MultiFAL provides a tailor-made solution to adapt to the characteristics of the MultiFunctional Fuselage Demonstrator (MFFD), and for each of the welding technologies and case studies involved.
When the MultiFAL Modules designs were frozen, a final agreement with partners has been necessary to launch the last iteration for the 3D models, Finite Element Model, manufacturing and assembly drawings. The purchase and manufacturing phases were performed so MultiFAL Modules have been manufactured and installed. Reuse of existing hardware and early planning of station assembly allowed a cost-efficient realisation of the project.
In addition, simulation of moveable parts was available to check the welding heads positions along the fuselage. It has been used to support first trials and to define the end-effector positions for the final process.
The mechanics, pneumatics and automation of the Inner Positioner have been successfully tested. The hydraulic system for the Bridge Support. And the drive motors, gear boxes and the grease pumps of the linear axes. PLC systems were also installed and the communication set up and tested. Using OPC-UA as main communication protocol allowed efficient and transparent data exchange between the control systems.
Final tests on-site with coupons were completed so welding parameters could be defined and fuselage shells finally placed for the longitudinal welds. Virtual CAD simulation has resulted in several design details for more efficient station assembly. All tolerances of the assembly station were significantly smaller than the shell manufacturing tolerance. Thus, station tolerances did not become a driving factor for the finally achieved geometric accuracy and all welding end effectors were integrated without any need for late hardware changes.
The implementation of the MFFD has been a success, as all three case studies have been successfully completed. The three welding technologies employed have proven to be robust and capable of being applied on a scale such as MULTIFAL. However, for future implementation, further research into these welding processes is needed to explore their maximum potential. In order to improve heads, continue to expand the knowledge of these technologies and maximize the final properties of the weld.
Due to the lack of time was still not possible carried out NDT inspections on the welding areas, but they will be done on the future by AIRBUS to have a better understanding of the welding quality.
Dissemination of the project:
- MultiFAL website:
https://www.multifal.eu/(opens in new window)- MultiFAL project in AIMEN´s website:
https://www.aimen.es/proyectos/multifal(opens in new window)- Dassault Systemes website:
https://www.3ds.com/insights/customer-stories/ct-engineering-plant-commissioning(opens in new window)- Linkedin publications:
https://www.linkedin.com/posts/thectengineeringgroup_clean-sky-2s-multifal-project-has-successfully-activity-7024317152002203648-YMrO?utm_source=share&utm_medium=member_desktop(opens in new window)- Magazine publication: FFT has published a 2-page publication for the 2024 “Futured” magazine: “Automated CFRP Fuselage Assembly using Different Welding Technologies”
MultiFAL partners are exploiting the results participating in R&D European projects in order to develop more applications for composite processes.
