Providing Custom Solutions
Nova-Tech strives to stay current with trends in the aerospace industry and is continually pushing for new technologies to improve the products it provides to its customers. Nova-Tech works with other companies that are leaderes in their field that provide the best solutions using the most up-to-date technology.
Nova-Tech Has a Diverse Customer Base
Jigs and Assembly Fixtures
Nova-Tech has extensive experience in supplying high-quality precision assembly jigs and fixtures to the aerospace industry. As a turnkey provider, Nova-Tech is adept at working with its customers in defining the assembly process and in providing a complete family of coordinated tools, from sub-assemblies to major assemblies.
Embraer Legacy 450/500 Forward Fuselage Assembly Tooling
- Turnkey supply: design, build, installation, acceptance
- Complete family of tools for forward fuselage assembly (52 tool designs)
- Tools included: assembly jigs, drill templates, lifting devices, handling carts, and work platforms
- Utilized Brazilian suppliers for tool manufacture and installation
Embraer Legacy 450/500 Center Fuselage Wing Stub Assembly Tooling
- Turnkey supply: design, build, installation, acceptance
- Complete family of tools for center fuselage wing stub assembly (33 tool designs)
- Tools included: assembly jigs, drill templates, lifting devices, handling carts, and work platforms
- Integrated crane system with main assembly jigs
- Utilized Brazilian suppliers for tool manufacture and installation
HondaJet Final Mate Tooling
- Turnkey supply: design, build, installation, acceptance
- Family of tools to support alignment and assembly of wing and vertical stabilizer to fuselage
- Tools include: precision NLG index, fuselage scissor lifts and support cradles, vertical stabilizer alignment jig, wing transport & lift dolly, platforms, dollies, lifting devices
Spirit G650 Wing Assembly Tooling
- Turnkey supply: design, build, installation, acceptance
- Tools include: spar assembly jigs, wingbox assembly jigs, wing assembly laydown tool, and automated wing join system
- Wingbox assembly tool with integrated scissor lift work platforms
Workstands and Ancillary Equipment
Nova-Tech provides a wide variety of custom work platforms and ancillary equipment that enhance ergonomic access to the workpiece for a multitude of operations. Nova-Tech access solutions can be fixed or mobile and include either powered or manually actuated deck elevation, sliders, flip doors, etc. among the many possible features.
HondaJet Final Mate Workstand
- Provides access for horizontal and vertical stabilizer installation
- Flip doors to close out gap with aircraft
Spirit AeroSystems G650 Scissor Lift Workstands
- Commercially available powered scissor lift integrated with custom work platform
- Provides access to all levels of main wingbox assembly jig
Boeing 787 Door Uploader
- Traveling elevator and deck for loading interior components into the aircraft at doors 1 & 4
- Integrates with moving line spine
- Deck adjusts height to match height of aircraft as it moves down the line
- Repositioned using powered tugs
Boeing 787 Workstands
- Elevating workstand to provide access to nose of aircraft
Boeing 787 Door Uploader
- X-axis platform drive system
- Decks with vertical motion
Lifting Devices
Nova-Tech offers a wide range of overhead lifting solutions that range in complexity from simple spreader beams to complex assemblies with powered motion axes (i.e. rotation and tilt) and on-board vacuum supply.
Spirit AeroSystems Wingbox Assembly Lift Device
- Handles LH and RH wingbox assemblies
- Rotation via cranes from vertical to horizontal orientation
- On-board vacuum supply
Spirit AeroSystems Wing Skin Lift Device
- Handles upper and lower wing skin assemblies
- Powered rotation and tilt
- On-board vacuum supply
Accurate and reliable alignment of major assemblies is a critical step in every aircraft production line. Nova-Tech excels at providing turn-key positioning and alignment solutions that set the standard for accuracy, operability, ease of use, flexibility and integration with other assembly operations and processes. Nova-Tech Assembly System applications include: wing-to-wing join, wing-to-fuselage join, fuselage final join, fuselage section assembly, and part positioning.
