Periodic Reporting for period 2 - HERON (Fully controlled RTM tooling and high deposition rate ALM technologies for cost-effective and sustainable manufacturing of hybrid laminar wing demonstrator)
Reporting period: 2020-11-01 to 2021-10-31
The overall objective of HERON is to develop and manufacture a comprehensive set of innovative, cost-effective and sustainable tooling for RTM processes as well as the use of high deposition rate ALM technologies, aiming at improving the energy and resource efficiency of the manufacturing of a leading edge and trailing edge for integration on aeronautical demonstrator.
To this end, four innovative technologies have been combined and demonstrated at operational environments in aeronautic sector reached TRL 6:
A. Modular design for RTM tooling to facilitate leading edge parts demoulding and heating strategies, combining different heating systems in customized surfaces.
B. Near real time process monitoring as path to control RTM process parameters (such us temperature) relying on in-mould sensors (thermocouples, strain and pressure gauges), external gauges (thermal cameras) and a control algorithm for thermal distribution.
C. High deposition rate hybrid ALM for trailing edge production to reduce resources consumption, using resins specifically developed for aeronautical applications.
D. Finally, a fully automated and high accuracy production environment for the manufacturing of the necessary tooling for the leading edge and the application of the ALM technologies for the trailing edge, could ensure an accurate integration on the hybrid laminar wing demonstrators and an easy reparation or modification of the RTM tooling and ALM parts These four innovative approaches can lead up to a direct 25 % of energy consumption reduction, 20 % of cost reduction and 30 % reduction in time cycle for the production of aeronautical structures. The project concept addresses 100% tooling needed in the RTM and ALM processes, both for manufacturing and validating purposes, leading to a reduction of CO2 equivalent emission by up 30% linked to the Clean Sky 2 Programme High-level Objectives.
To this end, four innovative technologies have been combined and demonstrated at operational environments in aeronautic sector reached TRL 6:
A. Modular design for RTM tooling to facilitate leading edge parts demoulding and heating strategies, combining different heating systems in customized surfaces.
B. Near real time process monitoring as path to control RTM process parameters (such us temperature) relying on in-mould sensors (thermocouples, strain and pressure gauges), external gauges (thermal cameras) and a control algorithm for thermal distribution.
C. High deposition rate hybrid ALM for trailing edge production to reduce resources consumption, using resins specifically developed for aeronautical applications.
D. Finally, a fully automated and high accuracy production environment for the manufacturing of the necessary tooling for the leading edge and the application of the ALM technologies for the trailing edge, could ensure an accurate integration on the hybrid laminar wing demonstrators and an easy reparation or modification of the RTM tooling and ALM parts These four innovative approaches can lead up to a direct 25 % of energy consumption reduction, 20 % of cost reduction and 30 % reduction in time cycle for the production of aeronautical structures. The project concept addresses 100% tooling needed in the RTM and ALM processes, both for manufacturing and validating purposes, leading to a reduction of CO2 equivalent emission by up 30% linked to the Clean Sky 2 Programme High-level Objectives.
The work has been distributed in four work packages:
• In Work Package 1 (Project Management and Coordination) AITIIP provided legal, administrative and coordination support to the project.
• Concerning Work Package 2 (HERON design and documentation) AITIIP has focused on the development of an innovation plan, taking into account the activities carried out previously. Firstly, an aluminium tooling was made to solve the different problems generated in the union between the skin of the Leading Edge and the skin of the Torsion Box. For the first half of the project, mechanised pieces and pieces manufactured by means of 3D printing were also made. Different designs were made to study the feasibility of manufacturing the Leading Edge using RTM, in this design key factors were included (forcing geometries) to be able to study the feasibility of manufacturing such a complex piece in a single shot (One-Shot RTM). In addition, several innovations were included in this mould, manufacturing of internal mandrels using WAAM technology, possibility of temperature control using coolants (tubes in the ring to be able to circulate liquid), thermal study and temperature control in real time.
