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Aerospace companies have formed integrated product teams to improve their new product introduction process. Where significant components are outsourced, the suppliers’ expertise should be harnessed for a “win-win” solution to benefit both customer and supplier. CE practices for remote team work have been developed and used in a component engineering contract between a customer-supplier pair in the United Kingdom. Details of the producibility interaction dialogue between design team and supplier production engineers were captured. The resulting model represents the deployment of engineering capability of aerospace suppliers. It supports the setting up of CE projects with subcontract engineering work and is a reference for suppliers to develop their design/engineering capability.

In the civil aircraft industry there is a continuous drive to increase the aircraft production rate, particularly for single aisle aircraft where there is a large backlog of orders. One of the bottlenecks is the wing assembly process which is largely manual due to the complexity of the task and the limited accessibility. The presented work describes a general wing build approach for both structure and systems equipping operations. A modified build philosophy is then proposed, concerned with large component pre-equipping, such as skins, spars or ribs. The approach benefits from an offloading of the systems equipping phase and allowing for higher flexibility to organize the pre-equipping stations as separate entities from the overall production line. Its application is presented in the context of an industrial project focused on selecting feasible system candidates for a fixed wing design, based on assembly consideration risks for tooling, interference and access.

This paper describes and demonstrates the use of an assembly centric design algorithm as an aid to achieving minimal hard tooling assembly concepts. The algorithm consists of a number of logically ordered design methodologies and also aids the identification of other enabling technologies. Included in the methodologies is an innovative systems analysis tool that enables the comparison of alternative assembly concepts, and the prediction and control of the total assembly error, at the outline stage of the design.

The aviation sector has played a significant role in shaping the world into what it is today. The rapid growth of global economies and the corresponding sharp rise in the number of people now wanting to travel on business and for pleasure, has largely been responsible for the development of this industry. With a predicted rise in Revenue Passenger Kilometers (RPK) by over 150% in the next 20 years, the industry will correspondingly be a significant contributor to environmental emissions. Under such circumstances optimizing aircraft trajectories for lowered emissions will play a critical role amongst various other measures, in mitigating the probable environmental effects of increased air traffic. Aircraft trajectory optimization using evolutionary algorithms is a novel field and preliminary studies have indicated that a reduction in emissions is possible when set as objectives.

In a multi-pass weld, the development of residual stress to a large extent depends on the response of the weld metal, heat affected zone and parent material to complex thermo-mechanical cycles during welding. Previous investigations on this subject mostly focused on mechanical tensioning or heat treatment to modify the residual stress distribution in and around the weld. In this research, microstructural refinement with modification of residual stress state was attempted by applying post weld cold rolling followed by laser processing. The hardening of the weld metal was evaluated after welding, post weld cold rolling and post weld cold rolling followed by laser processing. The residual stress was determined non-destructively by using neutron diffraction. Hardness results showed evidence of plastic deformation up to 4 mm below the weld surface.

The installation of essential systems into aircraft wings involves numerous labour-intensive processes. Many human operators are required to perform complex manual tasks over long periods of time in very challenging physical positions due to the limited access and confined space. This level of human activity in poor ergonomic conditions directly impacts on speed and quality of production but also, in the longer term, can cause costly human resource problems from operators' cumulative development of musculoskeletal injuries. These problems are exacerbated in areas of the wing which house multiple systems components because the volume of manual work and number of operators is higher but the available space is reduced. To improve the efficiency of manual work processes which cannot yet be automated we therefore need to consider how we might redesign systems installations in the enclosed wing environment to better enable operator access and reduce production time.

Significant effort has been applied to the introduction of automation for the structural assembly of aircraft. However, the equipping of the aircraft with internal services such as hydraulics, fuel, bleed-air and electrics and the attachment of movables such as ailerons and flaps remains almost exclusively manual and little research has been directed towards it. The problem is that the process requires lengthy assembly methods and there are many complex tasks which require high levels of dexterity and judgement from human operators. The parts used are prone to tolerance stack-ups, the tolerance for mating parts is extremely tight (sub-millimetre) and access is very poor. All of these make the application of conventional automation almost impossible. A possible solution is flexible metrology assisted collaborative assembly. This aims to optimise the assembly processes by using a robot to position the parts whilst an operator performs the fixing process.

