1 st Call for Proposals (CFP01)

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Written Proc. 2014 - 07 Annex III of Amendment nr. 1 to the Work Plan 2014 – 2015 Page 1 of 375

Annex III:

1st Call for Proposals (for Partners): List and full description

of Topics

Version 2

15 December 2014

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-Written Proc. 2014 - 07 Annex III of Amendment nr. 1 to the Work Plan 2014 – 2015 Page 2 of 375

Revision History Table

Version n° Issue Date Reason for change

V1 4/11/2014 First Release

V2 17/11/2014 The Annex III is amended to reflect the outcome of the discussion which took place between the European Commission, the SRG Members and the JU on the Type of Action of some topics. In particular, the updates mainly regard the following topics:

 JTI-CS2-2014-CFP01-LPA-02-05 “Environmental Friendly Fire Suppression”

 JTI-CS2-2014-CFP01-SYS-02-04 “Smart Oil pressure sensors for oil cooled starter/generator”

The Annex III is amended to change the identification of the topics from the AIRFRAME ITD JTI-CS2-2014-CFP01-AIR

Clean Sky 2

Work Plan 2014-2015

ANNEX III:

1st Call for Proposals (CFP01): List and Full Description of Topics

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Index

1.1. Clean Sky 2 – Large Passenger Aircraft IAPD ... 8

1.2. Clean Sky 2 – Regional Aircraft IADP ... 91

1.3. Clean Sky 2 – Fast Rotorcraft IADP ... 103

1.4. Clean Sky 2 – Airframe ITD ... 174

1.5. Clean Sky 2 – Engines ITD ... 264

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Written Proc. 2014 - 07 Annex III of Amendment nr. 1 to the Work Plan 2014 – 2015 Page 4 of 375 List of Topics for Partners (CFP01)

Identification Title Type of

Action #Topics Value (Funding in M€) JTI-CS2-2014-CFP01-LPA 12 14,9 JTI-CS2-2014-CFP01-LPA-01-01

OPEN ROTOR Engine Mounting System IA 2

JTI-CS2-2014-CFP01-LPA-01-02

Support to future CROR and UHBR propulsion system maturation

IA 2

JTI-CS2-2014-CFP01-LPA-01-03

Development of advanced laser-beam welding technology for the manufacturing of structures for titanium HLFC structures.

RIA 0,45

JTI-CS2-2014-CFP01-LPA-02-01

Cost Reduction On Composite Structure Assembly – Blind fastener inspection technology for quality control

IA 0,35

JTI-CS2-2014-CFP01-LPA-02-02

Cost Reduction On Composite Structure Assembly - Definition And Development Of An Inspection Tool To Characterize Inner Surface Hole Quality

IA 0,35

JTI-CS2-2014-CFP01-LPA-02-03

Rapid Assembly Of Bracket For Structure-System Integration

RIA 0,35

JTI-CS2-2014-CFP01-LPA-02-04

Automation in Final Aircraft Assembly Lines and Enabling Technologies

IA 0,6

JTI-CS2-2014-CFP01-LPA-02-05

Environmental Friendly Fire Suppression IA 0,6

JTI-CS2-2014-CFP01-LPA-02-06

Development of Thermoelastic Stress Analysis for the detection of stress hotspots during structural testing

IA 0,35

JTI-CS2-2014-CFP01-LPA-03-01

Process and Methods for E2E Maintenance Architecture development and demonstrations and solutions for technology integration

RIA 1,75

JTI-CS2-2014-CFP01-LPA-03-02

Aircraft System Prognostic solutions integrated into an airline E2E maintenance operational context

RIA 1,7

JTI-CS2-2014-CFP01-LPA-03-03

Airline Maintenance Operations implementation of an E2E Maintenance Service Architecture and its enablers

RIA 4,4

JTI-CS2-CFP01-REG 1 0,5

JTI-CS2-2014-CFP01-REG-02-01

Aerodynamic characterization of control devices for wing loads control and aircraft response characterization of a regional turboprop aircraft

(5)

Action #Topics Value (Funding in M€) JTI-CS2-CFP01-FRC 8 4,4 JTI-CS2-2014-CFP01-FRC-02-01

Support to the aerodynamic and aeroelastic analysis of a trimmed, complete compound R/C and related issues.

RIA 0,8

JTI-CS2-2014-CFP01-FRC-02-02

Aerodynamic and functional design study of a full-fairing semi-watertight concept for an articulated rotor head

IA 0,4

JTI-CS2-2014-CFP01-FRC-02-03

Support to the aerodynamic analysis and design of propellers of a compound helicopter

RIA 0,4

JTI-CS2-2014-CFP01-FRC-02-04

Tools development for aerodynamic optimization on engine air intake

IA 0,4 JTI-CS2-2014-CFP01-FRC-02-05 HVDC Starter/Generator IA 0,8 JTI-CS2-2014-CFP01-FRC-02-06

High Voltage Network Battery IA 0,8

JTI-CS2-2014-CFP01-FRC-02-07 Power Conversion IA 0,4 JTI-CS2-2014-CFP01-FRC-02-08 HVDC Network management IA 0,4 JTI-CS2-2014-CFP01-AIR 14 9,55 JTI-CS2-2014-CFP01-AIR-01-01

Aerodynamic and acoustic capabilities developments for close coupling, high bypass ratio turbofan Aircraft integration.

RIA 2,4

JTI-CS2-2014-CFP01-AIR-01-02

Advanced predictive models development and simulation capabilities for Engine design space exploration and performance optimization

RIA 0,35

JTI-CS2-2014-CFP01-AIR-01-03

CROR Engine debris Impact. Shielding design, manufacturing, simulation and Impact test preparation

IA 0,36

JTI-CS2-2014-CFP01-AIR-01-04

Aero-acoustic experimental characterization of a CROR (Contra Rotating Open Rotor) engine WT model with core flow in propellers architecture.

