Periodic Reporting for period 4 - MultiFAL (Multifunctional automation system for Fuselage Assembly Line)
Okres sprawozdawczy: 2022-09-01 do 2023-12-31
With actual production rates, the existing backlog of aircraft manufacturers without taking into account new orders would be machined off in several years. One attempt for increasing the production rate is implementing flexible manufacturing solutions, especially new lightweight robot kinematics, digital assisted manufacturing together with new process technologies, which can be used for varying and restricted workspaces in the existing production (brownfield approach).
The main objective of the MultiFAL project is to design, develop and construct an automated plant system for joining thermoplastic fuselage shells considering three different design use-cases, taking into account the existing assembly plant system at the topic managers’ facility.
MultiFAL will consider automation and virtual commissioning technologies in order to bring both an increase in the assembly process performance and a deep understanding of the relevant factors implementing a full size automated plant following a brownfield approach. Different assembly approaches and joining process for different use-cases will be considered, taking into account the currently existing double-sided and limited accessibility for full fuselage sections.
MultiFAL will also facilitate the adaptability of both the robotic machinery and the central control system. Objectives include reducing the commissioning time of automated plant systems up to 20% by the use of virtual commissioning tools, increasing the level of detail for production steps around 25% by implementing interfaces between plant system and production control. Additionally, usability and re-utilization of automation systems by the development and implementation of standardized interfaces will be enhanced. In the MultiFAL project, lean development approaches will be combined with agile methodologies to develop not only software modules for the simulation but also for the virtual commissioning of the plant system.
The implementation of the MFFD has been a success at the end of MultiFAL project. 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.
The main objective of the MultiFAL project is to design, develop and construct an automated plant system for joining thermoplastic fuselage shells considering three different design use-cases, taking into account the existing assembly plant system at the topic managers’ facility.
MultiFAL will consider automation and virtual commissioning technologies in order to bring both an increase in the assembly process performance and a deep understanding of the relevant factors implementing a full size automated plant following a brownfield approach. Different assembly approaches and joining process for different use-cases will be considered, taking into account the currently existing double-sided and limited accessibility for full fuselage sections.
MultiFAL will also facilitate the adaptability of both the robotic machinery and the central control system. Objectives include reducing the commissioning time of automated plant systems up to 20% by the use of virtual commissioning tools, increasing the level of detail for production steps around 25% by implementing interfaces between plant system and production control. Additionally, usability and re-utilization of automation systems by the development and implementation of standardized interfaces will be enhanced. In the MultiFAL project, lean development approaches will be combined with agile methodologies to develop not only software modules for the simulation but also for the virtual commissioning of the plant system.
The implementation of the MFFD has been a success at the end of MultiFAL project. 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.
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/
- MultiFAL project in AIMEN´s website: https://www.aimen.es/proyectos/multifal
- Dassault Systemes website: https://www.3ds.com/insights/customer-stories/ct-engineering-plant-commissioning
- 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
- 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.
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/
- MultiFAL project in AIMEN´s website: https://www.aimen.es/proyectos/multifal
- Dassault Systemes website: https://www.3ds.com/insights/customer-stories/ct-engineering-plant-commissioning
- 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
- 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.
MultiFAL will consider process simulation, automation, plant concepts and virtual commissioning technologies in order to bring both an increase in the assembly process performance and a deep understanding of the relevant factors implementing a full size automated plant following a brownfield approach. Different assembly approaches and joining processes for different use-cases will be considered, taking into account the currently existing double-sided and limited accessibility for full fuselage sections. As a result, MultiFAL will also facilitate the adaptability of both the robotic machinery and a central control system.
The successfully completion of MultiFAL project will ensure a strategic impact and will have clear Socio-Economic benefits within the next five to ten years by contributing to:
- Enhance European aeronautic industry competitiveness
- Enhance European employment
- Meet societal needs for more environmental friendly, safer and efficient manufacturing
The successfully completion of MultiFAL project will ensure a strategic impact and will have clear Socio-Economic benefits within the next five to ten years by contributing to:
- Enhance European aeronautic industry competitiveness
- Enhance European employment
- Meet societal needs for more environmental friendly, safer and efficient manufacturing