Dents on the aircraft skin are frequent and may easily go undetected during airworthiness checks, as their inspection process is tedious and extremely subject to human factors and environmental conditions. Nowadays, 3D scanning technologies are being proposed for more reliable, human-independent measurements, yet the process of inspection and reporting remains laborious and time consuming because data acquisition and validation are still carried out by the engineer. For full automation of dent inspection, the acquired point cloud data must be analysed via a reliable segmentation algorithm, releasing humans from the search and evaluation of damage. This paper reports on two developments towards automated dent inspection. The first is a method to generate a synthetic dataset of dented surfaces to train a fully convolutional neural network. The training of machine learning algorithms needs a substantial volume of dent data, which is not readily available.

Digital Twin (DT) is a dynamic digital representation of a real-world asset, process or system. Industry 4.0 has recognised DT as the game changer for manufacturing industries in their digital transformation journey. DT will play a significant role in improving consistency, seamless process development and the possibility of reuse in subsequent stages across the complete lifecycle of the product. As the concept of DT is novel, there are several challenges that exist related to its phase of development and implementation, especially in high value manufacturing sector. The paper presents a thematic analysis of current academic literature and industrial knowledge. Based on this, eleven key challenges of DT were identified and further discussed. This work is intended to provide an understanding of the current state of knowledge around DT and formulate the future research directions.

The flow field and body aerodynamic loads on the DrivAer reference model have been extensively investigated since its introduction in 2012. However, there is a relative lack of information relating to the models wake development resulting from the different rear-body configurations, particularly in the far-field. Given current interest in the aerodynamic interaction between two or more vehicles, the results from a preliminary CFD study are presented to address the development of the wake from the Fastback, Notchback, and Estateback DrivAer configurations. The primary focus is on the differences in the far-field wake and simulations are assessed in the range up to three vehicle lengths downstream, at Reynolds and Mach numbers of 5.2×106 and 0.13, respectively. Wake development is modelled using the results from a Reynolds-Averaged Navier-Stokes (RANS) simulation within a computational mesh having nominally 1.0×107 cells.

Cooling drag, typically known as the difference in drag coefficient between open and closed cooling configurations, has traditionally proven to be a difficult flow phenomenon to predict using computational fluid dynamics. It was seen as an academic yardstick before the advent of grille shutter systems. However, their introduction has increased the need to accurately predict the drag of a vehicle in a variety of different cooling configurations during vehicle development. This currently represents one of the greatest predictive challenges to the automotive industry due to being the net effect of many flow field changes around the vehicle. A comprehensive study is presented in the paper to discuss the notion of defining cooling drag as a number and to explore its effect on three automotive models with different cooling drag deltas using the commercial CFD solvers; STARCCM+ and Exa PowerFLOW.

As aviation is one of the fastest growing industrial sector world wide, air-traffic emissions are projected to increase their stake in the contribution to global warming. According to recent studies, both CO2 and contrails will be the principal air-traffic pollutants. Since the environmental impact of contrails is potentially larger, their avoidance is becoming discussed in the aeronautical community. Work on this topic has been carried out at Cranfield University in form of a PhD project. A project summary is given in this paper where contrail avoidance strategies and the different aspects of contrail avoidance are highlighted. The first section provides an overview on the formation principles of contrails based on a literature review. Different technologies are given in the second part, and their introduction is discussed in the last section.

The interactions between automatic controls, physics, and driver is an important step towards highly automated driving. This study investigates the dynamical interactions between human-selected driving modes, vehicle controller and physical plant parameters, to determine how to optimally adapt powertrain control to different human-like driving requirements. A cyber-physical system (CPS) based framework is proposed for co-design optimization of the physical plant parameters and controller variables for an electric powertrain, in view of vehicle’s dynamic performance, ride comfort, and energy efficiency under different driving modes. System structure, performance requirements and constraints, optimization goals and methodology are investigated. Intelligent powertrain control algorithms are synthesized for three driving modes, namely sport, eco, and normal modes, with appropriate protocol selections. The performance exploration methodology is presented.

