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Automation of Sorting and Kitting from cutting tables

Broetje-Automation GmbH-Erik Berg
  • Technical Paper
  • 2019-01-1899
To be published on 2019-09-16 by SAE International in United States
Within the current part production of carbon fiber parts a lot of manual work is included for sorting and kitting of automatic cut plies. This is required due to the high raw material costs and enables a good utilization of the materials. Automation of this non-value adding process will be a big benefit for the part production. The high variety of shapes and the different materials to be processed are complex boundary conditions, which are to be overcome. Broetje is in development of handling systems and automation solutions, which are used for a high variety of materials as well as for a high variety of shapes. These systems are meant to be an add-on for existing cutting tables as well as for fully integrated production systems with downstream automation equipment like draping hoods. Mayor challenges to overcome are safe gripping capabilities, detection of #non-cut fibers, high variety of shapes, complex logistic management. These challenges are addressed with Broetje’s ASK Solution. This paper will focus on the innovative automated sorting and kitting solution invented by Broetje-Automation.
 

Identifying Virtuous Cycles of Using Real-Time Process Data in Portable Semi-Automated Electric Drilling

Airbus Operations GmbH-Jan Sturhmann
Airbus UK-Luke bagshaw, Philip Edwards
  • Technical Paper
  • 2019-01-1875
To be published on 2019-09-16 by SAE International in United States
Purpose: Thanks to the long lifetimes of aerospace platforms, manufacturers face opportunities for improving the manufacturing processes of legacy products. However, the potential benefits of process innovations must be carefully balanced with the costs. One such opportunity is offered through portable semi-automated electric drilling. The purpose of this paper is to identify critical elements in building a business case for incorporating portable semi-automated electric drills on aerospace products and processes. Design/methodology/approach: Drawing on institutional knowledge, we distinguish three entities in hole-generation tasks: hole types, hole-cutting tools, and hole-cutting assets (e.g. portable drills). We identify the specific needs, requirements and constraints in hole generation by focusing on each entity and the relationships between them. We then examine the implications of introducing sensor-equipped portable electric drills that allow real-time process data collection. Finally, we assess the impact of innovation in hole-cutting assets in general. Findings: It was found that the benefits of real-time process data collection can lead into a virtuous cycle where a first-order benefit can lead to multiple higher-order benefits. For example, provision of spindle…
 

Line Side Equipment

Broetje-Automation Gmbh-Bertrand LAPORTE
  • Technical Paper
  • 2019-01-1879
To be published on 2019-09-16 by SAE International in United States
The aircraft production rate is now increasing and requires to keep the production tools as close as possible from the assembly work area. As production sites cannot be extended as much as the rate increases, this has created the need for developing innovative & efficient line side equipment, which fulfils storage capacity, ergonomical accessibility, easy handling & quick load unload performance for all aircraft part assemblies. This paper will focus on the development and the integration into the production on our innovative solutions on Line Side Equipment . The Line Side Equipment is custom designed and built for manual or semi-automated assembly lines. It offers a wide range of solutions such as dedicated storage areas, trolleys, easy acces, tool kits & smart cabinets.
 

Flight Optimization Model on Global and Interval Ranges for Conceptual Studies of MEA Systems

Akita University-Yotsugi Shibuya
IHI Corporation-Hitoshi Oyori, Hirotaka Sugawara, Naoki Seki
  • Technical Paper
  • 2019-01-1906
To be published on 2019-09-16 by SAE International in United States
In development of more electric aircraft applications, it is important to discuss aircraft energy management on various level of aircraft operation. This paper presents a computationally efficient optimization model for evaluating flight efficiency on global and interval flight ranges. The model is described as an optimal control problem with an objective functional subjected to state condition and control input constraints along a flight path range. A flight model consists of aircraft point-mass equations of motion including engine and aerodynamic models. The engine model generates the engine thrust and fuel consumption rate for operation condition and the aerodynamic model generates the drag force and lift force of an aircraft for flight conditions. These models is identified by data taken from a published literature as an example. First, approximate optimization process is performed for climb, cruise, decent and approach as each interval range path. Next, optimization for global range path involves whole flight path to find optimal operation condition in the flight. In aircraft energy management, fuel consumption converts into not only thrust power, but power of…
 

Investigation into the benefits of implementing a fully integrated MRO Software system in Airlines Maintenance and Engineering

SORT Engineering GmbH-Adel A. Ghobbar
  • Technical Paper
  • 2019-01-1908
To be published on 2019-09-16 by SAE International in United States
Case studies of various MRO organizations were researched in order to gain a better understanding of the business procedures used in each department of an aircraft maintenance company. The software systems available to aid business processes were researched to understand the computer processes, functions and operational requirements of these software programs. The planning and scheduling of inventory and manpower resources is complex and requires various parameters to be computed by the software systems in order to adequately plan the necessary aircraft maintenance resources. Case studies of aircraft maintenance companies that previously implemented integrated IT software solutions to control and monitor department functions were researched to identify and understand the various problems encountered by these companies during the software implementation phase. Understanding the problems that could potentially occur during the implementation is necessary to ensure similar mistakes are not repeated. The improvements and gains to efficiency that can be expected once the integrated IT system is operational were also considered. The work flow processes in the Brussels Airlines MRO Stores (incoming inspection) and Maintenance Planning departments…
 

