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Report

Teaser, summary, work performed and final results

Periodic Reporting for period 1 - CALITO (CAbin LIning auTOmation)

Teaser

Summary

According to the largest european aircraft manufacturer has the air traffic doubled every 15 years since 1974 and itÂ´s expected that from 2015 until 2034, more than 30,000 passenger and freighter aircraft will be delivered.
The current situation at the a/c manufacturers is driven by increased production rates combined with the simultaneous need for declining manufacturing costs,
which result from global aircraft demand growth combined with high competition in the aviation market. With todayâ€™s production technology and organizational structures, this will continue to be a big challenge.
For instance, as the current single aisle family was designed for a total fleet size of roughly 500 aircraft and started out with a production rate of 1 to 2 aircraft per month,
it is necessary to set up a new manufacturing principle to achieve a rate of more than 60 aircrafts per month.
Important challenges of future products are: high customization and ramp-up capability, design for automation and product lifecycle.

The purpose of CALITO is to face the challenges and to develop a redesign for cabin and cargo lining and hatrack and fastening concepts with the focus on:
- Optimization for automation, robotics and human-robot collaboration
- Use of latest materials and innovative manufacturing processes (e.g. additive manufacturing)
- Modular and multi-functional solutions with high customization capability
- Self adjustment solutions to minimize installation effort

Overall, CALITO project will provide solutions to the a/c manufacturer and tier-one suppliers to make cabin installation more efficient in the future.
This results in cost and weight advantages through a modular construction of the solutions as well as time advantages in the installation by reducing the assembly steps.
By optimizing the concepts for the automated assembly of the cabin and the cargo lining, the a/c manufacturer is offered completely new possibilities for perfecting the final assembly.
The CALITO concepts are designed so that the degree of automation can be varied freely. From conventional manual assembly, through cooperative assembly in conjunction with human-robot, to fully automated assembly.

Work performed

The work carried out during the first 18 months of the CALITO project defined the re-design of cabin lining parts (sidewall and ceiling), hatracks and cargo lining parts including innovative fastening concepts optimized for automation. We also completed the analysis of state of the art designs and technologies, simulations of different innovative installation scenarios and definition of requirements for automation. For sidewall and ceiling panels latest materials and weight optimized design for automation are used.
In detailed developing the initial concept ideas, we drew on the expertise of three companies: SFS intec as an expert in the development and production of fastening solutions, Solvay as an expert in high-performance aerospace material, and subcontracting partner Bertrandt as an expert in development and design services, particularly with regard to detailing aircraft cabin lining components. The ZAL TechCenter provided the perfect space to enable a highly efficient collaboration of all players. Direct face-to-face coordination, rapid implementation of concept ideas using the SFS 3D production system , as well as the additional opportunity to coordinate with the AC manufacturer and topic manager at short notice have ensured a smooth development process in the project.

After intensive analysis phase and assessment sessions with all ACCLAIM partners these concepts were selected for design freeze:

- Stringer snap concept for cabin lining: Instead of integrated fasteners the shaping material of the sidewall is part of the fastening system itself. Reduction of number of necessary fasteners and integration of additional systems and functionalities as air conditioning pipes, secondary and primary insulation, electrical routings would be possible.
- Multifunctional clamping system for cabin lining: Innovative clamping system with integrated light bar and/or OLED panel for passenger information or advertisement. Simplified sidewall and ceiling lining design optimized for fully automated installation and with smart tolerance compensation and adjustment functionality. This concept will be realized as prototypes for testing phase.
- Easy snap fastening solution for xl bin: New design of xl bin based on a sandwich construction with foam core made from the Solvay Tegracore. Smart easy snap fasteners enable simple linear installation movements optimized for automation. Integration of self-adjusting functionality eliminates complex positioning. This concept will be realized as prototypes for testing phase.for testing phase.
- Integrated fastening concept for cargo lining: Due to less requirements for cargo lining we realized simplified sandwich panel design with Solvay TegraCore foam core and with integrated smart bracket solution optimized for automation.This concept will be realized as prototypes for testing phase.

Final results

Until the completion of the project, we will have developed several different concepts optimized for the automated installation of lining parts in the aircraft cabin and in the cargo area. After assessment sessions with all ACCLAIM project partners we will implement selected concepts as functional prototypes and intensively test and develop them together with our partners. Our claim is that finally there are no blocking points that could stand in the way of an aviation qualification and certification.
The CALITO project results will be highlighted by:
- Both the design of the components, the materials and surface finishes used and all the components of the fastening concepts have been selected and developed with focus on automation. However, much attention was paid to the fact that not only a robot can assemble the components efficiently, but also the assembly by a manufacturer has been perfected in ergonomic and economic terms. Disassembling process by a manufacturer in maintenance cases has also been optimized.
- The planned modularized fastening system as well as lining design will save costs in production, standardization and qualification, thus ensuring competitive advantages for the a/c manufacturer. In addition, we pursue a new approach by using existing components in the cabin to integrate them into the fastening solution. This not only saves weight but also installation time, space and cost. The implementation of multifunctional approaches is at the forefront of concept development. For example, an approach for integrating the cabin lighting into the design of the lining and also offering the airline the option of displaying passenger information and/or advertising via the OLED displays. Upon realization, the airlines will be offered completely new opportunities, which will bring with them enormous benefits, since each airline could design such a panel customized to its own needs.
Due to the permanent presence in the ZAL TechCenter in Hamburg, the CALITO project members have the opportunity to present the project results in the best possible way. The ZAL offers the perfect platform to present a/c manufacturer, major tier-1-suppliers and system suppliers with results in the form of movies, face-to-face presentations, exhibitions and mock-ups.