DELTA - Digitally Enhanced Low-cost Technology for Aerostructures

With a large number of Aircraft orders and an increase in aircraft sales in the future to replace existing aircraft and grow the global airline fleet, Airbus is looking to increase production rates to meet global demand. In parallel, it must drive for lower production costs to remain competitive in the ever increasing global market. This demands production efficiency and flexibility into its own factories and its supply chain.

For Airbus in the UK the focus is on Wing assembly, which is undertaken in the Airbus Factory in Broughton, Wales. Airbus is looking to benefit from the industrial digital revolution to drive reduced production lead-times and costs, whilst improving quality.

The project DELTA - Digitally Enhanced Low-cost Technology for Aerostructures, will develop and test a set of innovative digital assembly technologies that will form part of the aircraft industrial system that will reduce manufacturing costs and improve build quality, whilst enabling adaptability. The aim is to apply these technologies to the existing and future aircraft production systems and are applicable to Airbus and its supply chain.

Some of these technologies being developed are:

* End to end full product life digital data thread by capturing and using data from fabrication, assembly and inspection for upstream and downstream processes.
* Traceability and control on assembly tools through embedded sensors to achieve automatic generation of build records, part/process traceability, tool life estimation and process certification.
* Cost-effective, large-volume metrology using off-the-shelf sensor networks delivering sub-mm geolocation of components and tools as well as allowing real-time monitoring and product certification.
* Human-centered automation using self-aware robots for large-scale cooperative working environment and automated systems to enable repeatability and productivity.
* Intelligent fixtures with integrated automation allowing quick setup, adjustments and removal of components/product from the fixture.

The project will culminate in three demonstrators that will test the technology developed in a representative environment. Each addresses different stages of production, from a digital enabled workstation used to produce small assemblies, through to a technology demonstrator for final wing assembly.

Airbus will partner with Spirit AeroStructures, a primary supplier of structural assemblies and Atlas Copco, who produce manufacturing tools and equipment, enabling these companies to develop their production systems.

Airbus will also engage with research organisations: University of Sheffield, Loughborough University, University College London and The Science and Technology Facilities Council. They will bring academic innovation and research to the project which will be developed for industrial applications.