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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.
 

Energy Recovery Rate from an Electric Air-cycle System under the Cruising Altitude and Speed.

Akita University-Takahiro Adachi
  • Technical Paper
  • 2019-01-1905
To be published on 2019-09-16 by SAE International in United States
In this study, we focus on an electric air-cycle system in an electric aircraft, where the system has an electric compressor instead of a hydraulically-operated oil-based compressor. The electric compressor consumes the power to compress the rarefied air outside and take it in the system. The air goes through the air-cycle as a working fluid to exchange the heat and work. The main purpose of the air-cycle is to adjust the temperature and pressure in a cabin. Therefore, the working fluid of the air repeats compression and expansion. The working fluid passing through the cabin absorbs heat from the passengers and avionics. After that, the air is discharged outside with higher heat level and pressure levels. This means that the discharged air has a potential energy to recover the power consumption in the electric compressor. So, we have analytically estimated an energy recovery rate which is defined as a ratio of the potential energy of the discharged air to the energy consumption in the compressor, and shown the recovery rate under the condition of cruising…
 

Optimization of automated airframe assembly process on example of A350 S19 splice joint

Airbus SAS-Elodie Bonhomme, Pedro Montero-Sanjuan
SPbPU-Sergey Lupuleac, Julia Shinder, Maria Churilova, Nadezhda Zaitseva, Valeriia Khashba
  • Technical Paper
  • 2019-01-1882
To be published on 2019-09-16 by SAE International in United States
The paper presents the numerical approach to simulation and optimization of A350 S19 splice assembly process. The main goal is to reduce the number of installed temporary fasteners while preventing the gap between parts from opening during drilling stage. The numerical approach includes computation of residual gaps between parts, optimization of fastener pattern and validation of obtained solution on input data generated on the base of available measurements. The problem is solved with ASRP (Assembly Simulation of Riveting Process) software. The described methodology is applied to the optimization of the robotized assembly process for A350 S19 section.
 

The benefits of using Composite Bearings in Aircraft Shock Absorbers

Trelleborg Sealing Solutions-Brian Bowen, Torben A. Andersen
  • Technical Paper
  • 2019-01-1898
To be published on 2019-09-16 by SAE International in United States
This paper will use actual examples from aircraft recently introduced into service, to describe the main advantages of changing from the currently used metallic bearings, to composite bearings. Abstract: The introduction of composite bearing in a recently introduced twin aisle aircraft has resulted in: • Weight saving, by replacing bronze bearings with plastic bearings • Lowering of the particle count in the shock absorber oil, (Reduced contamination with metal particles) leading to reduced wear on seals and bearings. Qualification testing showed that Composite Bearings are able to provide longer service life than bronze bearings.
 

Improving competitiveness of Additive Manufacturing Aerospace serial parts

LISI AEROSPACE Additive Manufacturing-Alexis RENE-CORAIL, Guillaume IKER, Maxime gas, Stephane SUDRE, Sebastien EYRIGNOUX
  • Technical Paper
  • 2019-01-1900
To be published on 2019-09-16 by SAE International in United States
The interest of selective laser melting technology for aerospace parts is very high due to their high complexity and their freedom of design which allow functions integration. However, the competitiveness of Laser Beam Melting (LBM) machines for aerospace industry is limited by two major road blocks. On the one hand, basic parametric set sold with LBM machines are more oriented to historical qualification than productivity rates. For instance, the ongoing qualification on EOS M290 by AIRBUS COMMERCIAL AIRCRAFT only enables us to produce a hundred pieces per machine per year. On the other hand, wasted times between two consecutive manufacturing batches are significant and are impacting the yearly output of the machines. The present project focuses on two activities, focusing on the largest available machines, XLINE2000R and M400, in order to maximize the amount of pieces per build. The first one was the improvement of parametric set productivity, to reduce production time, while keeping material and mechanical properties. We focused on main aerospace materials: titanium alloys, aluminum alloys (Scalmalloy®) and nickel-chromium-based superalloys. The second one…
 

