Periodic Reporting for period 2 - WELDER (Welding Equipment for optimised, fast and accurate LongituDinal barrEl joint closuRe)
Berichtszeitraum: 2022-07-01 bis 2023-12-31
The manufacturing large-scale parts/components is a complex and challenging process that requires the implementation of an integrated approach capable of ensuring the manufacturability, quality and high-precision of the large-parts from the engineering stages –i.e. design, simulation/modelling and production planning—. Europe is leading the manufacturing of complex large-scale components with worldwide and top-class manufacturing companies (e.g. AIRBUS, FOKKER). This demanding manufacturing of large parts is the foundation for the
competitiveness of the EU aeronautic strategic value chain. The welding operations of the airplane fuselage (i.e. manufacturing of large-scale components) demand the implementation of a holistic data management and a comprehensive automation methodology to achieve the desired levels of productivity, efficiency and quality based on the development and implementation of modular and flexible equipment (Plug-and-Produce concept).
The main objective of the WELDER project is to design, develop and deploy at Topic Manager´s facilities two robot-based and fully operative welding solutions (namely, ultrasonic welding end-effectors and resistance welding end-effectors), including all the needed tooling and auxiliaries for the longitudinal barrel joint of the 8m long fuselage demonstrator. Moreover, WELDER will be focused on implementing an online monitoring and control system based on an endto-end digital manufacturing solution, enabling a bidirectional dataflow to feed the whole lifecycle management digital twin and, thus, optimising the process and product performance and 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 relying on fastening, riveting and adhesives, thus highly improving the environmental and economic performance of the aerospace sector, according to Clean Sky 2 objectives.
At the end of the project the main objectives have been achieved. WELDER has provided the welding end-effectors to the MFFD for the longitudinal join in the overlap side and for the frame coupling integration in both sides of the barrel. After the welding trials campaing process parameters, welding windows and online monitoring system were defined for both technologies. Because of that the full barrel could be welded with promising quality results that will be deeply checked by the Topic Leader beyond WELDER analyses.
competitiveness of the EU aeronautic strategic value chain. The welding operations of the airplane fuselage (i.e. manufacturing of large-scale components) demand the implementation of a holistic data management and a comprehensive automation methodology to achieve the desired levels of productivity, efficiency and quality based on the development and implementation of modular and flexible equipment (Plug-and-Produce concept).
The main objective of the WELDER project is to design, develop and deploy at Topic Manager´s facilities two robot-based and fully operative welding solutions (namely, ultrasonic welding end-effectors and resistance welding end-effectors), including all the needed tooling and auxiliaries for the longitudinal barrel joint of the 8m long fuselage demonstrator. Moreover, WELDER will be focused on implementing an online monitoring and control system based on an endto-end digital manufacturing solution, enabling a bidirectional dataflow to feed the whole lifecycle management digital twin and, thus, optimising the process and product performance and 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 relying on fastening, riveting and adhesives, thus highly improving the environmental and economic performance of the aerospace sector, according to Clean Sky 2 objectives.
At the end of the project the main objectives have been achieved. WELDER has provided the welding end-effectors to the MFFD for the longitudinal join in the overlap side and for the frame coupling integration in both sides of the barrel. After the welding trials campaing process parameters, welding windows and online monitoring system were defined for both technologies. Because of that the full barrel could be welded with promising quality results that will be deeply checked by the Topic Leader beyond WELDER analyses.
First tasks in WP1 were to detail the potential welding solutions and functionalities to be integrated, the experimental plan and testing program. In close cooperation with Topic Manager and MFFD partners the tooling design was started in WP2 for the ultrasonic and resistance welding head as well as the hardware architecture for inline control system.
The WP7 was also started for the from the beginning, running throughout the project, to perform all needed tests and simulations to minimize the technology risk through Finite Element Models for test pieces and welded parts
Once the interfaces were agreed with MFFD stakeholders, the manufacturing and delivery of the heads were completed in WP3. Frame coupling parts were also manufactured in this work package to be integrated in the Major Component Assembly.
The WP4 has assured the quality of the welding by a set-up and a fine tuning of the equipment to ensure the integration at Topic Manager Facilities. End-effectors and thermoplastic behaviour were tested with a test campaign. The digital monitoring and control systems for the end-effectors were finally tested and configured during the trials as a result of WP5 were the process performance is evaluated.
