Boeing boosts shot peener performance with Concept Systems’ upgrades

July 2012 - The speed of modern technology renders many machines and gadgets obsolete. But not all technology is easily replaceable. For decades-old shot peener machines at The Boeing Co.’s plants in Frederickson, Wash., and Auburn, Wash., retrofitting the controls with streamlined technology has reduced downtime and given the machines a new lease on life.

To spearhead the upgrades, Chicago-based Boeing turned to Concept Systems Inc., Albany, Ore., an integrator of automated control systems. Boeing uses its shot peener machines to form and contour wings for its 737, 767 and 777 aircraft. The machines are 31⁄2 stories tall, spacious enough to fit a 747’s wing skin. They use high speeds (up to 900 pounds per minute) to blast aluminum wing parts with shot diameters as big as 0.54 inch for forming and down to 0.28 inch for cold working and surface hardening.

“They’re just machines that are designed to self-destruct and wear,” says Franklin French, equipment engineer at Boeing.

Each machine was from a different generation. Some used hardwired relay logic. Others used aging PLC and CNC technology. “As far as the controls, they are all the same now,” French says.

The first phase included removing and replacing existing controls and power distribution. Concept Systems first addressed Boeing’s 30-year-old Spanwise shot peener because it had the most downtime. It also was the most challenging, according to Jim Ford, principal engineer at Concept Systems. Boeing allotted about three weeks of downtime to work on each machine.

The key upgrade was a Rockwell Automation ControlLogic PAC with Kinetix Motion Control paired with RSView32 HMI software, providing clear graphic displays for operator interface.

“One machine may have more peening wheels than another so that portion may be slightly different,” says French. Beyond slight variation among shot peeners, the standardized controls let operators use any of the seven machines between the two sites.

“Since they were involved in part of the design, I think the training curve is pretty low,” French adds. “They can go from one machine to the next, I think that’s an advantage.”

Internally, Concept Systems replaced original DC motors with AC servo motors. It also added gearboxes and armor plate shrouding to protect the mechanics. The motors feature vibration transducers and resistance temperature detectors that operators monitor on the HMI for potential warnings.

“This takes great effort to engineer, develop and implement,” Ford adds. Concept Systems also added safety considerations, such as door locks and emergency stop buttons.

Calibrated, certified

There’s no room for error with machine hardware and control upgrades for processing aircraft wings. Excel spreadsheets originally managed the part parameters controlling the Spanwise’s shot speed and flow—a time-consuming method. Concept Systems’ engineers programmed the HMI to translate the spreadsheets into machine code. This boosted productivity, saved operators time and lessened the risk of manual entry errors.

Ford says the most difficult part, however, was understanding all of the certifying qualifications for the machines to comply with FAA standards.

“Many of the qualifications were measured manually. We wanted to provide functionality enough to do this semiautomatically,” he says.

Boeing’s Cal-Cert group worked with Concept Systems to retain existing testing and calibration HMI functions, a step that included collaboration with machine operators to make the controls more efficient. 

Although the peening process takes just as much time, the reduced downtime and improved reliability added about 5 percent to 7 percent in plant productivity, according to French. Communication and access to machine status and functions are quicker. Because the hardware is current, finding spares or replacements is easier, slashing maintenance costs.

French says the overhaul of controls has tightened specified forming tolerances on parts. Along with providing training, Concept Systems met Boeing’s timeline, which was important for the manufacturer’s massive operation.

“Crucial to the success of the upgrades was the training that was provided along the way,” French says. “The training allowed our technicians to make a seamless transition to the new, upgraded controls.” MM

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