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control engineering | inside machines: upgrading boeing 777 wing fastening machine

control engineering | inside machines: upgrading boeing 777 wing fastening machine

Rosie the Riveter of WWII fame has long-since been replaced by automated descendents. Boeing Company has been doing automated assembly of aircraft components for decades. In fact, earlier generations of wing fastening machines are ready for rejuvenation using newer technology controller systems and touchscreen human machine interfaces (HMIs). To assist with the upgrades, Boeing engaged Concept Systems Inc., a system integrator with experience in the latest automation and machine vision technologies.

A recent project involved retrofitting the wing fastening machines that Boeing uses to make wings for the 777 commercial aircraft. These machines, originally manufactured by Gemcor of West Seneca, N.Y., were installed at Boeings Everett, Wash., plant. Nine of these machines are in use on the 777 line. At any given time, there are four wing panels being assembled, with two Gemcor machines working on each panel section, installing over 70,000 fasteners per wing set, one at a time.

Gemcor machines use fasteners to attach the wing skin panels to the underlying wing stringers in a four-step cycle. The machine drills and countersinks the holes, places each fastener in its hole, installs the fasteners with a specified force, and then shaves the top of the fastener flush with the wing panel. The machine is also capable of inserting bolts with a similar operation, first drilling and countersinking the holes, applying sealant, and then inserting bolts in the holes.

The control system upgrade project began in 2005 when Boeings 777 Production and Equipment Services Gemcor Team, as part of the companys commitment to continuous improvement of manufacturing operations, decided to upgrade the machines electrical systems and controllers. The machines on the 777 line were originally installed in 1992 and had been added to and modified several times since then. With each modification, new wiring was laid on top of old wiring, and the machines were starting to exhibit downtime due to problems with the wiring network that had become difficult to troubleshoot. The original controllers and drives had also become obsolete, and the Boeing Gemcor Team could see opportunities to improve productivity if the machines old vision system were replaced with the newest technology, and the operator interfaces were replaced with more user-friendly systems. There were also opportunities to add new automated functions to the machines to minimize operator interface.

To implement all of the machine upgrades, engineers from Concept Systems, an Albany Ore.-based systems integrator with a regional office in Seattle, Wash., worked very closely with the Boeing Gemcor Team. One of the first steps was the review of available documentation for the machines, which consisted of one set of drawings per machine. As the machine controller upgrade brought commonality to all machines, the Concept Systems engineers consolidated the drawings to one set.

The upgrade plans called for removing all of the old wiring and replacing the CNC controller, PLC, motor drives, and motion controller on each Gemcor machine and adding new touchscreen HMIs. In the process, Concept Systems improved the HMIs to standardize the operator interfaces with other wing manufacturing systems in the plant.

One new function that Concept Systems supported was addition of the tack re-sync camera and monitor (tack re-synch refers to the operation of removing a tack fastener and replacing it with an actual fastener). In addition to the main operator consoles that are used to run the machine, Concept Systems added a maintenance console connected to a PC that is used for maintenance programming. The lower operator console consists of a main PanelView operator screen and monitors for the tack re-sync operation, the CNC, and an injector camera that shows the fasteners as theyre inserted.

When wiring problems would occur with a machine before the upgrade, sometimes the machine would be down for a day or two, said Fred Rassoulian, Boeings Wing Fastening Systems lead engineer. Now the downtime is minimal. A guess would say that we saved at least a couple of days per month of machine downtime. And with the new HMIs and online maintenance procedures, keeping the machines running and troubleshooting what problems do occur is now a lot easier.

The quicker fastener placement has also improved the speed of the machine, increasing its capacity. And as part of the upgrade, the machines were made more energy efficient by replacing the air compressor and pneumatic air dryer with more efficient units, helping Boeing win energy credits from the local public utility district (PUD).

Concept Systems understood Boeings requirement for absolute precision and exacting tolerances, said Rassoulian. Concept Systems engineer Mike Dodds went over every step in the test and acceptance process in detail and made sure that the new system functioned successfully to meet Boeing standards.