IA 0,96

JTI-CS2-2014-CFP01-AIR-01-05

Blade FEM impact simulations and sample manufacturing for CROR Aircraft

RIA 0,36

JTI-CS2-2014-CFP01-AIR-01-06

Design and demonstration of a laminar nacelle concept for business jet

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Action #Topics Value (Funding in M€) JTI-CS2-2014-CFP01-AIR-01-07

Eco Design for Airframe - Re-use of Thermoplastics Composites

IA 0,35

JTI-CS2-2014-CFP01-AIR-02-01

Flightworthy Flush & Lightweight doors for unpressurized Fast Rotorcraft

IA 1

JTI-CS2-2014-CFP01-AIR-02-02

Bird strike - Erosion resistant and fast maintainable windshields

IA 0,6

JTI-CS2-2014-CFP01-AIR-02-03

Curved stiffened panels in thermoplastics by preindustrial ISC process

IA 0,425

JTI-CS2-2014-CFP01-AIR-02-04

New enhanced acoustic damping composite material

RIA 0,35

JTI-CS2-2014-CFP01-AIR-02-05

Structural bonded repair of monolithic composite airframe

RIA 0,5

JTI-CS2-2014-CFP01-AIR-02-06

Simulation tool development for a composite manufacturing process default prediction integrated into a quality control system

RIA 0,7

JTI-CS2-2014-CFP01-AIR-02-07

Design Against Distortion: Part distortion prediction, design for minimized distortion, metallic aerospace parts

RIA 0,45

JTI-CS2-2014-CFP01-ENG 10 13,4

JTI-CS2-2014-CFP01-ENG-01-01

Engine Mounting System (EMS) for Ground Test Demo

IA 1,5

JTI-CS2-2014-CFP01-ENG-02-01

Development of an all-oxide Ceramic Matrix Composite (CMC) Engine Part

RIA 3

JTI-CS2-2014-CFP01-ENG-03-01

Characterisation of Thermo-mechanical Fatigue Behaviour

RIA 0,56

JTI-CS2-2014-CFP01-ENG-03-02

Advanced analytical tool for the understanding and the prediction of core noise for large civil aero engine with low emission core

RIA 1

JTI-CS2-2014-CFP01-ENG-03-03

VHBR Engine - Advanced bearing technology RIA 2,4

JTI-CS2-2014-CFP01-ENG-03-04

Crack growth threshold analysis in TiAl alloys IA 0,44

JTI-CS2-2014-CFP01-ENG-04-01

Power Density improvement demonstrated on a certified engine

IA 0,5

JTI-CS2-2014-CFP01-ENG-04-02

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Action #Topics Value (Funding in M€) JTI-CS2-2014-CPW01-ENG-04-03

Alternative Architecture Engine research RIA 2,5

JTI-CS2-2014-CFP01-ENG-04-04

Engine Installation Optimization IA 1

JTI-CS2-2014-CFP01-SYS 8 5,2

JTI-CS2-2014-CFP01-SYS-02-01

Smart Integrated Wing – Life extended hydrostatic & lubricated systems

RIA 0,7

JTI-CS2-2014-CFP01-SYS-02-02

Modular, scalable, multi-function, high power density power controller for electric taxi

IA 1,5

JTI-CS2-2014-CFP01-SYS-02-03

Robust package for harsh environment and optimization of electrical characteristic of rectifier bridge using high current diode

RIA 0,7

JTI-CS2-2014-CFP01-SYS-02-04

Smart Oil pressure sensors for oil cooled starter/generator

RIA 0,6

JTI-CS2-2014-CFP01-SYS-02-05

Instrumented bearing for oil cooled starter/generator

RIA 0,5

JTI-CS2-2014-CFP01-SYS-02-06

Evaluate mechanical and fatigue capabilities for diode die in harsh environment

RIA 0,4

JTI-CS2-2014-CFP01-SYS-02-07

Development of MODELICA libraries for ECS and thermal management architectures

RIA 0,5

JTI-CS2-2014-CFP01-SYS-02-08

Embedded sensors technology for air quality measurement

IA 0,3

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1.1. Clean Sky 2 – Large Passenger Aircraft IAPD

I.

Open Rotor Engine Mounting System

Type of action (RIA or IA) IA

Programme Area LPA

Joint Technical Programme (JTP) Ref. WP1.1.3 – Open Rotor Demo Engine (CROR) Indicative Funding Topic Value (in k€) 2000 k€

Duration of the action (in Months) 72 months Start Date1

09-2015 (T0)

Identification Title

JTI-CS2-2014-CFP01-LPA-01-01

Open Rotor Engine Mounting System Short description (3 lines)

Design, manufacture, assembly and instrumentation of an Engine Mounting System for CROR Flight Test Demo Engine; EMS Set for characterization and validation through Partials tests: manufacture, assembly and instrumentation, mechanical tests.

1

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1. Background

Originating in mid to late 1970’ies NASA concept studies, the Open Rotor engine has been shown to offer significant fuel savings over traditional ducted engines. Compared to these engines, the Open Rotor should save up to 40% of fuel burn. The Clean Sky 2 Open Rotor Demonstration Project aims at designing, manufacturing & testing such engine which will be installed on a pylon located on the flight tests aircraft (A340-FTD).

The scope of the project is targeting the engine mounting system, which will attach the engine on one side by the means of links and bearings and integrate into the pylon structure on the other. Depending on the final concept chosen, it may also include some form of cradle between the pylon and engine.

The Clean Sky 1 Open Rotor Demonstration will serve as a baseline for these studies, in order to minimize the rework on the different components composing the engine mounting system.

The breakdown in this WP1.1.3 is the following:

Front mount Aft mount

Elastomeric dampers

pylon

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2. Scope of work

The scope of work of this CfP is covering the perimeter of the Engine Mounts System for the Flight Test Demo engine (FTD) and the applicant’s tasks are mainly located in WP 1.1.3.2. In the first phase, the applicant is required for checking the feasibility, freezing the architecture and interfaces, and for identifying the validation plan in order to comply with the EMS specifications that will be provided by the Engine Manufacturer and the Airframer in WP 1.1.3.1

In the second phase, the applicant will perform preliminary design, detailed design, manufacture of three sets of EMS:

- Pass-off test demonstrator EMS - CROR FTD demonstrator EMS - Component Test EMS

As well as:

- instrumentation and partial tests of Component Test EMS

- instrumentation and support for pass-off test of CROR FTD demonstrator EMS - instrumentation and support for flight test of CROR FTD demonstrator EMS

Tasks associated with the activities “Instrumentation and support for pass-off and flight test of CROR FTD demonstrator EMS” will be located in WP 1.1.3.5.

