Compact Shipboard Swaging Machine

Creare is nearing completion of development of a compact swaging machine (CSM) to replace the current speltering process used on aircraft carriers to attach terminals to arresting-gear purchase cables (PC). The CSM is much smaller and lighter weight than existing swaging machines with the required capacity, enabling its use in the shipboard environment. The CSM and new PC swaging process will improve operability of the aircraft carrier, reduce operational costs, and improve the quality of life for Navy personnel. The Naval Air Systems Command estimates that this machine will reduce V-2 workload requirements by up to 500 man-hours per deployment, earning this technology the label of “the single biggest Quality of Life improvement in 20 years of V2.”

For each aircraft arrestment, the aircraft tailhook engages with the cross deck pendant, which is attached to a PC on each end. The PC and terminals must endure large impacts and engagement forces during the landing process. The current speltering process uses molten zinc to form the bond between the PC and the terminal. This process is workload intensive, hazardous, and prone to quality control problems. Creare’s CSM provides an automated terminal swaging method which reduces hazards and sailor workload while retaining the high quality needed for this safety-critical equipment. While the current speltering process takes multiple sailors as much as 12 hours to complete one terminal, our CSM enables one sailor to complete the automated and highly repeatable swaging process in less than one hour. 

Creare development of aircraft launch and recovery equipment (ALRE) for the U.S. Navy includes a robotic catapult inspection instrument in routine use on every carrier in the fleet as well as several technologies still in development: a repeatable release holdback bar health monitor; a catapult elongation sensor; and weight board operator and jet blast deflector operator safety and workload enhancements.

For more information on Creare’s ALRE technologies, contact us at info@creare.com.