Your Selections

Production
Show Only

Collections

File Formats

Content Types

Dates

Sectors

Topics

Authors

Publishers

Affiliations

Committees

Events

Magazine

Series

 

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.
 

Improvement of Hydraulic system tests in Aircraft Manufacturing by applying Lean techniques

Airbus-Kevin Forster
Cranfield Univ-Philip Webb
  • Technical Paper
  • 2019-01-1901
To be published on 2019-09-16 by SAE International in United States
Lean Manufacturing is generally a challenge across all manufacturing companies. Especially in the aerospace industry where production costs have a significant impact on the overall business success. Additionally, the aircraft Takt time is gradually being reduced to accomplish ramp up requirements. The hydraulic system tests are considered as a production waste (Muda Type I) since it is mandatory but does not add any value to the end customer. Furthermore, due to health and safety aspects, no other production task can be done while the test is being performed. This research project aimed at performing a Kaizen analysis of the hydraulic system test stations to reduce or eliminate idle time while it is taking place. To do so, an extensive literature review has be conducted to provide its research framework. Then, all the project requirements and constraints were identified in order to generate a design specification. As a part of the methodology, several design proposals to accomplish this specification are created. In parallel, a reverse engineering case scenario is used to generate a DMU using a…
 

Improving and Evaluating Aircraft Maintenance On-Time Performance for Wide-Body A-Checks Delays

SORT Engineering GmbH-Adel A. Ghobbar
  • Technical Paper
  • 2019-01-1909
To be published on 2019-09-16 by SAE International in United States
Martinair is based on Schiphol Oost and is part of the KLM Group since 2008. The KLM Group on its turn is part of the Air France – KLM Group. Martinair started as a charter company and was founded by Martin Schröder. Martinair is now a cargo operator with its own maintenance base at Hangar 32 on Schiphol Oost. It operates 7 McDonnell Douglas MD-11’s and 6 Boeing B747-400’s. The focus will be on the MD-11 tri-jet in this thesis. Due to the entry in the KLM Group in 2008, changes have been made for synergy reasons to the Martinair organisation. Martinair Maintenance and Engineering is now focussing on becoming a Regional Jet Center. The maintenance on the Embraer E-190 of KLM Cityhopper will be the main part of the work. Due to the new focus of the Martinair maintenance and engineering department, the maintenance capacity for a MD-11 A-check will no longer be available. It is therefore chosen to outsource the MD-11 A-check from Martinair maintenance and engineering to KLM engineering and maintenance. The…
 

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.
 

Statistical Process Control combined with a digital datalake usage is a scalable & automatisable mean to help for civil aircraft production rate increase

Project Management-Bernard Pierre RIBERE
  • Technical Paper
  • 2019-01-1881
To be published on 2019-09-16 by SAE International in United States
Aeronautical Industry faces several key challenges as far as the transport of passengers requires more and more vehicles every year. In the area of air transport, civil aircraft deliveries and in service availability have reached in the past year numbers which were not expected at the moment when the production and support industry were built. Talking about manufacturing of civil aircrafts, it is then needed to think about adapting the currently existing systems to be able to cope with the challenges as far as rate of production and recurring costs are concerned. Airbus plans to regularly, on a smooth mode, accelerate its production system to fulfil market’s expectations, securing in the same time both the safety and the quality of our aircrafts. On another hand, the digital revolution which is in application within Airbus provides with solutions of data storage, sorting and analysis, with purpose of contributing in a more adequate usage of information that each and every aircraft that Airbus manufactures may carry with himself, whatever during its manufacturing as well as its in…
 

Intelligent Real Time Inspection of Rivet Quality supported by Human-Robot-Collaboration

PIKON Deutschland AG-Benjamin Duppe, Albert Schulz
ZeMA gGmbH-Rainer Mueller, Matthias Vette, Tobias Masiak
  • Technical Paper
  • 2019-01-1886
To be published on 2019-09-16 by SAE International in United States
Aircraft production is facing various technical challenges, such as large product dimensions, complex joining processes and the organization of assembly tasks. Meeting the requirements that come with large dimensions, low tolerances and small batch sizes, in combination with complex joining processes, automation and labour-intensive inspection task, is often difficult to achieve in an economically viable way. ZeMA believes that a semi-automated approach is the most effective for optimizing aircraft section assembly. An effective optimization of aircraft production can be achieved with a semi-automated riveting process for solid rivets using Human-Robot-Collaboration in combination with an intuitive Human-Machine-Interaction operating concept. While using dynamic task sharing between human and robot based on their skills, and considering ergonomics, the determined ideal solution involves placing a robot inside the section barrel. The robot’s workspace is expanded by mounting it on top of a lifting unit so that it can properly position the anvil. In the meantime, the human performs the more complex tasks of inserting the solid rivets and operating the riveting hammer from the outside of the section barrel.…
 

Improving competitiveness of Additive Manufacturing Aerospace serial parts

LISI AEROSPACE Additive Manufacturing-Maxime gas, Alexis RENE-CORAIL, Sebastien EYRIGNOUX, Guillaume IKER, Stephane SUDRE
  • 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…
 

MANAGEMENT OF MANUFACTURING AND ASSEMBLY PROCESSES RISCS BASED ON MODIFIED FMEA

IRCUT-Galina Susova
National technology Chamber-Rostislav Sirotkin
  • Technical Paper
  • 2019-01-1870
To be published on 2019-09-16 by SAE International in United States
The quality of production is defined by the actual deviations from the requirements stated in design and technological documentation including drawings. In this article the problem of ensuring steady decrease in quantity of deviations from these requirements by production is considered. Carrying out preventive actions, in combination with control of time and costs of correction of discrepancies of such decrease it is possible to achieve. For the solution of an objective the method of the modified FMEA using parameters and levels of ranging as elements of operation of technological process where at a design stage of a product are set structure, is offered and are adjusted on the basis of feedback of production and operation. Such statement of a problem demands automation of collecting and data processing which can be used for creation of the knowledge base necessary for management of productions. Considering the specification level used in this analysis it is also possible to obtain the data necessary for the solution of some other the problems, for example, connected with productions, including technologies, the…
 

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…
 

Numerical investigation of Electrostatic Spray Painting Transfer Processes for vehicle Coating

Universidade Da Beira Interior-Mohammad Reza Pendar, Jose Pascoa
  • Technical Paper
  • 2019-01-1856
To be published on 2019-09-16 by SAE International in United States
In this study we examined numerically the electrostatic spray transfer processes in the rotary bell spray applicator, which is this case implemented in a full 3D representation. The algorithm implemented and developed for this simulation includes airflow, spray dynamics, tracking of paint droplets and an electrostatic modularized solver to present atomization and in-flight spray phenomena for the spray forming procedure. The algorithm is implemented using the OpenFOAM package. The shaping airflow is simulated via an unsteady 3D compressible Navier-Stokes method. Solver for particle trajectory was developed to illustrate the process of spray transport and also the interaction of airflow and particle that is solved by momentum coupling. As the numerical results in this paper indicates dominant operating parameter voltage setting, further the charge to mass ratio and air-paint flow rate deeply effect the spray shape and the transfer efficiency (TE). The spin of the bell forced the paint to fall off from the bell edge into the high-velocity airflow. By increasing the shaping airflow more uniform distribution of mass of paint is produced but the…