WP1.1.3

Open Rotor Demo Engine

WP1.1.3.0 Engineering

WP1.1.3.1 Propulsion System Integration

WP1.1.3.2 Modules Adaptations or Modifications WP1.1.3.3 Systems and Controls Development WP1.1.3.4 Component Maturation Plan

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DIAGRAMME GANT - CROR - cfp MOUNTS 2015 2016 2017 2018 2019 2020 2021

REF Label 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2

1 CFP MOUNTS

T0 Management

MS 1 Mount systems

development plan review

T1 mount system design

MS2 FTD demo Mounts System :

Preliminary Design Review

MS3 FTD demo Mounts System

:Critical Design Review

T2 Mount system component

tests

MS4 Mount system delivery for

component test

T3 Mount system delivery for

pass-off test

T4 Mount system delivery for

flight test

MS5 Mount system hardware

delivery for flight demo

T5 Support to ground & flight

test (mounts)

MS6 Flight test demo

TRL

5 6

Tasks

Ref. No. Title - Description Due Date

Task 0 Management

Progress Reporting & Reviews:

 Quarterly progress reports in writing shall be provided by the partner, referring to all agreed work packages, technical achievement, time schedule, potential risks and proposal for risk mitigation.

 Monthly coordination meetings shall be conducted via telecom.

 The partner shall support reporting and agreed review meetings with reasonable visibility on its activities and an adequate level of information.

 The review meetings shall be held at the topic manager’s facility.

General Requirements:

 The partner shall work to a certified standard process

T0 + 72 months

(12)

Tasks

Task 1 mount system design

 The partner shall design the mounts and elastomeric dampers, according to the topic manager and to the airframer’s demonstrator flight-worthiness requirements in case this mounts concept would be selected for flight tests.

 The partner shall deliver to the topic manager the mount system data required for Whole Engine Model Analysis and for the Airframer’s GFEM to be used for loads & Aero elastics loops

 The partner shall deliver a design justification report of the mounts and elastomeric dampers

 The partner shall support the technical review for mount system architecture approval organized by the topic manager.

T0 + 18 months

Task 2 Mount system component tests

 The partner shall propose a mount system verification plan. This verification plan will be approved by the topic manager through a technical review.

 The partner component test activities shall include:

o detailed design of test benches and manufacturing or procurement of components based on existing test plan & test bench sketches

o design and procurement of instrumentation required for the different tests

o test benches modifications and commissioning including test bench control and instrumentation

o testing of the relevant parts o tests results analysis o test results report

T0 + 39 months

Task 3 Mount system delivery for pass-off test The partner activities shall include:

o manufacturing and/or procurement of the instrumented mounts and elastomeric dampers for engine assembly o conformity documents

T0 + 37 months

Task 4 Mount system delivery for flight test The partner activities shall include:

o manufacturing and/or procurement of the instrumented mounts and elastomeric dampers for engine assembly o conformity documents

T0 + 41 months

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Tasks

Task 5 Support to ground & flight test (mounts)

The partner shall support the topic manager during the ground & flight tests:

o monitoring o measures analysis

o hardware changes if required by engine dynamic behavior

T0 + 70 months

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3. Major Deliverables / Milestones and schedule (estimate)

Deliverables

Ref. No. Title - Description Type(*) Due Date

D1 Mount systems development plan

Including detailed risk analysis and mitigation proposal and a preliminary test pyramid

R T0 + 1 month

D2 Mount system preliminary design substantiation document for Preliminary design review

To check the feasibility and to freeze the architecture and interfaces, to identify the validation plan

R and RM T0+10 months

D3 Design progress reports for mount systems

To check the feasibility and to freeze the architecture and interfaces, to identify the validation plan.

D4 Mount system detailed design substantiation document for the critical design review

To approve design before hardware manufacturing engagement. Including Test pyramid, structural FEM model adapted for integration to global Aircraft FEM (GFEM) & local thermal model

D5 Mount systems Components Tests benches readiness review

To verify test benches capability to meet validation plan requirements

D6 Mount system hardware delivery for component test

Hardware for component test

D T0+27 months

D7 Mount systems Components Tests completed – hardware inspection review

To substantiate mount systems design & permit to fly

D8 Mount system hardware delivery for demo pass-off test

Engine assembly

D T0+37 months

D9 Mount system hardware delivery for flight demo

Hardware for flight demo R T0+ 41 months

D10 Component Tests reports for mount systems

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Deliverables

Ref. No. Title - Description Type(*) Due Date

D11 Engine readiness review documentation: o Delivered Hardware status compared o Instrumentation

o Test plan requirements

To contribute to engine test readiness review

R and RM T0+ 41 months

D12 Engine pass-off test report for mount systems

To contribute to engine after-test review R T0+ 57 months D13 Engine Flight Test report for mount systems

To contribute to engine after-test review R T0+ 70 months *Type:

R: Report

RM: Review Meeting

D: Delivery of hardware/software

Milestones (when appropriate)

Ref. No. Title - Description Type Due Date

MS 1 Mount systems development plan review RM T0 + 4 months

MS 2 FTD demo Mounts System : Preliminary Design Review

RM

T0 + 10 months MS 3 FTD demo Mounts System :Critical Design Review RM T0 + 18 months MS4 Mount system hardware delivery for Component

Test

D

T0+27 months MS5 Mount system hardware delivery for flight demo D T0 + 41 months MS 6 Engine Flight Test report for mount systems R T0+ 70 months

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4. Special skills, Capabilities, Certification expected from the Applicant(s)

 Experience in design, manufacturing, testing and certification of aircraft engine mounts is mandatory

 Experience in elastomeric dampers is mandatory

 Experience in dynamic and vibration engine complex environnement analysis is mandatory

 Experience in test bench design and modification is mandatory

 Experience in endurance tests or other relevant tests contributing to risks abatment is mandatory

 Availability of test benches to support test campaign is mandatory

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5. Glossary

CFP Call for Proposals

CROR Counter Rotating Open Rotor

CS2 Clean Sky 2

CSJU Clean Sky 2 Joint Undertaking

EC European Commission

EMS Engine Mount System

FTD Flight Test Demonstrator

GTD Ground Test Demonstrator

IADP Innovative Aircraft Development platform

ITD Integrated Technology Demonstrator

SPD Strategic Platform Demonstrator

STD Strategic Topic Description

TRL Technology Readiness Level

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II.