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appliance repair harrison 551-777-8075 | refrigerator | washer | dryer | oven | stove | dishwasher

appliance repair harrison 551-777-8075 | refrigerator | washer | dryer | oven | stove | dishwasher

Call today 551-777-8075, for a 5 star appliance repair service if you are located near Harrison or in Hudson County for same day or next day appointment for a small diagnostic fee, cheaper than the industry average (Appliance Blue Book pricing) which goes toward the repair price. The Appliance Repair Men provides service for Appliance Repair at an affordable price. All appliance repair technicians in Harrison work on all major appliances 24/7 everyday anytime and also offer same day service accepting all major credit cards. We only use the best technicians in the Hudson County area that are reliable, honest and professional. They all provide service for Washer Repair, Dryer Repair, Dishwasher Repair, Oven Repair, Stove Repair, Freezer Repair, Range Repair, Cooktop Repair, Refrigerator Repair, Wine Cooler Repair, Ice Machine Repair, Ice Maker Repair, Garbage Disposal Repair, Walk in Freezer Repair, Commercial Appliance Repair, Residential Appliance Repair, Pizza Oven Repair, Air Conditioner Repair, Central Air Repair, etc.

Do you have an emergency and are located in the Harrison area? Call us 551-777-8075 anytime and we will have an appliance repair technician be there within hours. Most appliance repair technicians in Harrison carry all major appliance parts on their vehicles including Maytag, Frigidaire, Whirlpool, GE, Electrolux, Kenmore, Kitchenaid, and many more which makes the fix easy to do the same day visit.

Having any appliances break down on you when least expected whether you're living on your own or with a big family is really frustrating. Finding a good appliance repair company is the hardest part. Luckily you found us as we can take that daunting task out of your hands and schedule a qualified technician to come out as soon as possible (same day no extra cost) that is reliable and honest and will communicate with you from the initial diagnosis to the final repair.

If you find yourself in need of appliance repair within the Harrison area, call 551-777-8075 The Appliance Repair Men, we can give you service that very day or within 24 hours and we are available at all times. Whether you're having problems with your washer, dryer, dishwasher, refrigerator, oven, stove, cooktop, range, heating, air conditioning, or appliances, we can send a technicians that can repair or service models for all major brands. You will always be provided with a written estimate, which you will have to authorize before any repairs or services are done, and if the technician does the repair, the service fee goes toward the total cost. You can call for same-day service via 551-777-8075 anytime day or night if you are located in Harrison. If you are located near Hudson County and need any major appliance repair, please call us today 551-777-8075 and we will send you a qualified appliance repair technician.

Frigidaire Appliance Repair Harrison | GE Appliance Repair | LG Appliance Repair Harrison | Maytag Appliance RepairHarrison | Samsung Appliance Repair Harrison | Whirlpool Appliance RepairHarrison | Frigidaire Appliance Repair Harrison | Kenmore Appliance RepairHarrison | Kitchenaid Appliance Repair Harrison | Electrolux Appliance RepairHarrison | Bosch Appliance Repair Harrison | Miele Appliance Repair Harrison | Haier Appliance RepairHarrison | Jenn-Air Appliance RepairHarrison | Roper Appliance RepairHarrison | Sears Appliance RepairHarrison | Speed Queen Appliance Repair Harrison | Coin Operated Appliance Repair | Amana Appliance Repair | Sub Zero Appliance Repair | Viking Appliance Repair | Thermador Appliance RepairHarrison | Fisher Paykel Appliance Repair | GE Monogram Appliance Repair Harrison | Hotpoint Appliance Repair Harrison| Dacor Appliance Repair | Uline Appliance RepairHarrison | Frigidaire Gallery Appliance Repair Harrison | Ice Machine Appliance RepairHarrison | Wolf Appliance Repair Harrison |

Call The Appliance Repair MenHarrison 551-777-8075 today if you need any appliance repair service and live anywhere in Hudson County. Get a qualified, honest and reliable appliance repair technician dispatched directly to your home for a same day (at no additional cost) or next day service. The Appliance Repairmen accepts all major credit cards. Don't try to fix the appliance yourself as this could cost you more money down the road and possibly an entire new appliance, if you make a mistake. We have seen this many times where a customer tries to fix their own appliance and when the technician shows up, the appliance is taken apart and the appliance cannot be salvaged. Don't gamble with not only your appliances life but also your own as incorrectly repairing an appliance could be a fire hazard. Our diagnostic fee is 30% below industry average diagnostic fees given by The Appliance Repair Blue Book.

All technicians provide service for Washer RepairHarrison, Dryer RepairHarrison, Dishwasher RepairHarrison, Oven RepairHarrison, Stove RepairHarrison, Freezer RepairHarrison, Range RepairHarrison, Cooktop RepairHarrison, Refrigerator RepairHarrison, Wine Cooler RepairHarrison, Ice Machine RepairHarrison, Ice Maker RepairHarrison, Garbage Disposal RepairHarrison, Walk in Freezer RepairHarrison, Commercial Appliance RepairHarrison, Residential Appliance RepairHarrison, Pizza Oven RepairHarrison, Air Conditioner RepairHarrison, Central Air RepairHarrison, etc. If you have an emergency we offer same day appliance repair service for no additional cost as long as you are located within Hudson County.

