Periodic Reporting for period 2 - INNOTOOL (Development of Thermoplastic press-forming Tool for Advanced Rear End Closing Frame Prototype and Tooling 4.0 for Assembly and transportation of the Advanced Rear End Prototype)
Periodo di rendicontazione: 2021-05-01 al 2022-06-30
The programme CS 2 pursues the delivery of full-scale in-flight demonstration of novel architectures and configurations including advanced technologies demonstrated at a full systems level. The Advanced Rear End prototype is within the LPA 2 (Large Passenger Aircraft) IADP (Innovative Aircraft Demonstrator Platforms) devoted to carrying out proof of aircraft systems, design and functions on fully representative innovative aircraft configurations in an integrated environment and close to real operational conditions. .This Call for Proposal is included within the CS2 LPA WP 1.2 Advanced Rear-End (ARE) Workpackage to find new innovative solutions that improve the current state of the art in terms of novel material and manufacturing processes adressing high production rates and sustainability.
In order to face this challenge, the development of innovative press-forming tool for Thermoplastic Closing Frame, including consolidation of stiffeners and press-forming of frame caps considering variable frame thickness and innovative assembly Tooling Set (including Drilling templates, Handling devices, Assemblies and Transportation) for the Advanced Rear End Prototype Specimen, including ALM techniques and strengths/deformations sensorization has been developed. Both manufacturing and assembly tooling have been improved by integrating Cyber Physical Sensors (CPS) for process monitoring to characterize and understand their performance and apply specific corrections or method changes when required. The objective is to gather and analyze process meaningful data separately, improve each process and consequently obtain a more value-added and cost efficient product.
In order to face this challenge, the development of innovative press-forming tool for Thermoplastic Closing Frame, including consolidation of stiffeners and press-forming of frame caps considering variable frame thickness and innovative assembly Tooling Set (including Drilling templates, Handling devices, Assemblies and Transportation) for the Advanced Rear End Prototype Specimen, including ALM techniques and strengths/deformations sensorization has been developed. Both manufacturing and assembly tooling have been improved by integrating Cyber Physical Sensors (CPS) for process monitoring to characterize and understand their performance and apply specific corrections or method changes when required. The objective is to gather and analyze process meaningful data separately, improve each process and consequently obtain a more value-added and cost efficient product.
Thermoplastic frame tooling:
- Definition of part and process specification by concurrent engineering to understand the specimen architecture and the available design level as well process quality requirements.
- Preliminary tooling design comprising the design (mechanical, thermal, automation), the justification, the manufacturing and the quality control of the Tooling Set within the adjoining elements. Moreover, auxiliary device or equipments have been identified at this stage.
- Main tooling design and validation including matured 3D models and 2D drawings with the operational assessment. Key Tolerances and specification have been defined at this stage and a mock up mould and auxiliary components have been manufactured for preliminary experimental testing. In parallel, the thermal control system have been determined as well as the automatic control system architecture which aims to deal with high production rate scenarios.
- Manufacturing of the tooling and set-up of the thermal control system and logic process. Previous testing results has been considered to adjust the design and process workflow as required.
- Manufacturing of the parts comprising the closing frame. Process optimization driven by iterative testing, quality evaluation and process output enhancement.
- Delivery of the parts and assembly aided by tooling set.
Assembly tooling set:
- Plateau phase-Concurrent Engineering where the specimen architecture and the available design level in order to outline tool options and best assembly sequence/philosophy has been established. Within this task all the information regarding geometry, constraints, preliminary assembly philosophy and related key characteristics, as well as tools for the handling, assemblies and transportation for the built assembly and adjoining elements integration. During these tasks, innovative solutions for tooling related to the sensorization of the assembly tooling, the automation of parts positioning and ALM techniques have been technologically screened and discussed.
- Concurrent engineering with the Topic Manager to reach the Preliminary Design Review (PDR) level of the Tooling Set. Within this task, the inputs of the design, the justification, the manufacturing and the quality control of the Tooling Set within the adjoining elements have been defined as a basis fur topling devlopment. The outcome of this task have included preliminary 3D models including the former design of measuring and monitoring systems.
- Main tooling design, validation and development of measuring tools. A Failure Mode and Effect Analysis (FMEA) analysis has been carried out to foresee and prevent any risk for the project, proposing an appropriate mitigation plan. Moreover, FEM analysis including the weight of the components and assembly loads created through the process has been conducted bringing the PDR design to CDR maturity level. In parallel, the measuring and sensing solutions have been selected and developed (in simulation, by experimental testing) driven by assembly process specifications.