A portable numerical control drilling template

Allison Schraier
Electroimpact Inc.-Glauber Lopes Mosqueira
  • Technical Paper
  • 2019-01-1876
To be published on 2019-09-16 by SAE International in United States
The automation market for aircraft assembly features several options, from deployable crawlers through mobile industrial manipulators to large scale riveters, not to mention fiber layup machines. When drilling, such equipment will typically handle at least a few hundred holes in a given area and setup, with the part most often being a nearly flat panel free of obstructions or with obstructions with a constant cross-section such as stringers. Automation is now widely employed in the manufacturing of wing and fuselage panels and major segment joints, to name a few uses. The assembly of inner structures, however, and especially those in the range of a hundred holes or less, located in areas of limited access crowded with other product structures or even positioning fixtures sitting outside and preventing machine access, is still largely manual and dependent on drilling templates or jigs (DJs). These are robust tools of simple use and very low maintenance, yet of relatively high manufacturing costs (many require 5-axis machining) and design costs (most are one off tools), low flexibility (cannot absorb product…
 

Analytical Model for Calibration Results performances enhancement, resulting in automated prescription for equipments

AIRBUS-Juan Manuel García Lasanta
Airbus-Damian MENDEZ-HUELVA
  • Technical Paper
  • 2019-01-1878
To be published on 2019-09-16 by SAE International in United States
The current aeronautical manufacturing sector is characterized by the high level of competence and the required requirement in its production processes, based on the objectives of profitability and safety (airworthiness). In recent years, there is a real revolution in the sector, where the most advanced tools for the organization and optimization of production are given priority, supported by the latest massively used techniques of automatic data collection. , their organized storage and their analytical classification. Metrology plays a key role in ensuring the quality and reliability of the information generated in these productive cycles. The provision of an analytical model of flexible measurement systems, capable and easily adaptable to the dynamics of the company, is presented as one of the pillars in which this new conception of production is based. The provision of an analytical model of flexible measurement systems, capable and easily adaptable to the dynamics of the company, is presented as one of the pillars in which this new conception of production is based. At the Airbus plant in Puerto Real, and in…
 

C919 Trailing Edge Assembly Interchangeable Tooling

Electroimpact-James Dineley
  • Technical Paper
  • 2019-01-1880
To be published on 2019-09-16 by SAE International in United States
Traditional Trailing Edge (TE) assembly that utilise fixtures for accurate positioning of aircraft (a/c) parts do not allow for removal of specific tooling from the fixtures to travel with the TE, post assembly. Instead, the tooling that positions all the primary a/c assembly datums generally utilise precision pins of various sizes that index and clamp the a/c ribs. Often it is difficult to remove the pins post assembly before the spar can be taken out of the fixture. Use of hammers is common place to hit pins out of holes which is less than ideal considering the a/c parts can be fragile and the tooling is precision set. Also, the Main Assembly Fixture (MAJ) that will receive the TE will inevitably need to relocate some if not all the primary a/c ribs and therefore will most likely be subject to some amount of persuasion. Electroimpact have for many years used cup cone locators that allows static tooling to be temporarily ‘loosened’ and therefore made more compliant for pin insertion/removal, this has been successful to reduce…
 

Compensating the Effects of Ice Crystal Icing on the Engine Performance by Control Methods

Central Institute of Aviation Motors-Oskar Gurevich, Sergei Smetanin, Mikhail Trifonov
  • Technical Paper
  • 2019-01-1862
To be published on 2019-09-16 by SAE International in United States
Aircraft equipment is operated in a wide range of external conditions, which, with a certain combination of environmental parameters, can lead to icing of the engine internal elements. Due to icing, the engine components performance change what leads to decrease in thrust, gas dynamic stability, durability, etc. Safe aircraft operation and its desired performance may be lost as a result of such external influence. Therefore, it is relevant to study the possibilities of reducing the icing effect with the help of a special engine control. The focus of this paper is to determine control methods of an aircraft gas turbine engine addressing this problem. The object of the study is a modern commercial turbofan with a bypass ratio of about 9. In this paper analysis of the effect of ice crystal icing on the engine components performance is conducted. To perform simulation of the engine performance under such impact, degraded components characteristics was introduced into physics-based turbofan model. Control algorithms for this model were developed applied to various regulated variables used in the setpoint controllers…
 
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Type IV Anti-Icing Fluid Subjected to Light Freezing Rain: Visual and Thermal Analysis

UQAC - AMIL-Jean-Denis Brassard, Caroline Laforte, Christophe Volat
Published 2019-06-10 by SAE International in United States
Deicing the aircraft using fluid, prior takeoff is mandatory; since a thin layer of ice or snow can compromise the safety. With the same idea, to use anti-icing fluid during a frozen precipitation to protect the aircraft is also essential. Commercialized anti-icing fluids all pass the process of qualification as described in the SAE documents. One of these documents specifies a set of tests that reproduce freezing precipitation to obtain endurance time and then the holdover timetables. The endurance time is determined by visual inspection: when 30% of the plate is covered with frozen contaminants. With the evolution of technology and the venue of new tools, it may simplify the process, and at least confirm the observations. This paper proposed a thermal and visual analysis of the behavior of a Type IV fluid subjected to light freezing rain. During the precipitation, the plate temperature is measured with thermocouples and recorded using a visual camera and an IR camera. The use the visual camera in conjunction with the IR camera allowed to understand how the water…
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