If you need hours outside of your work schedule we can also accommodate, whether it be during the weekend hours, before 9:00 am or after 5pm, we are here to make your life easier. If it is your first time calling, you will not be disappointed, if you have been with us before and have a favorite technician, let us know. Pick up the phone and call 551-777-8075 and schedule an appliance repair appointment in a time slot that is most convenient for you.

Brown Washer Repair, Bryant Refrigerator Repair, Caloric Oven Repair, Carrier Dishwasher Repair, Crosley Appliance Repair, Dacor, Day & Night, Electrolux Washer Repair, Emerson Stove, Friedrich AC, Frigidaire Freezer, Gaggenau, GE Profile Repair, GE washer repair General Electric, Gemline, Gibson, Goldstar, Goodman, Hampton Bay, Hardwick, Heil, Honeywell Oven Repair, Hotpoint Appliance Repair, Janitrol Appliance Repair, Jenn Air Dishwasher Repair, Kenmore Washer Repair, Kitchen Aid Dishwasher Repair, Freezer Repair, Lennox Refrigerator Repair, LG Appliance Repair, Litton Appliance Repair, Magic Chef Refrigerator Repair, Maytag Washer Repair, Modern Maid Cooktop Repair, Panasonic Dryer Repair, Puron Dishwasher Repair, Quasar Dishwasher Repair, RCA Appliance Repair, Roper Appliance Repair, Ruud Appliance Repair, Samsung Dryer Repair, Sanyo Washer Repair, Sears Dryer Repair, Signature Washer Repair, Speed Queen Washer Repair, Sub Zero Refrigerator Repair, Summit Appliance Repair, Sunray Appliance Repair, Tappan Stove Repair, Tempstar Appliance Repair, Thermador Oven Repair, Traulsen Commercial Repair, U-line (Uline) Oven Repair, Wards Refrigerator Repair, Weathertron Repair, Wedgewood Appliance Repair, Whirlpool Repair, White Rogers Appliance Repair, Westinghouse Appliance Repair, Wolf Appliance Repair.

We provide appliance repair technicians to service and repair all major appliances, air conditioners and heaters in Hudson County. All appliance repair technicians are trained and authorized to provide appliance repair services for all major brands including the high-end appliances such as Sub Zero RepairHarrison, Maytag RepairHarrison, Kenmore RepairHarrison, Viking RepairHarrison, Whirlpool RepairHarrison, Wolf RepairHarrison, Thermador RepairHarrison, LG RepairHarrison, GE RepairHarrison, Jenn-air RepairHarrison, Frigidaire RepairHarrison, Bosch RepairHarrison, Fisher Paykel RepairHarrison, Sears RepairHarrison, Kitchen Aid RepairHarrison, etc....

Reliable, specialized appliance service technician crews, using the latest tools and equipment will work around your schedule and provide you with high quality service and repairs. Feel free to check any of our references and we are confident that you can rely on us to be very dependent and responsible. Call Harrison Appliance repair for an emergency response to a refrigerator repair, washer repair, dryer repair, dishwasher repair, oven repair today.

Specially trained and educated technicians in radio-dispatched service trucks are on the alert to handle any emergency service within Hudson County when required. Every truck is stocked with a full inventory of replacement parts and equipment-making for highly responsive repair times. Harrison Appliance Repair, Inc. also maintains refrigerant recovery units on each service truck to prevent the illegal venting of refrigerants into the atmosphere.

Planned preventive maintenance programs are tailored to the individual needs of our customers. These programs have proven to be an excellent method of limiting the operating, repair, and replacement costs of appliances, air conditioning, and heating equipment.

Call today, 551-777-8075, repairHarrison to schedule a same day or next day appointment for a small diagnostic fee, cheaper than the industry average (Appliance Blue Book pricing) which goes toward the repair price.

Having any appliances inHarrison break down on you when least expected whether you're living on your own or with a big family it can be really frustrating. Finding a good appliance repair company is the hardest part. Luckily you found us as we can take that daunting task out of your hands and schedule a qualified appliance repair technician to come out as soon as possible (same day no extra cost) that is reliable and honest and will communicate with you from the initial diagnosis to the final repair. Call now, 551-777-8075 to schedule an appointment with The Appliance Repairmen.

Other Communities serviced: Bayonne , Jersey City, Hoboken , Union City , West New York , Guttenberg , Secaucus , Kearny , Harrison, East Newark , North Bergen, Weehawken ,

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