Forces vibration assistance for TA6V/CFRP drilling

ENSAM Paris-CHERIF MEHDI
  • Technical Paper
  • 2019-01-1874
To be published on 2019-09-16 by SAE International in United States
For aircraft structures, mechanical assembly using fasteners remains the most common technology. The setting of the numerous fasteners requires a large number of drilling operations. In the case of CFRP/TA6V stacks, the drilling still remains a technological challenge. Indeed the high-quality requirements by the aeronautic standards are limited by the fast damaging drilling tool phenomena. For TA6V, the forced assisted drilling provides a breakthrough technology. An axial forced oscillating displacement on the feed direction of the tool allows the creation of segmented chips. Those small chips are then easily evacuated from the cutting area using a vacuum device. This allows the improvement of the hole’s roughness and mastering the burr creation at the exit of the hole. The lubrication process is also enhanced during the exit sequence of the tool. For the CFRP/TA6V configuration, the segmented geometry of the chip avoids the roughness degradation on the composite part of the stack. This parameter can modify the cyclic bearing performance of the assembly. In this paper, the different forced drilling industrial solutions are analyzed. More specifically,…
 

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…
 

Simulation of aircraft assembly via ASRP software

Airbus-Elodie Bonhomme
SPbPU-Nadezhda Zaitseva, Tatiana Pogarskaia, Sergey Lupuleac, Olga Minevich, Julia Shinder
  • Technical Paper
  • 2019-01-1887
To be published on 2019-09-16 by SAE International in United States
ASRP (Assembly Simulation of Riveting Process) software is a special tool for modelling assembly process for large scale airframe parts. On the base of variation simulation, ASRP provides a convenient way to analyze, verify and optimize the arrangement of temporary fasteners. During the airframe assembly process certain criteria on the residual gap between parts must be fulfilled. The numerical approach realized in ASRP allows one to evaluate the quality of contact on every stage of the assembly process and solve verification and optimization problems for temporary fastener patterns. The paper is devoted to description of several specialized approaches that combine statistical analysis of measured data and numerical simulation using high-performance computing for optimization of fastener patterns, calculation of forces in fasteners needed to close initial gaps and identification of hazardous areas in junction regions.
 
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Microwave Technique for Liquid Water Detection in Icing Applications

University of Oxford-Matthew McGilvray, David Gillespie
University of Southern Queensland-John Leis, David Buttsworth, Ramiz Saeed, Khalid Saleh
Published 2019-06-10 by SAE International in United States
The partial melting of ingested ice crystals can lead to ice accretion in aircraft compressors, but accurately measuring the relatively small fraction of liquid water content in such flows is challenging. Probe-based methods for detecting liquid water content are not suitable for deployment within turbofan engines, and thus alternatives are sought. Recent research has described approaches based on passive microwave sensing. We present here an approach based on active microwave transmission and reflection, employing a vector network analyzer. Utilization of both transmission and reflection provides additional data over and above emission or transmission only, and permits a more controllable environment than passive sensing approaches. The paper specifically addresses the question of whether such an approach is viable within the context of representative icing wind tunnel and engine flow conditions. A quasi-thermal equilibrium approach is presented herein to estimate the melting ratio during microwave analysis of samples at 0 °C. Experimental results using microwaves in the 2.45GHz region are presented, and post-processing methods investigated. This is followed by an investigation of detection limits for ice accretion…
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Cork and Rubber Composition Sheet; for Aromatic Fuel and Oil Resistant Gaskets

AMS CE Elastomers Committee
  • Aerospace Material Specification
  • AMSC6183B
  • Current
Published 2019-06-10 by SAE International in United States

This specification covers vulcanized sheet made of granulated cork uniformly dispersed in a synthetic rubber compound, for use in gaskets where aromatic fuel or oil resistance is required.