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A digital twin approach for smart assembly of aircraft skin panels with mechanical fasteners
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Franciosa, Pasquale, Gerbino, Salvatore, Stella, Ettore, Berri, Luigi, Gramegna, Nicola, Gallo, Nicola and Martorelli, Massimo (2022) A digital twin approach for smart assembly of aircraft skin panels with mechanical fasteners. In: International Joint Conference on Mechanics, Design Engineering and Advanced Manufacturing, Ischia, Italy, 1-3 Jun 2022. Published in: Advances on Mechanics, Design Engineering and Manufacturing IV. JCM 2022 pp. 851-861. ISBN 9783031159275. doi:10.1007/978-3-031-15928-2_74 ISSN 2195-4356.
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WRAP-digital-twin-approach-smart-assembly-aircraft-skin-panels-mechanical-fasteners-Franciosa-2022.pdf - Accepted Version - Requires a PDF viewer. Download (1304Kb) | Preview |
Official URL: https://doi.org/10.1007/978-3-031-15928-2_74
Abstract
The current best-practice in the assembly process of aircraft skin panels involves several manual measurement-fit-adjust quality loops, such as loading part on the assembly frame, measuring gaps, off-loading parts, adding be-spoke shims and re-positioning parts ready for the fastening operation. The consequence is that the aircraft is re-assembled at least twice and therefore this process has been proved highly inefficient. This paper describes the framework developed under the “Integrated Smart Assembly Factory” (ISAF) project in the “Intelligent Factory” specialisation area in Italy. Taking advantage of the emerging tools brought by Industry 4.0 the ISAF framework spearheads innovation in the assembly process of aircraft skin panels by integrating smart and digital technologies such as in-line measurement systems with highly accurate sensors, large-scale physics-based simulations, multi-disciplinary process optimisation and additive manufacturing. ISAF implements a flexible alignment, which combines both rigid rotations/translations and local deformations to account part deformations. The proposed methodology allows predicting and fabricating shims using in-line measurement data with no need to iterate the measurement-fit-adjust quality loops. This will undoubtedly reduce inspection/measurement time and costs, enabling operators to virtually test assembly operations before installation in the field. The results were demonstrated during the assembly process of a vertical stabiliser for commercial aircrafts, and findings showed a significant time saving of 75%.
Item Type: | Conference Item (Paper) | ||||||
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Subjects: | T Technology > TA Engineering (General). Civil engineering (General) T Technology > TL Motor vehicles. Aeronautics. Astronautics T Technology > TS Manufactures |
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Divisions: | Faculty of Science, Engineering and Medicine > Engineering > WMG (Formerly the Warwick Manufacturing Group) | ||||||
Library of Congress Subject Headings (LCSH): | Additive manufacturing, Industry 4.0 , Contact mechanics , Airplane factories -- Automation , Airframes | ||||||
Series Name: | Lecture Notes in Mechanical Engineering | ||||||
Journal or Publication Title: | Advances on Mechanics, Design Engineering and Manufacturing IV. JCM 2022 | ||||||
Publisher: | Springer | ||||||
ISBN: | 9783031159275 | ||||||
ISSN: | 2195-4356 | ||||||
Official Date: | 25 September 2022 | ||||||
Dates: |
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Page Range: | pp. 851-861 | ||||||
DOI: | 10.1007/978-3-031-15928-2_74 | ||||||
Status: | Peer Reviewed | ||||||
Publication Status: | Published | ||||||
Access rights to Published version: | Restricted or Subscription Access | ||||||
Date of first compliant deposit: | 11 July 2022 | ||||||
Date of first compliant Open Access: | 25 September 2023 | ||||||
RIOXX Funder/Project Grant: |
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Conference Paper Type: | Paper | ||||||
Title of Event: | International Joint Conference on Mechanics, Design Engineering and Advanced Manufacturing | ||||||
Type of Event: | Conference | ||||||
Location of Event: | Ischia, Italy | ||||||
Date(s) of Event: | 1-3 Jun 2022 | ||||||
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