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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 2 Electroimpact Proprietary
Electroimpact is a world leader in design of 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 others. Electroimpact Proprietary
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 4 Electroimpact Proprietary
History of Employment 5 Electroimpact Proprietary
Mukilteo, Wa Campus 6 Electroimpact Proprietary
Broughton, UK Campus 7 Electroimpact Proprietary
Electroimpact Properties 8 Electroimpact Proprietary
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Organization Highlights • Engineering Focus • Vertical Integration • Concentrated Responsibility • Communication Methods • Data storage and accessibility • Personal responsibility and integrity 10 Electroimpact Proprietary
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 11 Electroimpact Proprietary
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Wing Spar Fastening 13 Electroimpact Proprietary
Wing Skin Fastening Systems A380 A340 Flexible A320 A380 14 Electroimpact Proprietary
Post Riveting Machines 15 Electroimpact Proprietary
Flextrack 16 Electroimpact Proprietary
Robot Drilling/Fastening 17 Electroimpact Proprietary
Automated Fiber Placement Machines 18 Electroimpact Proprietary
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 19 Electroimpact Proprietary
Integrating Tooling & Automation – A380 20 Electroimpact Proprietary
PAL – 737 21 Electroimpact Proprietary
Wing Assembly Lines 22 Electroimpact Proprietary
EI Automated Wing Assembly Systems (34 In Production to Date) A380 A400M A350 CSeries Legacy KC390 C919 777x (in design) 23 Electroimpact Proprietary
A350 Wing Assembly 24 Electroimpact Proprietary
Accurate Robots Secondary position feedback • * Mount at axis output * for each of the 6 robot axes (EI Patent Pending) • Control axis position directly from secondary feedback Electroimpact Proprietary
Accurate Robot – System Validation Results: • Test 1a: Off-part accuracy, entire volume: +/-0.0063 ” 3 -sigma • Test 1b: Off-part accuracy, entire volume: +/- 0.0049” 3 -sigma Axes in mm Axes in mm 0.25mm = 0.010” 0.25mm = 0.010” Electroimpact Proprietary
787 Trailing Edge Assembly 27 Electroimpact Proprietary
Riveting and Composites HISTORY AND OUTLOOK 28 Electroimpact Proprietary
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 279 th and final spar set was built • System sold at auction in 2015 29 Electroimpact Proprietary
C-17 Spar Machine 30 Electroimpact Proprietary
C-17 31 Electroimpact Proprietary
Economic Forecast for Projects • Boeing: – Mostly 777x • Embraer: – Mostly E2 • Airbus: – A350 and refurbs • Other 32 Electroimpact Proprietary
What is a Composite Aircraft? 777x A350 has CFRP fuse panels 787 http://aviation-futur.e-monsite.com/medias/images/787-1.vs 33 Electroimpact Proprietary
Published Customer Backlog Boeing & Airbus Only Assumes a multiplier between 6-10 Backlog as reported on Boeing and representing the additional “work” Airbus commercial aircraft websites as required to build wide-body aircraft. of 2/1/16. 34 Electroimpact Proprietary
C-130J Aft Fuselage 35 Electroimpact Proprietary
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 36 Electroimpact Proprietary
C-130J Flaps 37 Electroimpact Proprietary
777x Center Wingbox 38 Electroimpact Proprietary
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 39 Electroimpact Proprietary
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 40 Electroimpact Proprietary
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. 41 Electroimpact Proprietary
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 42 Electroimpact Proprietary
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 43 Electroimpact Proprietary
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