Highly automated manufacturing process of large airplane CFRP structures

Abstract

At the Center for Lightweight Production Technology (ZLP) in Augsburg novel manufacturing technologies are under development. The focus lies on automation of lightweight materials production processes for large aerospace components. Complex geometry, high quality requirements, low rates and expensive production manufacturing processes are canon there. Our goal was to develop highly automated production chain for Rear Pressure Bulk Head (RPBH) of a typical long range civilian aircraft made out of dry carbon fabrics. We have designed possible smart process chain automation and joining of single steps of an existing manual process chain. For this purpose we have improved technologies from previous projects or developed new ones, introducing automated quality measures into the process. Also a modular manufacturing execution system (MES) in order to monitor and control the process chain was developed. The accomplished maturity level of the process was validated during manufacturing of a full-size demonstrator. The technology was presented at our research multifunctional robotic cell using flexible layouts and up to four robots equipped with different end effectors within single sub-process. The demonstrated process spans from the material logistic of the very first cut-piece to ready to infiltrate preform including vacuum bagging. Using data from the demonstration we also have estimated economic benefits of the presented solution.