Flexible Simplair pipework solution for jigs to build Airbus wings
Flexible Simplair pipework solution for jigs to build Airbus wingsKeywords: Simplair, Wings
At BAE Systems Airbus UK in Broughton, North Wales, low weight Simplair aluminium compressed air pipework has been used in the design of jigs to construct wings for the Airbus A330/A340 and A340-5001600 aircraft. Installed by the Wrexham operation of Motherwell Bridge Air Systems, the Simplair pipework forms a framework for each of the jigs, transforming them into highly flexible workstations through the ability to connect air tools at any point in the Simplair pipework.
The Simplair frameworks on three of the Airbus UK wing assembly jigs were installed by Evans Picon Ltd of Warrington, with NG Bailey of Manchester installing the fourth. Each framework mainly comprises 80mm pipework with the air passing up the jigs through columned risers and branching out at each level in pipework sections measuring between 4m and 12m in length. Because of its lightweight construction, Simplair pipework can reportedly be suspended from, or fixed to, any existing ceiling or wall surface by means of hanging or wall mounting brackets but with no extra support to the structure. The tubing is also readily cut to length using a power saw or hacksaw, making it an easy process to fashion the pipework to match the shape of the wing jigs at Airbus UK.
Paul Scragg, site services engineer at Airbus UK highlighted the versatility offered by the pipework: "The jigs are three storey structures and air tools are used at every level in constructing the wings. It was therefore very important to have air power available at any point on the jigs. The Simplair pipework provides us with a neat solution as we can tap into the air at any point and it ensures a clean working environment around the wing."
The pipework is used on Jig 6 and the Stage 3 Assembly Jig for the A330/A340 wings and Jigs 1 and 2 for the A340-5001600 wings (Plate 5). It is reported that any quantity of outlets can be quickly and efficiently installed in the Simplair frameworks, allowing Airbus UK to add or change tools in a matter of minutes.
Plate 5A34-600 wing assembly at Broughton
The high capacity A340-600 will seat 380 passengers in a typical three class configuration and first deliveries are expected in 2002. Its sister aircraft,the long haul A340-500, will have a range of 8,500 nautical miles.
BAE Systems Airbus UK has been a full partner in the European plane-making consortium, Airbus Industrie, since 1979. Airbus UK's prime responsibility is the design and manufacture of high-technology wings for all Airbus models as well as overall design and supply of the fuel system. Assembly of the wing box structure for all Airbus aircraft takes place at the Broughton site.
Mike Saunders, Northern Area sales manager for Simplair, said: "We are delighted to be part of the tremendous investment Airbus UK continues to make in its manufacturing facilities. Airbus UK is the latest in a long list of prestigious companies that have recognised the advantages of Simplair aluminium pipework. There is vast potential for us in this industry and Airbus UK is leading the way. We are currently refurbishing other jigs at the Broughton plant, replacing the old pipework with Simplair".
The Simplair HBS Hollow Bar System claims flexibility by allowing compressed air pipework to be constructed in high grade, extruded aluminium tubing instead of traditional steel pipework systems. The pipework systems are described as modular, easy to install and simple to extend or modify using an installation kit supplied with the pipework. The system is based on simple push/fit assembly which also allows for easy interchange between bore sizes. As well as flexibility, the systems are said to be completely corrosion-free, providing high quality air when and where it is needed. The low friction, smooth bore of the pipework reportedly ensures very high flow rates, some 25-50 per cent greater than those in comparably sized steel pipework, making it possible to"downsize" tubing requirements using the Simplair system.
This high performance level often means that smaller bore sizes can be used than are necessary with conventional pipework to achieve the same compressed air flow. Dependable O-ring sealing is said to remove the likelihood of leaks therefore ensuring low pressure losses. The pipework can reach any part of the production area or workshop economically and without limitation to height or length.
There are six different bore sizes currently available in the Simplair range at 14, 25, 32, 50, 63 and 80mm offering flows as high as 848lls (1,800cfm) at 7 bar (100psig). Internationally approved, Simplair pipework is believed to be a major advance for the compressed air users, providing a corrosion-free and flexible alternative to galvanised steel systems, covering more than 95 per cent of all compressed air applications.
Further details are available from Simplair Marketing Services. Tel: +44 (0)20 8741 9828; Fax: +44 (0) 20 8741 9508.
