FUTURED. ZAL Magazin 2023
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FRAUNHOFER IFAM<br />
SMART AIRCRAFT<br />
ASSEMBLY<br />
42<br />
Prototype for joining upper and side panels.<br />
As part of Fraunhofer’s commitment to<br />
push the boundaries of aircraft manufacturing,<br />
Fraunhofer IFAM collaborates with<br />
industry leaders such as Airbus as end user<br />
and project lead, Broetje Automation, CENIT,<br />
and 3D.aero. Under tight cooperation, we<br />
have developed a fully integrated cyberphysical<br />
facility that automates the assembly<br />
of large fuselage composite panels.<br />
The first step is to extract geometrical data from<br />
the panels via cameras and to compare these<br />
with nominal data. Based on the result ing deviations,<br />
deformation movements are calculated for<br />
the grippers holding the panels by using algorithms<br />
to predict forces. This is then repeated<br />
iteratively until the measured deviation is within<br />
manufacturing tolerances. All this happens while<br />
the status of the facility is being monitored<br />
through a digital factory twin. Furthermore, the<br />
developed system includes several innovative<br />
features, such as:<br />
• a multi-camera-based markerless photogrammetry<br />
system<br />
• adaptable and modular grippers and<br />
actuator systems for fuselage-panel handling<br />
• an information system capable of<br />
deter ministic real-time communication<br />
• an automated assembly procedure that<br />
complies with built-in stress requirements<br />
Likewise, our collaboration with the <strong>ZAL</strong> GmbH<br />
in Hamburg has been instrumental in the development<br />
of this prototypical system, which represents<br />
a significant advancement in aircraft<br />
manufacturing technology.
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