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ZAero SIGNED

Zero-defect manufacturing of composite parts in the aerospace industry

Total Cost €

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EC-Contrib. €

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Partnership

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Project "ZAero" data sheet

The following table provides information about the project.

Coordinator
PROFACTOR GMBH 

Organization address
address: IM STADTGUT A2
city: STEYR GLEINK
postcode: 4407
website: www.profactor.at

contact info
title: n.a.
name: n.a.
surname: n.a.
function: n.a.
email: n.a.
telephone: n.a.
fax: n.a.

 Coordinator Country Austria [AT]
 Project website http://www.zaero-project.eu
 Total cost 4˙124˙143 €
 EC max contribution 3˙548˙206 € (86%)
 Programme 1. H2020-EU.2.1.5.1. (Technologies for Factories of the Future)
 Code Call H2020-FOF-2016
 Funding Scheme IA
 Starting year 2016
 Duration (year-month-day) from 2016-10-01   to  2019-09-30

 Partnership

Take a look of project's partnership.

# participants  country  role  EC contrib. [€] 
1    PROFACTOR GMBH AT (STEYR GLEINK) coordinator 927˙413.00
2    FUNDACION PARA LA INVESTIGACION, DESARROLLO Y APLICACION DE MATERIALES COMPUESTOS ES (Getafe) participant 665˙687.00
3    IDEKO S COOP ES (ELGOIBAR) participant 611˙250.00
4    DASSAULT SYSTEMES FR (VELIZY VILLACOUBLAY) participant 447˙125.00
5    AIRBUS DEFENCE AND SPACE GMBH DE (TAUFKIRCHEN) participant 365˙498.00
6    M TORRES DISEÑOS INDUSTRIALES SA ES (TORRES DE ELORZ) participant 315˙980.00
7    DANOBAT ES (ELGOIBAR) participant 215˙250.00

Map

 Project objective

In the aerospace industry very high quality standards have to be met. For the manufacturing of carbon fibre parts this is currently solved through extended end-of-line inspection in combination with re-work processes to deal with defective parts. Also, in-situ visual inspection is used for quality control, which is currently causing huge productivity losses (30%-50%) during lay-up and has become a real bottleneck in carbon fibre parts manufacturing.

The project will provide a solution by developing inline quality control methods for the key process steps: automatic lay-up (dry fibre placement and automatic dry material placement) and curing. At the system level decision support systems will be developed that assist human decision-making when assessing defects and when planning the part flow through the production line. These will be supported by simulation tools for part verification and logistical planning. The future manufacturing of the A320neo wing covers will be provide the background for the developments. Each such wing cover consists of two parts, that each cost several hundred thousand Euros in manufacturing. Assuming the planned production rates of 60 planes per month from 2025, savings of 150 MEUR in production costs can be obtained per year.

The consortium consists of all key players that will play a future role in the manufacturing of such large carbon fibre parts. Airbus with its research centers Airbus Group Innovations and FIDAMC will play a leading role in the consortium as far as the multi-stage manufacturing process is concerned. Machine builders (MTorres, Danobat) and research centers will develop the inline quality control, while Dassault Systémes will provide simulation support.

 Deliverables

List of deliverables.
\"Demonstration #3 and evaluation report\" Demonstrators, pilots, prototypes 2020-04-23 23:57:29
\"Demonstration #2 and evaluation report\" Demonstrators, pilots, prototypes 2020-04-23 23:57:29
Project web page Websites, patent fillings, videos etc. 2020-04-23 23:57:28
Data Management Plan Documents, reports 2020-04-23 23:57:28
\"Demonstration #1 and evaluation report\" Demonstrators, pilots, prototypes 2020-04-23 23:57:28

Take a look to the deliverables list in detail:  detailed list of ZAero deliverables.

 Publications

year authors and title journal last update
List of publications.
2019 Robert Steringer, Helmut Zörrer, Sebastian Zambal, Christian Eitzinger
Using Discrete Event Simulation in multiple System Life Cycles to support Zero-Defect Composite Manufacturing in Aerospace Industry
published pages: , ISSN: , DOI:
9th IFAC Conference on Manufacturing Modeling, Management, and Control August 2019 2020-04-23
2019 Pierre-Yves Mechin; Michael Clarke
Caractérisation de l\'incidence des défauts de manufacturing robot sur la résistance des composites Carbone-Epoxy haute performance dans l\'aéronautique
published pages: , ISSN: , DOI: 10.5281/zenodo.3354217
21ème Jounées Nationales sur les Composites(JNC) 1-3 July, 2019 2020-04-23
2019 Christian Eitzinger; Paulo Leitao; Salvador Izquierdo Estallo
Innovative Technologies and Methods for Zero Defect Manufacturing on Industrial Cyber-Physical Systems Context
published pages: , ISSN: , DOI: 10.5281/zenodo.3354144
INDIN 2019 Call for papers: Innovative Technologies and Methods for Zero Defect Manufacturing on Industrial Cyber-Physical Systems Context 2 2020-04-23
2018 Celine Le Gleuher, Christopher Buchmann, Katharina Schlegel, Alois Friedberger
Advanced flow front and cure monitoring using high frequency technology
published pages: , ISSN: , DOI: 10.5281/zenodo.3354175
Conference of the Society for the Advancement of Material and Process Engineering (SAMPE) September 2018 2020-04-23
2019 Helmut Zörrer, Robert Steringer, Sebastian Zambal, Christian Eitzinger
Using Business Analytics for Decision Support in Zero Defect Manufacturing of Composite Parts in the Aerospace Industry
published pages: , ISSN: , DOI:
9th IFAC Conference on Manufacturing Modeling, Management, and Control August 2019 2020-04-23
2018 Sebastian Zambal, Christian Eitzinger, Michael Clarke, John Klintworth, Pierre-Yves Mechin
A digital twin for composite parts manufacturing
published pages: , ISSN: , DOI:
Conference on Industrial Informatics (INDIN) 18th - 20th of July 2018 2020-04-23
2019 S. Zambal, C. Heindl, C. Eitzinger
Machine Learning for CFRP Quality Control
published pages: , ISSN: , DOI:
Conference of the Society for the Advancement of Material and Process Engineering (SAMPE) September 2019 2020-04-23
2018 Christian Eitzinger, Sebastian Zambal
Inline Inspection Technologies for Processing of Dry Fibre Materials
published pages: , ISSN: , DOI:
Conference of the Society for the Advancement of Material and Process Engineering (SAMPE) 11th-13th September 2018 2020-04-23
2017 Rodriguez, Ana Rosa; Cuenca, Jose; Ruiz, Rocio; Calero, Alvaro
ZAero - Zero defect manufacturing of composite parts in the aerospace industry
published pages: , ISSN: , DOI:
ZENODO 1 2020-04-23
2019 S. Zambal, C. Heindl, C. Eitzinger, J. Scharinger
End-to-End Defect Detection in Automated Fiber Placement Based on Artifcially Generated Data(How can we use deep learning for quality control with little data?)
published pages: , ISSN: , DOI:
International Conference on Quality Control by Artificial Vision, Mulhouse, France, 2019 May 15, 2019 2020-04-23
2018 Ana Rosa Rodriguez, Jose Cuenca, Rocio Ruiz, Alvaro Calero
ZAero- Cero Defectos en la fabricación de piezas de material compuesto en la industria aeroespacial
published pages: 128 - 131, ISSN: , DOI: 10.5281/zenodo.1247421
Materiales Compuestos vol 2, no 2, 2017 2020-04-23

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The information about "ZAERO" are provided by the European Opendata Portal: CORDIS opendata.

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