Final analysis of the process and data obtained from equipment is obtained during WP7. Furthermore the final validated version of WELDER ultrasonic and resistance equipment configuration is defined for the full barrel welding.
Dissemination activities have been done during the project. Apart from several publications in websites and social media, important fairs in the aerospace and composite sectors have been attended by WELDER partners: JEC WORLD in Paris, 11th EASN and MATCOMP.
The know-how of all partners involved in WELDER has been increased and will be exploited on technical services related to thermoplastics for aerospace applications and process monitoring systems for welding equipment. The benefit an impact in the aeronautic value chain is based on the development of tailored engineering solutions by WELDER, which equipment will be potentially adapted for tooling and auxiliaries for fuselage suppliers (or other sub-components). Providing more cost-competitive products due to the high TRL reached in WELDER for the two welding technologies.
The WP7 was also started for the from the beginning, running throughout the project, to perform all needed tests and simulations to minimize the technology risk through Finite Element Models for test pieces and welded parts
Once the interfaces were agreed with MFFD stakeholders, the manufacturing and delivery of the heads were completed in WP3. Frame coupling parts were also manufactured in this work package to be integrated in the Major Component Assembly.
The WP4 has assured the quality of the welding by a set-up and a fine tuning of the equipment to ensure the integration at Topic Manager Facilities. End-effectors and thermoplastic behaviour were tested with a test campaign. The digital monitoring and control systems for the end-effectors were finally tested and configured during the trials as a result of WP5 were the process performance is evaluated.
Final analysis of the process and data obtained from equipment is obtained during WP7. Furthermore the final validated version of WELDER ultrasonic and resistance equipment configuration is defined for the full barrel welding.
Dissemination activities have been done during the project. Apart from several publications in websites and social media, important fairs in the aerospace and composite sectors have been attended by WELDER partners: JEC WORLD in Paris, 11th EASN and MATCOMP.
The know-how of all partners involved in WELDER has been increased and will be exploited on technical services related to thermoplastics for aerospace applications and process monitoring systems for welding equipment. The benefit an impact in the aeronautic value chain is based on the development of tailored engineering solutions by WELDER, which equipment will be potentially adapted for tooling and auxiliaries for fuselage suppliers (or other sub-components). Providing more cost-competitive products due to the high TRL reached in WELDER for the two welding technologies.
The implementatio of the WELDER end-effectors in the full scale have been a success. The quality of the welds is correct and the barrel will be inspected and tested in the near future.
Further research into the welding processes is needed to explore their maximum potential and to improve the definition of the welding heas and welding areas of the barrel.
WELDER also advances beyond the SoA through the proposition of the monitorization of the welding quality by measuring in real-time the current being applied and the temperature at the surface of the thermoplastic material using thermocouples. This monitorization setup enables the implementation of a closed loop control system that paves the way to optimise the process in a production environment.
The following innovative results have been achieved at the end of WELDER project:
- A methodology for integrating welding end-effectors (ultrasonic and resistance) on the fuselage MCA.
- Frame coupling designs validation and an optimised manufacturing process based on the barrel constraints
- Inline monitoring and control digital pipeline to feed the Product Lifecycle Management within 3D Experience.
- Process optimisation guidance based on real-process data gathering and feeding into the simulation and design tools.
Further research into the welding processes is needed to explore their maximum potential and to improve the definition of the welding heas and welding areas of the barrel.
WELDER also advances beyond the SoA through the proposition of the monitorization of the welding quality by measuring in real-time the current being applied and the temperature at the surface of the thermoplastic material using thermocouples. This monitorization setup enables the implementation of a closed loop control system that paves the way to optimise the process in a production environment.
The following innovative results have been achieved at the end of WELDER project:
- A methodology for integrating welding end-effectors (ultrasonic and resistance) on the fuselage MCA.
- Frame coupling designs validation and an optimised manufacturing process based on the barrel constraints
- Inline monitoring and control digital pipeline to feed the Product Lifecycle Management within 3D Experience.
- Process optimisation guidance based on real-process data gathering and feeding into the simulation and design tools.