How do Airplanes Made
At the words "domestic production" in my head pops up a picture dilapidated shop with a leaking roof and rusty stairs, crooked going off the ceiling. What was my surprise when I found myself in Komsomolsk-on-Amur in the shop, which produces aircraft Sukhoi Superdzhet100 - absolutely clean shop, which nadraivayut 4 times a day, floor polishers, warning signs at each manhole, neatly dressed staff ...
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The plant employs about 12 thousand people, and production is divided into two areas. In the first blank is made of aluminum fuselage, and the second wings are attached to it, set in the plane all the avionics and engines. Today I'll show you how a piece of aluminum into a plane ...
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At the outset I wish to express my deep gratitude PR Services Dry and KLA for the opportunity to get to this production. Photographing is prohibited, but we made an exception:
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Modern aircraft are "in the figure." From Moscow to Komsomolsk-on-Amur on the network transmit electronic models of aircraft parts and assemblies. Plant engineers write programs for CNC machine tools and adapt designs to production. That is, they get out of Moscow's electronic models, and further develop their own apparatus, tools and processes to manufacture these parts.
Incidentally, the aircraft Sukhoi Superjet is the first Russian aircraft fully established on the basis of digital technologies, thereby reducing the time the preparatory process for its production in 2 years:
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It begins with the department of mechanical treatment, which drive up hefty aluminum billet and turning them into part of the future aircraft:
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In the shop there are huge fully enclosed machines:
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Results of these machines for the production of Superjet was purchased over 30 pieces:
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All shavings from machines automatically goes on struzhkoprovodu in containers and leaves for recycling:
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Workpiece is clamped on the turntable and processed by the program without human intervention:
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The operator of the machine standing outside and watching the process on the monitor. Hence it happens all the controls:
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Only manually set the blanks:
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One day, Michelangelo was asked how he creates his sculptures. He replied: "Very simply, I take a stone and cut off all unnecessary." Like the great Italian creator, Machine Dry cut off with sharp cutters all the extra metal:
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Milling machines can be very complex shape and large size parts, thanks to programs written by engineers KnAAPO:
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Anything that looks like a stamped, in fact, was "vystrugano" of a large piece of aluminum milling machines:
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In the fuselage of the aircraft more than 40 thousand rivets and another 15 000 in the wing. Drill holes and install rivets in the wing and fuselage panels produced on a laser machine riveting:
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Same laser cut small parts:
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On board there are practically no straight parts. In order to give the desired curvature using a set of forms stitched at a special press:
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Detail is set in the press, belts and pressed on the program are making the effort required for its formation:
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Wing skin adjusted to the desired shape on a separate press in manual mode:
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Made wing skin are controlled by a special bench with a set of templates. The deviation of the 14-meter wing skins should be no more than + / - 1 mm
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If the deviation is larger, the item is brought into a special unit shot:
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Once the details have acquired the desired shape, cover them with soil to protect against corrosion:
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For each panel, the fuselage has its own equipment, called a "pallet":
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Enshrined in the pallets hit the bar automatic machine riveting. In each plane by about 55 000 rivets:
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The entire process is fully automated and controlled by a pair of man:
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Layout installation process is done manually fixing:
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Automaton can not yet completely replace the human, and some space for a riveting account mark the workers:
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After joining the fuselage installed in rack vnestapelnyh works, where it is the final assembly:
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By number shows that the assembly is the 20th aircraft:
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Holes bolting treated in a special way to avoid backlash:
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The tighter the joint, the greater the resource in detail:
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Slipway wing spar assembly:
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Headphones - an indispensable element for the safety of work at hand riveting:
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Frame, which completes the passenger compartment and separates it from the rear, where the auxiliary power unit (APU)
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Center section - the central part of an airplane wing. He is joined in the wings, and it is located inside the fuel tank:
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The shop, which collect the wings:
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In the stocks are installing spars and ribs of the wing:
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Number 95 021 indicates that this detachable part of the wing for an aircraft with a serial number number 021. Total dry already produced 11 aircraft:
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The bottom surface of the wing left the hatches for access of the wing and its maintenance during operation of the aircraft:
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All of them are closed with removable covers like:
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The internal cavity of the wing, as well as the center section is used as the fuel tank:
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This workshop gathered sections of the fuselage, which then dock with each other:
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Docked panel fuselage before passing into the workshop production of fuselage sections:
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In every shop on the wall details that it is collected:
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Here we collect the next half plane with rails for chairs:
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And set it in the fuselage:
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After installation, it is covered technology floor:
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Beneath it is the baggage compartment:
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Sections of fuselage are joined automatically on the stand:
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There stands yet on any other Russian plant, including the military:
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In the next post please read the story of the second workshop Sukhoi aircraft which finally collected and sent into the sky. But the sky will be girls and, of course, airplanes. Stay Tuned!
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