This paper presents the design concept behind a novel remote visual inspection robotic system for fighter jet aircraft wing fuel tank inspection. This work is part of a larger research project which focuses on design, simulation, physical prototyping and experimental validation of a robotic system. Whereas this paper specifically focuses on the development concept of locomotion design choice for the robot. Therefore without an effective mobility method the robot will not be able to fulfill its purpose to access the hazardous confined spaces of the fuel tank. Aircraft wing fuel tank inspection is a challenging area of maintenance which requires a considerable amount of preparation and involvement of several tasks in order to conduct effective Visual and Non Destructive Inspection. The environment of an aircraft wing fuel tank poses several challenges due to both physical and atmospheric constraints which can be detrimental to human personal.

Jigless assembly is an approach towards reducing the cost and increasing the flexibility of tooling systems for aircraft manufacture through the minimisation of productspecific jigs, fixtures and tooling. A new, integrated methodology has been developed, which uses a number of building blocks and tools, to enable design for jigless assembly as a result of a logical, step-by-step process. This methodology, AIM-FOR-JAM, is currently being applied to redesign the Airbus A320 Fixed Leading Edge for jigless assembly, as part of the ‘Jigless Aerospace Manufacture’ (JAM) project.

This paper describes the impact of noise on the civil aircraft design process. The challenge to design ‘silent’ aircraft is the development of efficient airframe-engine technologies, for which integration is essential to produce an optimum aircraft, otherwise penalties such as higher fuel consumption, and, or noise are a concern. A description of work completed by Cranfield University will cover design methodologies used for a Broad delta airframe concept, with reference to future studies into alternate concepts. Engine cycle designs for ultra-high bypass ratio, constant volume combustor, and recuperated propulsion cycles are described, with a discussion of integration challenges within the airframe.

Autonomous vehicles have been shown to increase safety for drivers, passengers, and pedestrians and can also be used to maximize traffic flow, thereby reducing emissions and congestion. At the same time, governments around the world are promoting the usage of battery electric vehicles (BEVs) to reduce and control the emissions of CO2. This has made the development of autonomous vehicles and electric vehicles a very active research area and has prompted a significant amount of government funding. This article presents the detailed design of a low-cost platform for the development of an autonomous electric vehicle. In particular, it focuses on the design of the electrical architecture and the control strategy, tailored around the usage of affordable sensors and actuators. The specifications of the components are extensively discussed in relation to the performance target.

Water is always present in jet fuel, usually in a mixture of forms. At very low temperatures this phenomenon can lead to the formation of ice crystals within the aircraft fuel system, which can then stay in suspension within the entire volume of fuel. Pumps within the fuel system transfer fuel around the system. Pumps such as boost pumps that are typically used in fuel systems are protected by a weave type filter mesh at the inlet. Ice accretion on the surface of this mesh has operational implications as it can cause non optimal fuel flow. In this investigation, two fundamental tools are being used: 1) a high fidelity MATLAB model of a mesh strainer, pick-up line and pump, and 2) a test rig of the modelled system. The model is being used to investigate fuel system performance when exposed to fuel containing water/ice contaminants at cold temperatures.

This paper focuses on the investigation of the nature, process and effects of ice accretion on different feed pump strainers upstream of the aircraft feeding system. A suitable test rig was designed to circulate Jet A-1 containing water/ice contaminants at cold temperatures through the strainers. Following an extensive literature review, a number of screening tests were performed. These provided a strong base for an exhaustive study of fuel icing in the dynamic environment offered by the test rig. The effects of the rate of fuel cooling on the nature of ice were examined. As expected, it was observed that the yield of ice generated on the mesh screen increased with the water concentration in the fuel. It was also revealed that at higher cooling rates, a crust of snow formed on top of softer ice on the mesh screen.