Support to future CROR and UHBR propulsion system maturation

Type of action (RIA or IA) IA

Programme Area LPA

Joint Technical Programme (JTP) Ref. WP1.1; WP1.2; WP1.6

Indicative Funding Topic Value (in k€) 2.000k€

Duration of the action (in Months) 72 months Start

Date2

October 2015

Identification Title

JTI-CS2-2014-CPW01-LPA-01-02

Support to future CROR and UHBR propulsion system maturation

Short description (3 lines)

This topic consists of key activities dedicated to the maturation of future CROR and UHBR propulsion system integration from TRL3 to TRL6. The main areas of activities are aerodynamic and acoustic calculations, wind tunnel acoustic liners development and flight-test ground instrumentation & chase aircraft as well as blade/fuselage impacts calculations & tests.

2

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1. Background

The powerplant Integration activities in IADP-LPA, Platform 1 are aiming at identifying and developping innovative integration solutions for both, future large by-pass ratio turbofan engines (UHBR) and contra rotating open rotor engines (CROR).

The CROR technology demonstration will focus on the validation of the aerodynamic efficiency versus noise level for a full size airworthy CROR engine under operational conditions (TRL 6) , the demonstration and validation of the viability of the chosen engine concept and associated technologies like power gearbox, pitch control, lubrication system, etc. Synthesize available data from Clean Sky with CROR demo-engine flight test data, re-calibrate tools.

The UHBR technology demonstration will focus on the validation of key powerplant system technologies enabling the efficient integration of larger bypass ratio geared engine, notably in the domain of aerodynamic integration, acoustic sources & treatment, thermal management, loads & vibrations.

The scope of activities within the Large Passenger Aircraft is the maturation of solutions including flight testing or ground testing of key enablers for future applications. Also, in parallel to the technologies, the scope of activity contains the development of capabilities to enable those demonstrations in the most efficient manner.

This topic will contribute to those powerplant integration maturation exercise within the Work Package 1.1 related to the in-flight demonstration of a CROR Engine as well as Work Package 1.2 related to the ground demonstration of CROR Aircraft Rear End structure and finallyto the Work Package 1.6 related to the preparation and in-flight demonstration of large geared turbofan Engine together with the associated powerplant technologies.

Tasks

T1 Contribution to CROR Flight test demonstration WP1.1 T0+72 T2 Contributions to CROR ground test demonstration WP1.2 T0+72 T3 Contributions to UHBR flight test preparation WP1.6 T0+48 T4 Contributions to UHBR Flight test demonstration WP1.6 T0+60

Within the Task T1 the applicant will contribute to the CROR Flight test demonstration with the following activities:

- Numerical aerodynamic and acoustic characterization of both the CROR Flight Test Demonstrator (FTD) aircraft and the target product generic aircraft and transposition of in-flight data to target product aircraft. For high speed conditions, this shall include acoustic refraction effects on the fuselage.

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fluid-Written Proc. 2014 - 07 Annex III of Amendment nr. 1 to the Work Plan 2014 – 2015 Page 20 of 375 structure simulation techniques for blade flexibility effects CFD-CSM) and correlate with both wind tunnel and flight test results, to check impacts on performance, acoustics & vibrations. - Develop and validate in FTD-testing conditions advanced acoustic measurement for model,

wind tunnel, FTD and acoustic chase aircraft.

- Develop or enhance acoustic liner solutions for wind tunnels to improve the quality of CROR near field noise measures.

- Provide acoustic ground instrumentation in accordance to measurement specification such that the best transposition from FTD to target-product aircraft could be realized.

- Perform chase-aircraft acoustic measurement of the CROR FTD in low and High Speed conditions.

Within the Task T2 the applicant will contribute to CROR-ground test demonstration with the following activities:

- Perform blade and fuselage impact numerical simulations (including rebound and fragment trajectories).

- Contribute to the impact test and residual strength tests supporting the maturation of blade and shield technologies (from material characterization up to full component test).

Within the Task T3 the applicant will contribute to UHBR-flight test preparation in WP1.6 with the following activities:

- Numerical simulations of installed UHBR engines for load, vibrations and acoustic (near field and far field) in both high and low speed conditions. The interaction between the installed distorted flow field and the rotating fan shall be taken into account.

Within the Task T4 the applicant will contribute to UHBR-flight test demonstration in WP1.6 with the following activities:

- Provide acoustic ground instrumentation in accordance to measurement specification such that the best transposition from FTD to target product Aircraft could be realized.

- Perform chase-aircraft acoustic measurement of the UHBR FTD in low and high-speed conditions.

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3. Major Deliverables / Milestones and schedule (estimate)

Deliverables

D1.1 Numerical aerodynamic and acoustic characterization of

both the CROR-FTD aircraft and the target-product generic aircraft and transposition of in-flight data to target product aircraft.

CFD/CAA, reports

T0+72

D1.2 Perform blade deformation prediction under installed

conditions (CFD-CSM) and correlate with both wind tunnel and flight test results.

CFD, reports T0+72

D1.3 Develop and validate advanced acoustic measurement for

model, wind tunnel, FTD and chase aircraft.

Design &hardware

T0+30

D1.4 Develop or enhance acoustic liner solutions for wind tunnels

to improve the quality of CROR near-field noise measurements.

Design & hardware

T0+30

D1.5 Provide acoustic-ground instrumentation in accordance to

measurement specification such that the best transposition from FTD to target-product aircraft could be realized.

Design& hardware

TO+48

D1.6 Perform chase-aircraft acoustic measurement of the CROR

FTD in low and high-speed conditions.

