Highly automated manufacturing process chain for large double curved CFRP aircraft parts

Abstract

Application of novel materials in modern aircraft often goes along with challenges regarding to the manufacturing. The state-of-the-art carbon fibre reinforcing plastics (CFRP) for aircraft parts are still manufactured mostly in manual labour and therefore there is high demand for automation. Large, double curved parts, provide additional requirements concerning logistics and processing. As an example, the rear pressure bulkhead (RPBH), is an excellent sample for such aircraft part made entirely from CFRP. Our work aims to automate the whole manufacturing process of RPBH including quality assurance and manufacturing execution system (MES) which interlinks many high complex sub-processes. We will discuss our concept for the process, the reached status with emphasis on the most advanced sub-process of pick&place of reinforcing plies and give a short outlook for the future. The recent results show expected benefits of our solution compared to manual manufacturing regarding to quality, robustness, manufacturing times and costs. For the first time, the implemented MES allows to embed the process in industry 4.0 manufacturing environment.