Nova-Tech systems utilize industry standard equipment in an open architecture and typically provide seamless integration with laser based metrology systems. In many cases Nova-Tech solutions have been implemented into existing production lines with no delays to production.
Nova-Tech also specializes in custom automated fixtures and systems for assembly and other manufacturing processes.
Alignment Systems
Nova-Tech’s legacy of aircraft alignment system design, manufacture, and controls expertise is demonstrated in some of the finest aircraft flying today. Nova-Tech alignment solutions offer precision positioning, load sensing, metrology integration and analysis, and user friendly, PLC based, open architecture controls.
Nova-Tech alignment system solutions often interface with automated drilling and fastening or other processing equipment. Nova-Tech’s project management team excels in this multi-team environment and is also capable of integrating third-party drilling and fastening solutions.
Embraer Legacy 450/500 Fuselage Junction Assembly System (FJAS)
- Awarded 2011
- Turnkey supply: design, build, installation, acceptance
- Alignment of three fuselage sections (multiple configurations)
- Multi-axis positioner system with six (6) degrees of motion control
- Laser tracker integration and analysis
Boeing 737 Wing to Body Join System
- Unit #4 awarded 2011
- Units #5 and #6 awarded 2013
- Unit #7 awarded 2014
- Turnkey supply: design, build, installation, acceptance
- Alignment of wing halves to fuselage assembly
- Multi-axis positioner system with six (6) degrees of motion control
- Laser tracker integration and analysis
Spirit AeroSystems G650 Automated Wing Join
- Turnkey supply – design, build, installation, acceptance
- Alignment of LH and RH wing halves for assembly operations
- Multi-axis positioner system with six (6) degrees of motion control
- Laser tracker integration and analysis
Boeing 777 Final Body Join
- Turnkey supply: design, build, installation, acceptance
- Final alignment of fuselage sections (wings are already attached)
- Multiple, portable and fixed, multi-axis positioner system with six (6) degrees of motion control
- Integration with fuselage section transporters – “crawlers”
- Laser system integration and analysis
Specialty Application Systems
Clients frequently call on Nova-Tech to answer the need for customized solutions that require a combination its expertise in tooling, material handling, motion control, and automation.
Boeing 747-8 Bulkhead Assembly Fixture
- Turnkey supply: design, build, installation, acceptance
- Aligns bulkhead and landing gear beams for assembly operations
- Five (5) automated multi-axis positioners
- PLC based control system
Spirit AeroSystems B787 C-axis Rotation System
- Turnkey supply: design, build, installation, acceptance
- Holds and rotates +100,000 lb. mandrel assembly for loading/unloading of baggin material, caul plates, etc.
- 40,000 lb offset load
- Servo motor driven rotary and linear axes
- PLC based control system and HMI
- Interfaces with Nova-Tech supplied work platforms
Spirit AeroSystems B787 Stringer Forming System
- Turnkey supply: design, build, installation, acceptance
- Automated system for forming stringer charges into hat shape
- Multiple cross section configurations
- Servo motor driven and pneumatic motion controls
- PLC based control system and HMI
- Interfaces with third party conveyor system
Nova-Tech designs and manufactures highly unique and robust product handling systems for the aerospace industry. As aerospace manufacturers embrace lean manufacturing methods there is a greater need for proven solutions to move parts, processes, and tools. Nova-Tech has extensive experience in providing a full array of product handling solutions including Automated Guided Vehicles (AGV); moving line tugs; manually guided transporters; modular powered wheelsets for mobile equipment, and monorail and transfer systems.
AGVs, Tugs, & Transporters
Nova-Tech has a rich history in providing successful guided and unguided vehicle solutions for a wide array of payload size, load, and drawbar requirements. Vehicles may utilize one or a combination of guidance technologies to achieve the desired motion path and accuracy for the given application.