FT acoustic data

T0+72

D2.1 Perform blade and fuselage impact numerical simulations

(including rebound and fragment trajectories).

Simulation results, reports

T0+72

D2.2 Contribute to the impact test and residual strength tests

supporting the maturation of blade and shield technologies (from material characterization up to full component test).

Test results, reports

T0+72

D3.1 Numerical simulations of installed UHBR engines for load,

vibrations and acoustic (near field and far field) in both high and low-speed conditions.

CFD results, CFD-CAA results, reports

T0+48

D4.1 Provide acoustic ground instrumentation in accordance to

measurement specification such that the best transposition from FTD to target product aircraft could be realized.

Hardware, reports

T0+36

D4.2 Perform chase-aircraft acoustic measurement of the UHBR

FTD in low and high speed conditions.

Acoustic data, reports

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M1.1 Contribution to CROR Flight Test Demonstrator

Concept Freeze Review

Review T0+24

M1.2 Contribution to CROR FTD Preliminary Design

Review

Review T0+36

M1.3 Contribution to CROR FTD Conceptual Design

Review

Review T0+48

M1.4 Contribution to CROR FTD Flight Test Readiness

Review

Review T0+60

M2.1 Contribution to CROR integrated Rear End Demo

(iRED) Preliminary Design Review

Review T0+36

(iRED) Conceptual Design Review

Review T0+48

(iRED) Test Readiness Review

Review T0+60

M3.1 & M4.1 Contribution to UHBR Flight Test Demonstrator

Preliminary Design Review

Review T0+20

Conceptual Design Review

Review T0+32

Flight Test Readiness Review

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4. Special skills, Capabilities, Certification expected from the Applicant(s)

The applicant shall be able to demonstrate sound technical knowledge in the field of proposed contributions; he shall be able to demonstrate that this knowledge is widely recognized.

The applicant shall demonstrate experience in project management in Time, Cost and Quality together with evidence of past experience in large project participation.

The applicant shall have the following special skills:

- Extensive experience in High energy impact skills both from experimental and numerical stand-point, specifically in composite/metal impacts and in explicit formulations for the numerical analysis of impact.

- World-class experience in high energy impact simulation and test. Extensive experience in characterisation High speed deformation mechanical behaviour of innovative materials. Demonstrated knowledge and background on shielding developments.

- World-class experience in simulation and test on blade release trajectory evaluation.

- World-class experience in dynamic analysis, simulation and test of engine vibration and imbalance loads after blade and other debris release and other high speed dynamic phenomena. - Extensive experience in Aerodynamic CFD modelling, from simplified to unsteady methods

(RANS, URANS, disk Actuator, hybrid approach)

- Extensive experience in Aero-elasticity and flutter analysis, simulation and correlation by test (fluid-structure coupling approach integrated force/displacement/mesh deformation approaches) and adapted blades specificities: rotation, high twist, limited aspect ratio.

- The applicant should be able to support these studies with a multi-disciplinary approach, combining aerodynamic and structural simulations. Experience in this kind of research, in multi-national projects and with industrial partners, would be preferred.

- Ability to perform chase aircraft activities for flight tests: access to an adequate aircraft, habitations to instrument the aircraft & to perform such kind of tests.

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III.

Development of advanced laser-beam welding technology for the manufacturing of

structures for titanium HLFC structures

Type of action (RIA or IA) RIA

Programme Area LPA-IAPD Platform 1

Joint Technical Programme (JTP) Ref. WP Level 1.4 – HLFC Large Scale Demonstration

Estimated Topic Value (funding in k€) 450k€

Duration of the action (in Months) 32 months Start Date July 2015

JTI-CS2-2014-CPW01-LPA-01-03

Development of advanced laser-beam welding technology for the manufacturing of structures for titanium HLFC structures.

Development of process and system technology for reproducible laser welding and straightening of titanium structures for Hybrid Laminar Flow Technology (HLFC) structures with the assistance of an FE-based process for laser welding and straightening, including 3D deformation and residual stress prediction.

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1. Background

LPA-IAPD WP 1.4 investigates the application of Hybrid Laminar Flow Technology (HLFC) for drag reduction on commercial transport aircraft. One specific issue is the manufacturing of leading edge segments with microperforated outer skins out of titanium. Those skins are supported by spanwise titanium stringers which are laser-welded to the inner surface. The laser-welding process has to be reproducible and consistent with stringent surface quality requirements.

Such a reproducible laser beam welding and straightening process has to be developed for producing such structures consisting of multiple narrowly-spaced stringers-to-sheet joints made from of titanium.

Tasks

Ref. No. Title – Description Due Date

1 System technology – Development of a system technology for

reproducible manufacturing conditions

M9

2 Welding Process – Development of a laser welding process for

one-sided joining of stringers to the skin sheet

M15

3 Straightening Process – Development of a laser straightening process

for compensating welding distortion

M18

4 Demonstrator Manufacturing – Manufacturing of four large scale HLFC

demonstrators

M24

5 Distortion and Residual Stresses Modelling – Development and

validation of a process model to predict distortion and residual stresses in dependence of processing parameters

M10

6 Model-based Process Parameter Prediction – Processs parameter

prediction and optimisation for laser welding and straightening

M18

7 Tensile and Fatigue Strength – Tensile and fatigue strength testing at

coupon level

M20

For manufacturing of titanium parts for HLFC structures, the applicant should firstly design and implement a suitable system technology, allowing a reproducible positioning and clamping of skin sheets and stringers for a fillet-T-joint welding process, given the stringent requirements with respect to the required accuraccy. Typically, stringers with a length of 3800mm and a wall thickness of 0.8 mm should be weldable (fig. 1a). A process control system should be integrated considering seam tracking and seam penetration as well as temperature-field measurement to obtain a reproducible root formation in single-sided laser welding of narrowly spaced stringers (fig. 2). The signals from the process control system (such as temperature field data) shall also be used to validate the simulation. For compensating welding distortion (fig. 1b) the applicant should ensure a reproducible system technology for the straightening process (fig. 1c). Therefore the path and the angular distortion

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Written Proc. 2014 - 07 Annex III of Amendment nr. 1 to the Work Plan 2014 – 2015 Page 26 of 375 should be measurable online to control process parameters and ensure a flat outer skin after straightening (fig. 1d). Temperature field measurement shall also be integrated during the straightening process. The process combination welding and straightening should be demonstrated on test specimens with a length of 2000 mm.

