1 Electroimpact Proprietary About Ben Hempstead, PE BSME - - PowerPoint PPT Presentation

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1 Electroimpact Proprietary About Ben Hempstead, PE BSME - - PowerPoint PPT Presentation

Dec 19, 2023 257 likes •692 views

1 Electroimpact Proprietary About Ben Hempstead, PE BSME University of Washington Started at EI in 1994 Mechanical Engineer (Lead) for automation projects Chief of Staff 2 Electroimpact Proprietary Electroimpact is a world

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Electroimpact Proprietary

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About Ben Hempstead, PE

  • BSME University of Washington
  • Started at EI in 1994
  • Mechanical Engineer (Lead) for

automation projects

  • Chief of Staff

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Electroimpact Proprietary

Electroimpact is a world leader in design

  • f automated aerospace assembly

equipment.

Completing large scale projects for companies including Airbus, Boeing, SpaceX, NASA, Spirit Aerospace, Northrop-Grumman, Lockheed, XAC/AVIC, Bombardier, and Embraer among

  • thers.
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ELECTROIMPACT, Inc.

  • Founded in 1986 by President Peter Zieve Ph.D.
  • Since 1987 Vice-President John Hartmann
  • Since 2014 Vice-President Michael Zieve
  • 766 Employees worldwide
  • 615 Full-time Degreed Engineers (80%)
  • Offices:

– Mukilteo WA 595 employees + interns – Hawarden UK 130 employees – Filton UK 3 employees – Melbourne Australia 1 employee – Charleston SC 2 employees – Wichita KS 1 employee – Evora Portugal 3 employees – Ankara Turkey 1 employee – Xian China 8 employees – Toronto 1 employee – Belfast 1 employee

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History of Employment

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Mukilteo, Wa Campus

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Broughton, UK Campus

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Electroimpact Properties

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Organization Highlights

  • Engineering Focus
  • Vertical Integration
  • Concentrated Responsibility
  • Communication Methods
  • Data storage and accessibility
  • Personal responsibility and integrity

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EI Systems Integration Experience

  • 28 years of in-house Production Auto-Fastening

Machines

  • 23 years of Turnkey Aircraft Assembly Systems

Supply

  • 18 years of Production Tool Design, Fabrication and

Metrology

  • Boeing (NWP) Approved Design/Build Tooling

Supplier

  • Full Integrated Project Teams under one roof.
  • Fully developed international supply chain.
  • Responsive Local Support for all engineering

disciplines

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Wing Spar Fastening

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Wing Skin Fastening Systems

Flexible A380 A380 A340 A320

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Post Riveting Machines

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Flextrack

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Robot Drilling/Fastening

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Automated Fiber Placement Machines

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Time for a Break!

Videos of Automated Fiber Placement Machines

EI’s AFP Channel on Youtube: https://www.youtube.com/user/AFPatEI NASA Marshall Robotic AFP: https://www.youtube.com/watch?v=uWhoV0 2AuTU

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Integrating Tooling & Automation – A380

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PAL – 737

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Wing Assembly Lines

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EI Automated Wing Assembly Systems (34 In Production to Date)

A380 A400M A350 CSeries Legacy KC390 C919 777x (in design)

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A350 Wing Assembly

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Secondary position feedback

  • * Mount at axis output * for each of the 6 robot axes (EI Patent Pending)
  • Control axis position directly from secondary feedback

Accurate Robots

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Results:

  • Test 1a: Off-part accuracy, entire volume: +/-0.0063” 3-sigma
  • Test 1b: Off-part accuracy, entire volume: +/-0.0049” 3-sigma

Accurate Robot – System Validation

Axes in mm 0.25mm = 0.010” Axes in mm 0.25mm = 0.010”

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787 Trailing Edge Assembly

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HISTORY AND OUTLOOK

Riveting and Composites

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C-17 Spar Machine

  • EI designed, built, and installed the ASAT4

spar riveting machine and fixtures in 1998

  • 3-axis riveter and servo-controlled fixture
  • Purchase customer was McDonnell-

Douglas

  • Boeing & M-D merged before handover
  • October 2014 the 279th and final spar set

was built

  • System sold at auction in 2015

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C-17 Spar Machine

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C-17

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Economic Forecast for Projects

  • Boeing:

– Mostly 777x

  • Embraer:

– Mostly E2

  • Airbus:

– A350 and refurbs

  • Other

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What is a Composite Aircraft?

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http://aviation-futur.e-monsite.com/medias/images/787-1.vs

787 777x

A350 has CFRP fuse panels

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Published Customer Backlog

Boeing & Airbus Only

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Assumes a multiplier between 6-10 representing the additional “work” required to build wide-body aircraft. Backlog as reported on Boeing and Airbus commercial aircraft websites as

  • f 2/1/16.
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C-130J Aft Fuselage

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C-130J – Why a new Machine?

  • Rate increase due to recent sales
  • Aging workforce
  • Quality concerns with manual work
  • Engineering solution for the lower ram
  • Smaller footprint than legacy machines
  • Siemens control vs Fanuc

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C-130J Flaps

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777x Center Wingbox

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Riveting Machine Outlook

  • EI believes there is a significant market &

is aggressively developing new technology

  • 737 backlog is 8 years at current rates
  • 777x riveted fuselage is not even in

production yet

  • E2 and other regional aircraft are riveted

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Composites Outlook

  • CFRP wingboxes for wide-bodies are here

to stay

  • Aluminum looks to be better for fuselages
  • Will CFRP make its way into the single-

aisle product?

– Bombardier’s Cseries is interesting

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777x Skin and Spar AFP

  • EI is currently installing carbon fiber

lamination machines that are purpose-built for the 777x wing skins and wing spars.

  • We are contracted to deliver 2 of each

type.

  • Future orders will depend on the need and

performance of the overall cell.

  • Installation in Everett, WA.

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777x Wingbox Assembly

  • EI is under contract to design, build, and

install the factory system for wingbox assembly

  • Tools to fixture the spars, ribs, and skins
  • Machines to drill and fasten skins to ribs

and spars

  • Material handling equipment to pulse the

wingbox and parts

  • Installation in Everett, WA

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Summary

EI provides equipment and tooling with Predictable and Verified Performance to meet design requirements. Questions? benh@electroimpact.com 425 609 4980

Find me on:

https://www.linkedin.com/in/benhempstead

Also TEDx on Youtube:

https://www.youtube.com/watch?v=r540VOI Vufc

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