Boeing 737 Wing Assembly Transporter
- Turnkey supply: design, build, installation, acceptance
- Wing transporters for moving production line
- Integrated lift mechanism
- Reconfigurable part cradle
Gulfstream G650 Wing Join/Transporter
- Turnkey supply: design, build, installation, acceptance
- Wing transport dollies and tug for wing join and transport to final join
- Manually guided tug with omni-directional movement
Boeing 737 Moving Line Tug
- Turnkey supply: design, build, installation, acceptance
- Metal tape guidance
- Lifts nose gear and tows spine
Boeing 777 Systems & Integration (S&I) Crawlers
- Turnkey supply: design, build, installation, acceptance
- Pendant and autonomously controlled transport of 777 FWD and Aft fuselage through moving production line – S&I, final body join, and final assembly
- Reconfigurable for 777 variants
- Utility distribution for towed workstands
ULA Delta IV Tank Transports with Rotation
- Turnkey supply: design, build, installation, acceptance
Modular Wheelset System (MWS) & Powered Wheelsets
For years Nova-Tech has developed custom drive/steer wheelsets to meet a wide range of draw bar and load requirements. Wheelsets are used in groups or in conjunction with casters to provide a means to move large parts, tools and equipment throughout the factory for a variety of applications.
Nova-Tech has recently developed a family of compact, modular drive/steer wheelsets and controls called the Modular Wheelset System (MWS) that can be easily fitted to existing equipment (e.g. workstands, mobile robot platforms, etc.) to provide greater mobility, flexibility and safety while eliminating the need for forklifts or powered tugs.
Boeing 777 Workstand MWS
- Turnkey supply: design, build, installation, acceptance
- Total of 49 wheelsets installed on 16 workstands
- Supports lean production line operations
Bombardier C-Series Mobile Wing & Spar Trollies with MWS
- Turnkey supply: design, build, installation, acceptance
- Total of 34 wheelsets installed on 17 trollies
- Supports lean production line operations
Powered Wheelsets
- Traction and steering drive options include: electric, hydraulic, pneumatic
- Transmission options include: geared, chain, belt, planetary, single or multi-speed
- Power source options include: battery, umbilical, LP, compressed air
- Guidance technology includes: inductive sensor – metal tape/wire, vision system, and laser
- Full range of load, speed, draw bar and suspension capabilities
Monorail & Transfer Systems
As todays aerospace production lines move toward lean manufacturing methods there is an increasing need for monorail and local transfer systems move parts. Rather than reinventing the wheel, Nova-Tech typically utilizes commercially available products or teams with monorail/crane experts to offer fully integrated handling, tooling, and controls solutions.
BAE Systems F-35 Pulse Line
- 2011 award
- Turnkey supply: integration, design, build, installation, acceptance
- Monorail based pulse line systems for aft boom and empennage assembly
- Multi-phase implementation
BAE upgrades part production facilities at fighter jet factory > Read more
Bombardier Aerospace – Belfast – Spar Tool Transfer System
- 2011 award
- Turnkey supply: integration, design, build, installation, acceptance
- Gantry style overhead manipulator transfers forming tools between storage system and AGVs
Nova-Tech is an industry leader in providing user-friendly, open architecture, PLC based control system solutions for both new applications and upgrades for equipment in the field. Nova-Tech has been recognized for its ability to seamlessly execute control system implementations with limited schedule windows. Customers frequently contract Nova-Tech to replace the proprietary controls offered by its competitors.
Boeing 777 Section 44 Alignment System Controls Upgrade
- Turnkey supply: design, build, installation, acceptance
- Installed PLC controls for system with 6 servo controlled jacks, 4 planer lasers, and 34 targets for two systems
- Successful startup and commission during 7 day window
Boeing 777 Wing to Body Join System Controls Upgrade
- Turnkey supply: design, build, installation, acceptance
- Supplied build-to-print jack system
- Installed PLC controls for system with 12 servo controlled jacks, a planer laser, and targets for two complete systems
- Successful startup and commission during limited production window