Design and optimization of flexible fixtures towards effective aircraft assembly

Purpose and goal:

The aim of the project was to continue developing and improve the production of the aircraft at BLACKWING. The aim was to develop better fixtures that facilitate the assembly of components. A goal was to look at how a process to introduce automation in the area of trimming and preparation for joining pre-cured components in composite. A process was developed and tested on a number of different test contours and components which were evaluated with promising results.

Expected results and effects:

Clumsy tools have been replaced with lightweight carbon fiber tools with guides for fixtures. A new fixation system has been developed where steel balls are used as reference points. The new way of working improves the ergonomics of the employees and increases the precision when gluing parts together.

Regarding the trimming, it has been shown that it is possible to trim components using a conventional robot. A process has been developed that RISE will continue to improve, there is great potential in being able to mill composite or core material with a robot. Approach and implementation:

Manufacturing of composites is labor intensive. Wages are approx. three times as high in Sweden as, for example, the Czech Republic. To build an airplane, half the cost is direct wages. It is therefore of the utmost importance that the production time be reduced so that companies that manufacture parts in carbon fiber can remain in Sweden. Automation is therefore an enabler.

RISE and BLACKWING have for many years collaborated aiming to improve production. Thanks to the support from Vinnova, more efficient production methods have been evaluated and concepts for these have been developed.