A380 Section 19 Systems Integration and Assembly
Getafe, Spain 

The largest passenger airliner in the world, the A380 is a double-deck, wide-body, four-engine airliner manufactured by Airbus. Because of its size and to reduce its potential weight, the aircraft was constructed of 40% new composite materials, which also significantly improves the quality of the completed plane. These new materials mandated automated production, rather than the costly and time-consuming manual labor of the past, as well as innovative equipment. AIT was armed with both.

In 2002, AIT was selected as the Prime Contractor to provide automated turnkey tooling to assemble the Airbus A380 rear fuselage section (Section 19) in Getafe, Spain.  The tapered Section 19 is over 32 feet long and 28 feet tall at the forward end – the largest primary structure carbon fiber fuselage section constructed at that time.

Along with new automated production assemblies came a new plant floor layout and processes, which AIT defined for Airbus. Inherent efficiencies in AIT’s deliverables resulted in faster cycle times to keep up with the demanding “just-in-time” scheduled transport of various components for final assembly in Germany. 

System Features  
For the project, AIT provided not only automated, flexible alignment and positioning equipment but also conventional tooling, including lifting fixtures, assembly jigs, working platforms, and body fittings. The new, flexible tooling helped increase production efficiencies by allowing equipment to work on various parts with minimal retooling.

• 6 conventional panel assembly systems
• 2 automated shell assembly systems
• 2 automated circular and longitudinal drill/fasten machines
• 1 automated final assembly system
• 50 positioning machines
• 100 axes of servo motion
  

AIT also created unique PC-based graphical interface software to control the positioning systems. Its ease of use has greatly reduced training and operating time.

In addition to the rear fuselage positioning systems, AIT engineered two circumferential drilling machines that automatically drilled the upper and lower shell assemblies. This new technology was developed to accommodate the enormity of the Section 19 composite structures as well as to speed drill time and accuracy. The driller, which is 6 meters in diameter and 9 meters long, was designed in AIT’s Plano, TX, and Seattle, WA, facilities and manufactured in our facility in Vancouver, BC, Canada.

AIT is accustomed to managing multiple simultaneous major international turnkey projects and has installed equipment in facilities around the world.  AIT has four facilities strategically located worldwide to help provide superior service and support to our customers.

To make systems more affordable and reduce lead time, AIT performed mechanical detailing and manufacturing in-house. The result of this integration has been the institution of standard subassembly designs and manufacturing processes, which have reduced lead times to as short as 7 months ARO.

Project Features

• prime contractor/integrator – sole supplier to airbus
• Process and workflow definition
• Cycle time and rate analysis
• 6 conventional panel assembly systems
• 2 automated shell assembly systems
• 2 automated circular and longitudinal drill/fasten machines
• 1 automated final assembly system
• Shell rollover systems
• Pin installation jigs
• 50 positioning machines
• 100 axes of servo motion
• Work platforms
• Mechanical handling devices and lift fixtures
• Body fittings
• Transportation dollies

Achievements
Met composite and structure size challenges with redefined technology, integration, and tooling equipment

Increased production and cost efficiencies with precision-engineered, multi-purpose, flexible tooling

Maintained “just-in-time” schedule of transport for final assembly of the entire A380 aircraft