Fig. 1: Laser processing steps and its results

On the basis of the system technology, the applicant shall develop a welding and straightening process, investigating the effect of all relevant parameters on the resulting properties first on coupon level, then on demonstrator level. In special, on coupon level, microstructure, static strength and fatigue properties shall be assessed. On demonstrator level, dimensional accuracy shall be measured (flatness, distortion).

In order to facilitate process development and reduce experimental effort, the experimental process development shall be supported by the development of a process modell based on FEM. With this model, the dependence of both global and local deformation and residual stresses on the process paramteres shall be described. This model shall then be able not only to predict angular welding distortion of the skin sheet along the stinger joint, but also longitudinal distortion and buckling effects, which have proven to be of special significance in large-scale welded skin-stringer structures. Furthermore the model should be able to simulate the straightening process and predict suitable straightening parameters to compensate the angular welding distortion. The final stringer position and outer sheet flatness should be simulated and measured to verify the reproducibility and dimensional accuracy of the process combination.

Finally the applicant should manufacture four demonstrator structures (fig. 3).

Drawings of the Demonstrator and Materials for both skin sheets and stringers are provided by Airbus. Moreover, temperature-dependent data of the Titanium alloy will be provided by Airbus.

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Fig. 2: Cross-section of a T-joint made by laser welding from

Fig. 3: Stainless steel skin sheet with welded stringers for HLFC structures

3. Major Deliverables and Schedule (estimate)

Deliverables

Ref. No. Title – Description Type Due Date

1 Kick-off meeting - Presentation of planned manufacturing and

modelling method to Airbus

Report M0

2 System technology – Report on the implementation of system

technology

Report M9

3 Test Samples - Delivering of welded and straightened test

specimens, with report on metallurgical evaluation of the seam formation

Report M16

4 FE-Process – Documentation of the final process chain including

Task 5 and 6 in a comprehensive report

Report M18

5 Demonstrators – Delivery of four large-scale manufacturing

demonstrators to Airbus with reports

Reports / Hardware

M24

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4. Special skills, Capabilities, Certification expected from the Applicant

- The applicant should provide large-scale system technology with suitable laser-welding equipment.

- The applicant should have extensive expertise in laser-beam welding of large thin sheet structures in T-joint configurations.

- The applicant should have extensive expertise in welding of titanium.

- The applicant should have extensive expertise modeling of laser welding and welding distortion. - The applicant should have expertise in optical measurment techniques and temperature

measurement during welding processes.

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IV.

Cost Reduction On Composite Structure Assembly – Innovative blind fastener

inspection technology for quality control

Joint Technical Programme (JTP) Ref. WP Level 1 – 2.2 Non-Specific-Design technologies

Indicative Funding Topic Value (in k€) 350 k€

Date3

06-2015

JTI-CS2-2014-CFP01-LPA-02-01

Cost Reduction On Composite Structure Assembly – Innovative blind fastener inspection technology for quality control

The expected outcomes are the definition, development and prototype realization of an innovative inspection monitoring process for specific and complex high strength blind fasteners that pose a challenge in terms of online process monitoring in typical aerospace assembly application.

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1. Background

To change from today’s differential design to a more integral design strategy by merging functions and parts, design and manufacturing processes must be more driven by a holistic point of view. This specific WP is orientated to development, assessment and selection of integrative concepts, which will be completed by specific technologies development to optimize assembly and integration of elementary parts, sub-components and modules. The solutions identified are part of a wider strategy leading to cost reduction on composite structure assembly and rivet less assembly on the aircraft, with focuses to save weight and provide greener solution than current processes applied.

WP2.2.2.1 COST REDUCTION ON COMPOSITE STRUCTURE ASSEMBLY

In order to reduce cost on composite structure assembly, one of the major objectives is to promote blind fastener & related inspection method

LPA IADP. Platform 2 - “Innovative Physical Integration Cabin – System –

Structure”

WP 2.2 Non-Specific Design

technologies

WP 2.2.2

Technologies for elementary parts, sub-components and modules

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Tasks

T2221-05 Blind fastener installation monitoring April 2019

T2221-05

Aircraft structures are still mainly assembled by fasteners. Beneath one piece solid rivets and two part bolts with nut or collar, blind fasteners are applied mainly in closed structures which do not allow to install a nut or collar to the pin or to squeeze a solid rivet. Inspection of correct blind head formation in closed structures – necessary to guarantee the fastener function – often only is possible using costly and time consuming borescope testing or in worst case no inspection possibility exists at all, leading to heavier design compensating for possible fastener failures. In this project, possibilities to enable a monitoring process ideally performed during fastener installation shall be assessed. The aim is to identify imperfect installations only by measurement and evaluation of installation parameters. Failed installations could result from fastener defects itself (e. g. no preload generation, defective blind heads, premature rupture of pull or threaded spindles) as well as from installation of not suitable fastener lengths or insufficient hole preparation operations. Time consuming endoscopic inspections of the fastener blind heads in closed structures could be ceased if an appropriate monitoring or inspection process would be resulting from the project.

Process monitoring during the installation of simple blind or “pop” rivets is commonly used in the automotive industrie for years. The more complex high strength blind fasteners used in the aviation industry nevertheless pose a challenge in terms of online process monitoring. Two fastener types are under investigation since some time, threaded stem (Figure 1) and pull stem (Figure 2) blind bolts. Torque-angle of rotation respectively force-travel measurements to date did not deliver a comprehensive process control possibility, only a few of the quality criteria could have been detected so far. Thus, in the frame of this project, new strategies of blind fastener monitoring are in demand. The project partner shall develop strategies and investigate applicability in a serial production environment.

