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Crafting the future of manufacturing in aviation: A collaborative approach
Motivation, impact, problems addressed
Global aviation accounts for approximately 2.1% of global CO2 emissions and, by 2050, these are expected to be seven to ten times higher than in 1990 due to the increase in air-traffic. To achieve the EU environmental goals by 2050, drastic improvements over current existing aircraft configurations should be implemented in terms of energy efficiency, reduction of the environmental impact, or increase of passenger comfort and safety[1]. In this context, the implementation of novel holistic and circular approaches, leveraging the potential of Artificial Intelligence (AI), Internet of Things (IIoT), digital twins (DT), and automatised robotics solutions will offer the European aeronautics industry and the whole aviation ecosystem the opportunity to maintain their global competitiveness and leadership while moving forward towards climate neutrality.
Thus, in GENEX, the development of a novel holistic end-to-end DT-driven approach is proposed. The main goal is to provide a framework for managing data from all systems and tools for gaining knowledge from overall composite component lifecycle by the integration of (1) innovative in-line process monitoring systems for measuring the manufacturing quality, (2) optimized on-board and on-site sensors for structural health and usage monitoring and remaining useful life prediction, and (3) advanced digital-based tools and methods for improving maintenance and repairing.
By building the new DT framework, GENEX target to deliver digital and eco-efficient manufacturing technologies to ensure flawless entry into service of composite parts as well as to advance further health assessment and MRO processes to allow continuous airworthiness of European aircrafts.
Work performed and main achievements
During the first 6 months of the project, the consortium worked on the definition of specifications of materials, sensors, and systems to be developed and/or used during the project as well as on the definition of a representative use case to demonstrate the manufacturing and monitoring technologies. An aircraft spar structure was selected with this purpose. Furthermore, the agreement on the Architecture Solution Design or the IIoT framework and its functional and non-functional requirements were achieved.
Once the ground of the project was established, parallel work was launched in the three main technological blocks, namely: manufacturing, health and usage monitoring and repair. The main achievements of each block are summarised as follows:
Transversal to all these activities, the design of the DT framework architecture and its synchronization with the data sources has been performed.
Results beyond the state of the art
The main purpose of GENEX is to develop a disruptive holistic approach covering the whole value chain of composite parts, from design, material, and manufacturing to operation, MRO and EOL to support the next-generation digital aircraft transformation. The integration of all these technologies into a single IIoT platform is expected to impact on the disruptive technologies entering into service by 2035. However, to allow for the implementation of such solution, a supportive regulatory and standardisation framework must be developed and supported by future demonstration.
Policy relevant evidence of the Project
At the end of the project, an activity aiming at setting the basis for an extensive and standardised use of the GENEX’s digital-based tools and methods for facilitating repair certification and life-cycle monitoring of repairs, while spreading the range of bonded composite repair applications from secondary structures to primary composite structures of current and future aircrafts is proposed. In this regard, GENEX is working on establishing a collaborative framework with EASA and other relevant stakeholders.