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Highly automated manufacturing process of large airplane CFRP structures

Malecha, Marcin and Full, Thomas (2019) Highly automated manufacturing process of large airplane CFRP structures. 22nd International Conference on Composite Materials 2019, 11 - 16 August 2019, Melbourne, Australia. (Unpublished)

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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.

Item URL in elib:https://elib.dlr.de/132039/
Document Type:Conference or Workshop Item (Speech, Poster)
Title:Highly automated manufacturing process of large airplane CFRP structures
Authors:
AuthorsInstitution or Email of AuthorsAuthors ORCID iD
Malecha, MarcinMarcin.Malecha (at) dlr.dehttps://orcid.org/0000-0003-2824-0914
Full, ThomasThomas.Full (at) dlr.deUNSPECIFIED
Date:16 August 2019
Refereed publication:Yes
Open Access:No
Gold Open Access:No
In SCOPUS:No
In ISI Web of Science:No
Status:Unpublished
Keywords:automation, rear pressure bulkhead, manufacturing, draping, CFRP, dry fibres, manufacturing execution system,
Event Title:22nd International Conference on Composite Materials 2019
Event Location:Melbourne, Australia
Event Type:international Conference
Event Dates:11 - 16 August 2019
Organizer:ICCM
HGF - Research field:Aeronautics, Space and Transport
HGF - Program:Aeronautics
HGF - Program Themes:fixed-wing aircraft
DLR - Research area:Aeronautics
DLR - Program:L AR - Aircraft Research
DLR - Research theme (Project):L - Structures and Materials
Location: Augsburg
Institutes and Institutions:Institute of Structures and Design > Automation and Production Technology
Deposited By: Malecha, Marcin
Deposited On:12 Dec 2019 11:50
Last Modified:12 Dec 2019 11:50

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