ram. The low center of gravity, weight optimization and backlash reduction allow rapid travel, excellent accuracy, and impressive repeatability. The system is offered in a modular frame design, resulting in faster field assembly and greater manufacturing flexibility to accommodate growth or future fastening programs.

Semi-Automatic Positioners

Each overhead positioning system, sized to meet customer-specifications, interfaces with the riveter to assure safe movement, without causing damage to the panel or riveter. These are commonly used to aid positioning and fastening of fuselage panels, bulkheads, door assemblies, large frame sub-assemblies and even simpler smaller wings and spars.

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Robotic Solutions

See our pages on robotics for more information about cost-effective robotic aircraft assembly configurations.

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