Search Results

Aerospace assembly operations are still highly dependent on human labor and processes. This paper will describe and illustrate the transformational technologies that will enable replication of the human cognitive (in context) textural ability to assemble airplane and space structure. The paper will also provide use case examples where these innovative technologies have been applied successfully. Without context, data are just dots, floating around without meaning. With context data becomes an enlightened component of knowledge that brings value to information. In-context enlightened knowledge provides manufacturing visibility within factory operations. Visibility is a key component of the Smart, Brilliant, or Intelligent Factory.

The introduction of composite materials onto air vehicles has complicated the traditional hole/countersink assessment criteria due its finished-part thickness variability; softer and dissimilar properties than the metallic substructure where it is mounted and attached; and the increased attention to other acceptance criteria such as fiber tear, fiber pull, and moisture propagation in the hole that degrades fastener capability. The addition of composite materials further complicates the assembly process by adding a boundary layer of liquid shim or sealant between the composite piece (usually a skin) and the substructure. Current hole inspection systems are absent the ability to assess the interior condition of the composite hole such as fiber tear, damage to the liquid shim, and debris or burrs between the multiple stacks of dissimilar material.

Rapid advances in cloud-based computing, robotics and smart sensors, multi-modal modeling and simulation, and advanced production are transforming modern manufacturing. The shift toward smaller runs on custom-designed products favors agile and adaptable workplaces that can compete in the global economy. This paper and presentation will describe the advances in Digital Manufacturing that provides the backbone to tighten integration and interoperability of design methods interlinked with advanced manufacturing technologies and agile business practices. The digital tapestry that seamlessly connects computer design tools, modeling and simulation, intelligent machines and sensors, additive manufacturing, manufacturing methods, and post-delivery services to shorten the time and cost between idea generation and first successful product-in-hand will be illustrated.

Probabilistic methods are used in calculating composite part design factors for, and are intended to conservatively compensate for worst case impact to composite parts used on space and aerospace vehicles. The current method to investigate impact damage of composite parts is visual based upon observation of an indentation. A more reliable and accurate determinant of impact damage is to measure impact energy. RF impact sensors can be used to gather data to establish an impact damage benchmark for deterministic design criteria that will reduce material applied to composite parts to compensate for uncertainties resulting from observed impact damage. Once the benchmark has been established, RF impact sensors will be applied to composite parts throughout their lifecycle to alert and identify the location of impact damage that exceeds the maximum established benchmark for impact.