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Figure 1: Threaded stem fastener installation sequence (cross sections)

Figure 2: Pull stem fastener installation sequence (cross sections except for stem)

In detail this process has to be capable to detect the failures listed here under: - Low or no preload due to lacking blind head to surface contact

- Cracked head

- Blind side spindle failure, e. g. premature rupture - Double bulbed blind head

- Tulip shaped sleeve And optionally :

- Determination of excessive blind side slope out of tolerance - Countersink angle deviation due to hole preparation process

Real time monitoring of installation parameters would be the prefered method to investigate but alternative innovative inspection could be investigated as long as they have low impact on the assembly time. Ultrasonic inspection shall be excluded of the scope of the methodologies to investigate. The 2 types of blind fasteners (pull type and threaded type) shall be addressed but the inspection method and/or monitoring can be different from one type to another.

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3.

Major Deliverables / Milestones and schedule (estimate)

Deliverables

T2221-05-01 Check of available documentation, selection of suitable installation monitoring variables and/or inspection process.

Report T0+9m

T2221-05-02 Test bench, specimen and test program definition. Report T0+16m T2221-05-03 Manufacturing of test bench and specimen and pilot test

including evaluation.

Report T0+24m T2221-05-04 If pilot test is conclusive, repeatability study with fasteners

from different lots, diameters and lengths. Variation of material thickness, hole diameters, installation parameters, assessment of sealant application influence.

Demonstration of applicability in production.

Report T0+36m

4.

Special skills, Capabilities, Certification expected from the Applicant(s)

T2221-05:

 Skill 1- Profound knowledge in metrology methods, contact free or in contact. Blind fastener function from installation start to end is to be recorded and suitably analysed in order to find quality-relevant characteristics. Improper installations e. g. without preload or misformed fastener closing heads shall be detectable directly within or after the installation process.

 Skill 2- Data management skills are important to find the essential information within the recorded data. Due to scatter and also altered installation conditions, graphs usually cannot be evaluated at a look. Mathematical analysis approaches thus are indispensable.

 Skill 3- Installation trials and analysis to be performed in a laboratory with mechanical assembly capability including drilling, countersink preparation in metallic and composite material, hole geometry measurement and blind fastener installation.

 Skill 4- Design and manufacturing engineering supporting test bench development. It will be designed for installation analysis, pull type and threaded type blind fasteners shall be monitored or inspected.

 Skill 5- Engineering development of interfaces, hardwares and softwares, to integrate the development technology into the industrial system capabilities.

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V.

Cost Reduction On Composite Structure Assembly - Definition and development of an

inspection tool to characterize inner surface hole quality

Date4

09-2015

JTI-CS2-2014-CFP01-LPA-02-02

Cost Reduction On Composite Structure Assembly - Definition and development of an inspection tool to characterize inner surface hole quality

The objective of this work is to define a relevant criteria to characterize the surface quality and which could be industrially controlled to characterise the inner surface of the hole.

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1. Background

WP2.2.2.1 COST REDUCTION ON COMPOSITE STRUCTURE ASSEMBLY

In order to reduce cost on composite structure assembly, one of the major objectives is to reduce cost of hole drilling by adaptation of requirements to composite environment.

Drilling is the most common operation in composite structures. Because of the heterogeneous nature of laminates, cutting modes generate different damage scenarios and complex defect mappings. For this reason the traditional roughness criteria widly used in metallic apllication is not enough representative of the quality of the produced holes. The defects can be divided into three groups: defects at the hole entry, defects at the hole exit, and hole wall defects. The first two types have been extensively studied in the literature because the tools can generate delamination that reduce the strength of the composite parts. In general, these defects have to be avoided, especially in aeronautics. The third type of defects has been less studied although evaluation criteria, usually used for metals, such as Ra, do exist.

The objective of this work is to define a criteria which is relevant to characterize the surface quality

Structure”

technologies

WP 2.2.2

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Written Proc. 2014 - 07 Annex III of Amendment nr. 1 to the Work Plan 2014 – 2015 Page 36 of 375 and which could be industrially controlled to characterise the inner surface of the hole that will complete recent developed roughness surface measurements, such as in LOCOMACHS works.

Tasks

T2221-01 Identify possible outcomes from LOCOMACHS, JU project and associated benchmark

Q1/2016 T2221-02 Define an innovative criteria to characterise the inner surface of a

hole made by drilling processes in composite materials

Q4/2016 T2221-03 Characterise the interest, advantage and limitations in composite

joints with fastening systems of the innovative criteria (interaction with the fasteners…)

Q2/2017

T2221-04 Definition of methods to measure the criteria including interest, advantage, limitations…

Q3/2017 T2221-05 Validation of the applicability in industrial environment Q4/2017

Airbus will provide state of the art, including outcomes from LOCOMACHS. Development of the innovative technology will deliver a complete description of a new measurement device.

3. Major Deliverables/ Milestones and schedule (estimate)

Deliverables

D2221-01 Bibliography survey Report Q1/2016

D2221-02 Definition of an appropriate innovative

methodology to control the surface quality and relevant associated criteria

Report Q2/2017

D2221-03 Finale report including validation in industrial environment of the innovative method

Maturity report

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M2221-01 Presentation of intermediary results Milestone meeting

Q1/2016 M2221-02 Presentation of intermediary results Milestone

meeting

Q4/2016 M2221-03 Presentation of intermediary results Milestone

meeting

Q2/2017

4. Special skills, Capabilities, Certification expected from the Applicant(s)

The applicant shall have:

- Skill on composite materials characteriztion in general and particular in composite joints for typical aeronautic industries

- Skill on fastening systems and drilling processes used in aeronautic industries

- Capacities in creation of FMEA analysis

- Knowledge on standards applicable in aerospace specific to assemblies processes

- Capacity and knowledge in non destructive methodologies relative to hole measurements (including metrology)

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VI.