- Manufacturing and geoemtrical validation of the tooling set
- Set-up (mechanical, electrical, control) and preliminary testing of the developed technologies (force sensors, vision, metrology assistant, automatic drives, HMI) integrated in the automatic assembly machine. Pre-Ship acceptance test in TEKNIKER premises.
- Delivery of the tooling set to Topic manager facility.
- Installation and set-up in shopfloor conditions. Testing of technologies through the assembly process.
- Assembly of ARE product driven by the tooling set and advanced smart solutions.
Based on both tooling set, the different components have been manufactured and the ARE product has been assembled and measured. Moroever, developed technologies have been tested and process performance has been studied for further improvement.
- Definition of part and process specification by concurrent engineering to understand the specimen architecture and the available design level as well process quality requirements.
- Preliminary tooling design comprising the design (mechanical, thermal, automation), the justification, the manufacturing and the quality control of the Tooling Set within the adjoining elements. Moreover, auxiliary device or equipments have been identified at this stage.
- Main tooling design and validation including matured 3D models and 2D drawings with the operational assessment. Key Tolerances and specification have been defined at this stage and a mock up mould and auxiliary components have been manufactured for preliminary experimental testing. In parallel, the thermal control system have been determined as well as the automatic control system architecture which aims to deal with high production rate scenarios.
- Manufacturing of the tooling and set-up of the thermal control system and logic process. Previous testing results has been considered to adjust the design and process workflow as required.
- Manufacturing of the parts comprising the closing frame. Process optimization driven by iterative testing, quality evaluation and process output enhancement.
- Delivery of the parts and assembly aided by tooling set.
Assembly tooling set:
- Plateau phase-Concurrent Engineering where the specimen architecture and the available design level in order to outline tool options and best assembly sequence/philosophy has been established. Within this task all the information regarding geometry, constraints, preliminary assembly philosophy and related key characteristics, as well as tools for the handling, assemblies and transportation for the built assembly and adjoining elements integration. During these tasks, innovative solutions for tooling related to the sensorization of the assembly tooling, the automation of parts positioning and ALM techniques have been technologically screened and discussed.
- Concurrent engineering with the Topic Manager to reach the Preliminary Design Review (PDR) level of the Tooling Set. Within this task, the inputs of the design, the justification, the manufacturing and the quality control of the Tooling Set within the adjoining elements have been defined as a basis fur topling devlopment. The outcome of this task have included preliminary 3D models including the former design of measuring and monitoring systems.
- Main tooling design, validation and development of measuring tools. A Failure Mode and Effect Analysis (FMEA) analysis has been carried out to foresee and prevent any risk for the project, proposing an appropriate mitigation plan. Moreover, FEM analysis including the weight of the components and assembly loads created through the process has been conducted bringing the PDR design to CDR maturity level. In parallel, the measuring and sensing solutions have been selected and developed (in simulation, by experimental testing) driven by assembly process specifications.
- Manufacturing and geoemtrical validation of the tooling set
- Set-up (mechanical, electrical, control) and preliminary testing of the developed technologies (force sensors, vision, metrology assistant, automatic drives, HMI) integrated in the automatic assembly machine. Pre-Ship acceptance test in TEKNIKER premises.
- Delivery of the tooling set to Topic manager facility.
- Installation and set-up in shopfloor conditions. Testing of technologies through the assembly process.
- Assembly of ARE product driven by the tooling set and advanced smart solutions.
Based on both tooling set, the different components have been manufactured and the ARE product has been assembled and measured. Moroever, developed technologies have been tested and process performance has been studied for further improvement.
The progress beyond the state of the art has been realized in two main fields. On the one hand, the thermoplastic tooling set development will boost new design strategies and manufacturing methodologies comprising the overall press-forming process based on thermoplastic materials, large component conforming thermal control solution and the specific methods related to additive manufacturing approaches for the materialization of moulds and inserts. On the other hand, the development of the assembly tooling set will enable new assembly methods and tooling concepts (automatic, collaborative, smart) for high-tech materials and high production rate approaches. The assembly process has been monitored by a network of sensors to control the process performance. Moreover, in design stages simulation strategies driven by digital twins have been used to support the design and selection of suitable technologies (external measuring framework, anticollision 2D/3D system, force sensors) and measuring procedures.