Descripción del proyecto
Un juego de herramientas para la siguiente generación de dispositivos aeronáuticos
Los equipos de soldadura de precisión son un componente esencial de la fabricación aeroespacial de alta calidad. El proyecto WELDER tiene por objeto situarse a la vanguardia de la estrategia para la adopción de termoplásticos en la industria aeroespacial mediante la provisión y demostración de métodos de soldadura de fuselajes aeronáuticos. A largo plazo, pretende mejorar considerablemente los resultados ambientales y económicos del sector aeroespacial en consonancia con los objetivos de la Empresa Común Clean Sky 2. WELDER diseñará, desarrollará e implementará dos equipos de soldadura robótica modulares, flexibles y totalmente operativos y proporcionará un sistema de control y supervisión en línea para la gestión del ciclo de vida al completo.
Objetivo
The main objective of the WELDER project is to design, develop and deploy two robot-based, modular, flexible (Plug-and-Produce) and fully operative welding solutions (namely, ultrasonic welding and resistance welding end-effectors), including all the needed tooling and auxiliaries for performing the longitudinal barrel joint of the 8 m long fuselage at the Multi-Functional Fuselage Demonstrator. Moreover, WELDER will be focused on implementing an online monitoring and control system based on an end-to-end digital manufacturing solution, which will stablish a bidirectional dataflow to feed the whole lifecycle management digital twin and, thus, optimising the process and product performance while enabling new approval/acceptance procedures. Therefore, the successful execution of the WELDER project will become the spearhead of the aerospace industry thermoplastic adoption strategy through the provision and demonstration of the airplane fuselage welding replacing conventional joining systems that currently relies on fastening, riveting and adhesives, thus highly improving the environmental and economic performance of the aerospace sector, according to CS2 objectives.
The following results will also be achieved at the end of the project:
- A methodology for integrating new welding equipment (ultrasonic and resistance) on existing end-users´ facilities, regarding equipment set-up, tooling and auxiliary's integration.
- Frame coupling designs validation and an optimised manufacturing process based on the resistance metal mesh embedding within the coupling product.
- Inline monitoring and control digital pipeline in view to directly feeding into the demonstrators Product Lifecycle Management Digital Twin within 3D experience.
- Equipment and process optimisation based on real-process data gathering and feeding into the simulation and design tools.
Ámbito científico
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IA - Innovation actionCoordinador
28906 Getafe (Madrid)
España