Development of a smart production line for large CFRP box structures

In the aerospace industry, lightweight composite constructions are used more and more during the last decades. Novel airplanes like the Airbus A350 or the Boeing 787 contain a high share of composite material. The production costs for composite structures are currently on a high cost level, and it is required to decrease these. With the increased energy costs, the demand for energy efficient aircrafts is rising. For the next generation of aircrafts, lighter structures compared to the state of art are required. Highly integrated composite structures, produced in a co-curing process, offer the highest technical performance level and no additional fastener elements are required to improve the aerodynamic. Currently, there is a trade-off between two requirements. This research is focused on the question if it is possible to produce highly integrated CFRP structures on a cost competitive basis to the state of the art process. In this thesis, an industrial production line for highly integrated box structures has been developed. This concept has been validated with production tests. All results are integrated into a simulation model. The simulation is linked to parameters, which can be updated easily. Using this simulation model, a comparison of the developed concept to the state of the art manufacturing is done. The additional manufacturing effort for highly integrated structures can be evaluated. An assembly line based on a new build philosophy is then created. The advantage of a highly integrated structure in the assembly is analysed, and an improved assembly concept is developed. A digital factory simulation model is created for this developed concept. The simulation model is linked to parameter to allow an easy update of the model. The results are compared to the current state of the art assembly line to evaluate the saving potential in the assembly due to the high integration level of the single parts and the improved assembly line. Having the investigation results of assembly and manufacturing allows comparing the new concept-designed production line with that of the current state of the art production. The analysis results suggest that the developed combined assembly and manufacturing concept provide a potential cost saving of 12.5% in comparison to the state of the art production of composite box structures.