Rapid Assembly Of Bracket For Structure-System Integration

Type of action (RIA or IA) RIA

Date5 06-2015 (based on call period) Identification Title JTI-CS2-2014-CFP01-LPA-02-03

Rapid Assembly Of Bracket For Structure-System Integration

This specific WP is orientated to development, assessment and selection of integrative concepts, which will be completed by specific technologies development to optimize assembly and integration of elementary parts, sub-components and modules

5

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1. Background

WP2.2.2.2 RAPID ASSEMBLY OF BRACKET FOR STRUCTURE-SYSTEM INTEGRATION

Brackets are the link between the aircraft structure and systems and cabin. They are one of the most challenging part regarding the industrialization of the aircraft and one key for a successful commercially viable aircraft product. This is mainly due to the high number of stakeholders involved in their definition, manufacturing and assembly process.

Figure 1 : Standard brackets

Brackets represent ten of thousand parts on A350-XWB.

Structure”

technologies

WP 2.2.2

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Written Proc. 2014 - 07 Annex III of Amendment nr. 1 to the Work Plan 2014 – 2015 Page 40 of 375 The aim of this Work Package 2.2.2.2, is to develop ultrasonic welding as an alternative technology for bonded brackets assembly onto CFRP.

Figure 2 : Welding technology illustration

The benefits of this assembly method compared to bonding is that there is no surface preparation, no handling of adhesive “on the spot”, no curing time and no quality control.

Assembly cost and lead-time savings are expected at part level, Major Component Assembly and Final Assembly Line.

Weight savings opportunities are expected too if a multi-functional surfacing media can be validated and supplied.

The objective of this call for proposal is to define and develop an innovative test method to asses the welding compatibitity between bracket and the parent material on which it will be bonded, that will allow a quick charcterization of different materials. Based on the results, the partner will develop a surfacing media able to be co-cured with the thermoset composite and compatible with thermoplastic brackets.

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Tasks

1 Test method to evaluate welding compatibility T0+6

2 Development of a surfacing media for application on CFRP and compatible with PEI brackets

T0+36

3 Assessment of welding performances T0+54

Task 1:

The objective is to develop a test method to evaluate the compatability between thermoplastics materials such as PA 6.6 , PEEK, and PEI used for brackets manufacturing with thermoplastics and thermosets composites used for frames ans stringers manufacturing.

The test method should allow a quick evaluation of different materials and be the base for a first downselection of materials.

This test method could be a combination of chemical and mechanical test methods.

Figure 3 : Micrographic cut Figure 4 : Example of DSC curve

Task 2 :

Depending on the couple of material used, the technology requires the use of an additional surfacing material between the structure and the bracket.

PEI brackets are usually bonded onto thermoset composite.

The objective of this task is then to develop a surfacing media able to be co-cured with the thermoset composite and compatible with PEI brackets.

The actitviy will need to develop collaborations with R&T departments of materials suppliers, ensure the deployment of the test method and provide guidance in the formulation of new materials to be used as surfacing media.

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Written Proc. 2014 - 07 Annex III of Amendment nr. 1 to the Work Plan 2014 – 2015 Page 42 of 375 The objective is to assess the performances of bracket/(surfacing media)/composite assembly. The activity will include series of tests such as tensile tests at room temperature, after hot wet conditionning, fluid resistances, etc. to demonstrate that the assembly complies with the requirements stipulated in the bonded brackets specification.

Figure 5 : Tensile tests Figure 6 : Welded bracket

3. Major deliverables and schedule (estimate)

Deliverables

Ref. No.

Title - Description Type Due

Date 1 Creation of a test method to evaluate the welding compatibility of

materials (DSC, other…)

Test method T0+18

2 Search of compatibilities between PEI to be welded on other surfacing media. Discovery and/or definition of other surfacing medias.

Test report T0+36

3 Testing of welding performances Mechanical

testing

T0+48 4 Reporting test results of welding performances. Test report T0+54

4. Special skills, Capabilities, Certification expected from the Applicant

- Skill 1: in thermoplastic material and related manufacturing processes including welding

- Skill 2: material database,

- Skill 3: classical testing methods such as mechanical test, DSC, micrography…

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VII.

Automation in Final Aircraft Assembly Lines and Enabling Technologies

Joint Technical Programme (JTP) Ref.

WP 2.2.3.1 – Automation in Final Aircraft Assembly Lines and Enabling Technologies

Date6

09-2015

JTI-CS2-2014-CFP01-LPA-02-04

Automation in Final Aircraft Assembly Lines and Enabling Technologies

Development of automation concepts and technologies to radically increase the use of automation systems in Aircraft Section Assembly (MCA) and Aircraft Final Assembly (FAL) including concepts for realization of industry 4.0 approach. Linked to JTP chapter 6.6 (2.2.3)

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1. Background

Assembly of aircraft sections and final assembly of aircrafts including structural assembly, system installation, cabin installation and test nowadays is done mainly manually or semi automated, which is also true for the supporting activities like logistics.

Many of the activities are in non ergonomic conditions and the process chains are very complex and today not transparent.

In this context automation of logistic processes, delivery of aircraft parts e.g. to the stations, human-machine colaboration at installation and full automated processes for structural assembly, system and cabin installation shall be investigated integrating also possibilities to optimize process chains and to make the current status of the assembly transparent at each time.

There are challenges in many perspectives like the limited access for example inside the Aircraft and the need of moving autonomous automation systems through aircraft doors, because the fuselage will in the end be finally completed.

On the other side the automation systems have to be very flexible, to be able to perform different operations at different locations to minimize the amount of specialized systems and therefor to get a good utilization.

Another challenge will be the maximum allowed weight of the automation system to be able to work inside the Aircraft on the aircraft floor.

On the other hand, having such kind of automation would be a leap forward with regards to lead time, RC-costs and also flexibility and transparency, because autonomous systems could also use the night-shift without extra costs and by having all systems connected by a common data backbone with a direct link to the design systems, the system could be able to fully automatically assemble customized aircrafts.

Technical Description

In the frame of this work package the Topic Manager refers to (JTP chapter 6.6) the vision about the Future Factory, which shows an overview about the future assembly and installation processes in the Final Aircraft assembly line.

The first part of the work package is the concept development. Therefor the different tasks to be automated have to be collected and single automation solutions per task have to be selected from of the shelf available solutions.

In parallel a concept for a manipulator system (e.g. industrial robot on a moveable platform) has to be developed. Therefor the application areas have to be mapped and grouped in a meaningful way.