Many tasks in the assembly of an aircraft, such as the assembly of the interior components in the Cabin and Cargo areas, are performed manually, in non-ergonomic conditions, and with complex process chains. Recent advanced in robotics enable the completion of tasks between robots and human worker. Thus, the future of assembly of interior components in these areas will benefit with these new technologies. However, the planning of assembly tasks in which a human worker collaborates with a robot in a complex and many times narrow environment is extremely challenging. Many factor have to be analysed including the perception of different types of workers, logistic issues, addressing unexpected situation such as a malfunctioning of a robot, etc. New technologies such as Virtual Reality (VR) allows the study of this problem in a safe and cost effective way. Meanwhile Augmented Reality (AR) allows the inclusion of relevant information obtained from computational sources (such as the state of the robot, or new assembly plans) in their proper real context. The SIMFAL project proposes to develop a new testing tools based on VR to help aircraft manufacturers plan and evaluate different assembly alternatives. The information obtained in the VR simulator will be analysed to obtain the main factors that affect its performance. As a result, the advantages and disadvantages of different strategies of collaboration between the robot and the human will be obtained. This tool will also generate support data for an AR-based assistance tool based. The tool will provide information about the current assembly strategy, the current state of the system (including logistics, the robot, etc.) and maintenance information. This tool will also integrate a tool to help the worker to decide between alternative action plans under unexpected situations. A concept of middleware will be developed during the project to integrate the solution with the current design tools.

The future of aeronautic factories is oriented to manufacture lighter and cost-effective components using greener materials like thermoplastic composites (TPCs). In this sense, given their increasing use, providing with cost-efficient repair methods for their complete integration in production is needed. The main objective of RETPAIR is the development of new high performance, flexible and cost-effective, automated and robotized net-shape technologies to rework and repair TPC parts to be integrated in the manufacturing line. The proposed solutions assure one-side accessibility and are supported by a digital-based methodology to assist the patch design and manufacturing. An induction welding solution for structural damages repair based on pre-manufactured patches will be developed, and two in-situ consolidation solutions for structural and non-structural applications based on automated and robotized layer-by-layer patch in-situ creation: an automated laying (AL) solution based on ATL/AFP technologies (automated tape laying/automated fibre placement) will be investigated for structural and large size repairs, and a 3D printing FFF-based (Fused Filament Fabrication) solution, using both continuous carbon fibre filaments and short fibre filaments will allow to tune patches’ strength for different repair requirements (structural and cosmetic) To assure the thermal and mechanical quality of the repair, the critical process parameters (temperature, pressure, times/rates) will be monitored and controlled. The applicability of the new repair technologies for different damage scenarios (Single Part Level, on Major Component Assembly Level, Final Assembly Line) will be investigated, and the required work of a future industrial implementation for the technologies towards TRL6 will be analyzed RETPAIR developments will result in flexible and accurate repair technologies for high performance and quality solutions, thus collaborating in TPCs growing use in the aeronautic industry

The main objective of MultiFAL project is to design, develop and construct an automated plant system for joining thermoplastic fuselage shells considering three different design use-cases, taking into account the existing assembly plant system at the topic managers’ facility. MultiFAL will consider automation and virtual commissioning technologies in order to bring both an increase in the assembly process performance and a deep understanding of the relevant factors implementing a full size automated plant following a brownfield approach. Different assembly approaches and joining process for different use-cases will be considered, taking into account the currently existing double-sided and limited accessibility for full fuselage sections. As a result, MultiFAL will also facilitate the adaptability of both the robotic machinery and the central control system. Objectives include reducing the commissioning time of automated plant systems up to 20% by the use of virtual commissioning tools, increasing the level of detail for production steps around 25% by implementing interfaces between plant system and production control. Additionally usability and re-utilization of automation systems by development and implementation of standardized interfaces will be enhanced. In the MultiFAL project, lean development approaches will be combined with agile methodologies to develop not only software modules for the simulation but also for the virtual commissioning of the plant system. Moreover, following results will be achieved: • End-to-End design approach exploiting model based system-engineering methodologies • Flexible automated plant system enabling multi use-case coverage