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JIF4FLIGHT Report Summary

Project ID: 298114
Funded under: FP7-JTI
Country: Spain

Periodic Report Summary 2 - JIF4FLIGHT (Final Assembly Line Assembly Jigs and Fixtures for flight test demonstrator)

Project Context and Objectives:
The JIF4FLIGHT project, led by ARITEX and with partner ASCAMM (NOW EURECAT), is the materialization of a proposal to answer a Call for Proposal from Cleansky Program, which topic was to design, manufacture and deliver the Jig and Fixtures at FAL for the Blade project of the SFWA ITD lead by AIRBUS, where the BLADE is a Laminar flow wing to be tested in flight conditions.
In concrete the jig and fixtures are the ones needed tooling for disassembly the original outer wings of an A340 and to assembly the NLF wing to be tested in the Flight Tests Bench.
During the second reporting period of the project development, important milestone were:
• Specification and requirements finished
• All Design Completed
• All components manufactured
• All components accepted
The JIF4FLIGHT project has advanced and has not stopped at anytime, although it could not go at the pace that was assumed and planned at the beginning. This was mainly due to the complexity of the Blade wing product development, to which JIF4FLIGHT is attached, from which it requires the major and most important data for the jig and fixtures design and manufacturing.
The JIF4FLIGHT the project is being developed in a Phase and Gate approach, which means that until product maturity and build philosophy are not ready JIF4FLIGHT cannot run ahead. At the end of this period CDR for Stage 1 and 2 were passed.
Nevertheless at the moment of writing this summary all stages CDR has been passed (Stage3) and there is a clear path for dates of when the jig and fixtures are required. The installation of Stage 1 and 2 is underway.
A new schedule for the Flight Test, which is in implementation, will let JIF4FLIGHT to adapt it planning to the need of FTB of BLADE Project up to the end of 2016.

Project Results:
Work progress and achievements during the period
During this period the work has been centered on work packages WP1, WP2 and WP7. The project development has not achieved to be working on WP3, WP4 and WP5, due to shift in BLADE product design and Hangar definition, which original location was changed to Tarbes.

A shift of the project JIF4FLIGHT has been produced due to:
1. Blade product maturity, maturity progression and Hangar definition.
2. Point one has brought to delay in definition of more mature build philosophy of the different stages involved in the product assembly at the assembly hangar.
3. Delay in definition of the Hangar Location and the equipment available at the hangar for jig and fixture assembly
Sincé the begining of the Project it has been carried out:

Coneptual design of Stage 1 to 3
Preliminary design of Stage 1 to 3
Critical design of Stage 1 to 3
Passed PDR and CDR for all stages
Manufacturing of Stage 1 and 2

Potential Impact:
Project objectives for the period
The jig and fixtures targeted in this project, hereafter referred to as “tooling”, are parts of the Blade project, which is the project engaged at SFWA ITD for testing in flight a new wing concept for laminar flow.
The objectives of the JIF4FLIGHT project for this reporting period were to conduct the development, design, and manufacture of a jig platform, staging and operational tooling, plus project tooling for removing the outer wing sections of an A340-300 and tooling to assembly the SFWA laminar flow flight test demonstrator wings.

The SFWA flight test demonstrator aims to validate that a specific wing profile can sustain
Laminar flow with an acceptable stability versus in flight deformation and contamination

The new outer wing sections to be fitted will have a very accurate profile and high smoothness of the wing surface. These boxes will be dry areas (without fuel) and fully functional with Flight Test Instrumentation.

The outer wing dimensions that will be considered for this Project will be approximately 8.5 m in span length and 4.1m in chord at the wing box root.

To accommodate these new outer wings it has been analyzed in this project period:

• How to remove the original outer wing at Rib 27
• The best solution for the assembly jigs for the transition structure to take into account geometrical differences between standard and new outer wing.
• How to assembly the new outer wing (NLF wing)
• How to remove the laminar flow outer wing and transition structure after ending the flight test demonstrators..
• How to reassembly the original outer wings
• All the ancillary tooling required for assembly and disassembly operations

It means, for this goal the analysis of all stages of the assembly and disassembly of both Port and Starboard outer wing sections of an Airbus A340-300 will be performed. The necessary jigs and fixtures will be designed and manufactured.

Beside it will be developed and manufactured an assembly system for a transition structure, which will takes up the geometrical differences between the original inner wing and new outer wing. This transition structure will be assembled in-situ and joined to the inner wing at rib 27.

To correctly perform this study, development and manufacturing, the list of Key Inputs, that will be needed, are listed here below:

• Build philosophy for FAL operations
• Aircraft tolerance requirements
• Frontier drawings
• Wing models / drawings

Deep review with Topic Manager to understand on integral basis the Project goals and propose innovative concepts, respect to the list delivered in the Topic Description.

The following requirements will be analyzed in detail to be carefully addressed:

First under Pre-Flight Test tooling to support a build philosophy which includes:

1. Disassembly and withdrawal of the existing outer wingbox at rib 27 datum.
2. Assembly of new transition structure to inner wingbox.
3. Wing joins up of new outer wingbox to the assembled transition structure.

Second under Post-Flight Test tooling to support a build philosophy this includes:

1. Disassembly of the new outer wingbox from the transition structure.
2. Disassembly of the new inner wingbox transition structure back to the original Rib 27 datum.
3. Restore inner wingbox structure to rib 27 original conditions.
4. Wing join up to restore outer wingbox and inner wingbox to original condition.

Wing Twist
Maximum asymmetry final assembly: at Rib 28: 24’ at Rib 37: 40’
Wing Pitch
Tolerance = +/-5’
Wing Dihedral
Tolerance = +/-5’
Wing Sweep
Tolerance = +/-2’30”, with maximum asymmetry of 2’

Lifting & Handling
All manufactured tooling will be compliant with existing Airbus standards and health & Safety directives previously accorded.

The consortium will study a care design to ensure that any tooling will take into account the elimination or reduction of over-reaching, stretching and working overhead. Ease of loading of any component parts and the subsequent loading and un-loading of the completed assembly will also be considered.

Any tooling items that fall outside the Airbus weight limit (25kg) will be supplied with suitable lifting equipment. Particular attention will be given to removing weight where possible whilst still ensuring tooling functionality.

In order to facilitate disassembly & assembly operations, two rigid structural jig platform stages will be erected at both port and starboard wing positions for the purpose of supporting operational tooling and operator access. The interfaces of the structural jig platform and operational tooling will be qualified by laser tracking and positional setting to the airframe reference datums.

The study will be aimed to propose and alternative innovative designs, where possible, for tooling solutions to achieve project cost reductions and improved efficiency of operations in keeping with a one off or low volume build.

The consortium makes this proposal considering they will have full responsibility and charge of installation and certify the conformity of all jig platforms, stages and operational tooling with reports and quality documentation.

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