Single Source of Truth: Integrated Process Control and Data Acquisition System for the Development of Resistance Welding of CFRP Parts

Abstract

For the development of a novel (industrial) process, in particular within a research environment, a very flexible and adjustable control and data acquisition system is required. Traditional SCADA systems often are not designed for frequent changes. To facilitate the development process, the storage of all relevant data from process parameters to measurement data at a single location, as a "single-source-of-truth" is desirable. This paper introduces an integrated process control and data acquisition system that is built around the open-source central data storage system "shepard" which facilitates the evaluation of the process and offers potential for inline-optimization. The system is evaluated by the example of the production of a thermoplastic component. As part of the European Clean Sky II large passenger aircraft project, the German Aerospace Center produces the 8-meter long upper shell of the multifunctional fuselage demonstrator (MFFD) made from thermoplastic composites. The frames are attached to the skin by resistance welding, which is done using an actuated gantry system. This novel process has the potential to disrupt standard aircraft assembly by dust-less welding in a fully automated yet interactively customizable manner which is hence relevant for every process development context.