• Work Package 3 (HERON Manufacturing and Validation): This work package started in M10 and lasted until M30. WP3 is the work package where the manufacture, delivery and set-up of the tooling set and ALM part is done, in accordance to the Topic
Manager specifications. Between M19 and M30 all the manufacturing tasks have been carried out and finished, specifically all the tools required by the TM have been manufactured, both for the manufacture of the Torsion Box and for the manufacture of the LE, apart from the manufacture of the tools, all the necessary fittings have also been manufactured
• Work package 4 (Exploitation, dissemination and communication): includes all the activities around exploitation and communication of the project results. So far, “T4.2 implementation of the Dissemination and Communication Plan” has been the focus for the exploitation duties. AITIIP delivered the Plan for the Communication, Dissemination and Exploitation (PEDR) in Oct 2019 and have carried out different activities in order increase the project impact, from online presence, social networks, visual identity, to physical presence in a number of relevant forums. This line of work was continued until M30, with the addition of the HERON Exploitation and Innovation strategy.
• In Work Package 1 (Project Management and Coordination) AITIIP provided legal, administrative and coordination support to the project.
• Concerning Work Package 2 (HERON design and documentation) AITIIP has focused on the development of an innovation plan, taking into account the activities carried out previously. Firstly, an aluminium tooling was made to solve the different problems generated in the union between the skin of the Leading Edge and the skin of the Torsion Box. For the first half of the project, mechanised pieces and pieces manufactured by means of 3D printing were also made. Different designs were made to study the feasibility of manufacturing the Leading Edge using RTM, in this design key factors were included (forcing geometries) to be able to study the feasibility of manufacturing such a complex piece in a single shot (One-Shot RTM). In addition, several innovations were included in this mould, manufacturing of internal mandrels using WAAM technology, possibility of temperature control using coolants (tubes in the ring to be able to circulate liquid), thermal study and temperature control in real time.
• Work Package 3 (HERON Manufacturing and Validation): This work package started in M10 and lasted until M30. WP3 is the work package where the manufacture, delivery and set-up of the tooling set and ALM part is done, in accordance to the Topic
Manager specifications. Between M19 and M30 all the manufacturing tasks have been carried out and finished, specifically all the tools required by the TM have been manufactured, both for the manufacture of the Torsion Box and for the manufacture of the LE, apart from the manufacture of the tools, all the necessary fittings have also been manufactured
• Work package 4 (Exploitation, dissemination and communication): includes all the activities around exploitation and communication of the project results. So far, “T4.2 implementation of the Dissemination and Communication Plan” has been the focus for the exploitation duties. AITIIP delivered the Plan for the Communication, Dissemination and Exploitation (PEDR) in Oct 2019 and have carried out different activities in order increase the project impact, from online presence, social networks, visual identity, to physical presence in a number of relevant forums. This line of work was continued until M30, with the addition of the HERON Exploitation and Innovation strategy.
The potential impact of HERON is linked with its key technological results and the way they combine a number of different innovations with RTM tooling and Hybrid ALM Technologies. RTM tooling technologies has been used in the aeronautics sector for a long time, but HERON offers a number of advantages over other, more classic approaches to the aforementioned techniques:
• Modular design for RTM tooling to facilitate leading edge parts demoulding and heating strategies
• Near real-time process monitoring to control RTM process parameters
• High deposition hybrid ALM technologies
The innovations provided by the HERON tooling system allow for accurate and semi-automated manufacturing of medium sized parts of various thicknesses. As simple as it seems, this alone opens a fundamental path for exploitation in different industries, of which the most relevant are:
• Aerospace and Defense
• Automotive and Railway
• Construction
• Energy and large infrastructures
In M30, HERON clearly stands out as an initiative able to achieve:
• Increased efficiency and accuracy by 25 % and 8 % respectively, thanks to reduced manufacturing costs and system accuracy.
• Better control of the self-heating tooling, reducing energy consumption by 25% and reducing the workload by 10%.
• Free-form shapes, which mean flexibility (again less cost)
• Adaptability of these processes to other markets
• Modular design for RTM tooling to facilitate leading edge parts demoulding and heating strategies
• Near real-time process monitoring to control RTM process parameters
• High deposition hybrid ALM technologies
The innovations provided by the HERON tooling system allow for accurate and semi-automated manufacturing of medium sized parts of various thicknesses. As simple as it seems, this alone opens a fundamental path for exploitation in different industries, of which the most relevant are:
• Aerospace and Defense
• Automotive and Railway
• Construction
• Energy and large infrastructures
In M30, HERON clearly stands out as an initiative able to achieve:
• Increased efficiency and accuracy by 25 % and 8 % respectively, thanks to reduced manufacturing costs and system accuracy.
• Better control of the self-heating tooling, reducing energy consumption by 25% and reducing the workload by 10%.
• Free-form shapes, which mean flexibility (again less cost)
• Adaptability of these processes to other markets