Optimization of Assembly Processes by Heated Air Technology

Transcription

1 CoC Manufacturing Engineering Jens Winkler, Dipl. Ing. Optimization of Assembly Processes by Heated Air Technology

2 Content Introduction and Motivation Tolerance Compensation Curing of Sealant and Shim using Heated Air Summary and Conclusion 2 AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

3 Introduction and Motivation Vertical tail plane (VTP) of an Airbus single aisle aircraft Aerodynamic fairings Rudder Center box and rudder hinge fittings 3

4 Introduction and Motivation Optimum regarding single part manufacturing costs and assembly costs due to tolerance compensation manufacturing costs of CFRP single parts costs of single parts costs of tolerance compensation in assembly assembly costs due to tolerance compensation tolerance of CFRP single parts 4

5 Content Introduction and Motivation Tolerance Compensation Curing of Sealant and Shim using Heated Air Summary and Conclusion 5

6 Tolerance Compensation Two examples of process steps in SA VTP assembly: stress related shimming: Filling of inner gaps for tolerance compensation between CFRP single parts aerodynamic sealing Filling of outer gaps for aerodynamic surface smoothing 6

7 Tolerance Compensation resin-based materials are used for shimming: Liquid materials Long Curing times (depending on temperature and air humidity) polysulfide materials are used for sealing: Liquid materials Long curing times (depending on temperature and air humidity) Liquid shim material 7

8 Tolerance Compensation Current rate increase leads to "bottle necks" in production => time to do something (otherwise duplication of station necessary)! Aerodynamic sealing Station leadtime Shimming stations 8

9 Tolerance Compensation Curing time of the used shimming and sealant material in dependence of the curing temperature (Henkel EA 9394 AB) Shim material room temperatur (Chemetall MC780 B1/2) sealant material room temperatur 9

10 Content Introduction and Motivation Tolerance Compensation Curing of Sealant and Shim using Heated Air Summary and Conclusion 10

11 Use Tab 'Insert - Header & Footer' for Presentation Title - Siglum - Reference Month 2014 Curing of Sealant and Shim using Heated Air Known processes: - Heating lamps - Heating mats Warm air box project Shim heated curing system SA VTP assembly Heated air tubes for aerodynamic sealant Prototype heated air tubes for sealant Page 11

12 Curing of Sealant and Shim using Heated Air - Shimming of gaps - => relatively simple heating system design despite complex assembly situation Prototype heated air system for rapid curing of shim 12

13 Curing of Sealant and Shim using Heated Air - Shimming of gaps - Serial heated air system for rapid curing of shim Control unit 13

14 Curing of Sealant and Shim using Heated Air - Aerodynamic Sealing - Prototype of heated air tube system Heated air tube mounted on a VTP (for test purposes) 14

15 Curing of Sealant and Shim using Heated Air - Aerodynamic Sealing - heated air tube system 15 Heat distribution inside air tube

16 Content Introduction and Motivation Tolerance Compensation Curing of Sealant and Shim using Heated Air Summary and Conclusion 16

17 Summary and Conclusion Curing time of the used shim and sealant material in dependence of the curing temperature (Henkel EA 9394 AB) (Chemetall MC780 B1/2) 2h with heated air => 7h lead time reduction 1-2h with heated air 50 C) => approx. 7 h lead time red. Reliable process Reduction of leadtime Increase of production rate independent of environement shopfloor conditions 17

18 Airbus Operations GmbH. All rights reserved. Confidential and proprietary document. This document and all information contained herein is the sole property of Airbus Operations GmbH. No intellectual property rights are granted by the delivery of this document or the disclosure of its content. This document shall not be reproduced or disclosed to a third party without the express written consent of Airbus Operations GmbH. This document and its content shall not be used for any purpose other than that for which it is supplied. The statements made herein do not constitute an offer. They are based on the mentioned assumptions and are expressed in good faith. Where the supporting grounds for these statements are not shown, Airbus Operations GmbH will be pleased to explain the basis thereof. AIRBUS, its logo, A300, A310, A318, A319, A320, A321, A330, A340, A350, A380, A400M are registered trademarks. Thanks for your attention. Page 18

19 Curing of Sealant and Shim using Heated Air - Aerodynamic Sealing - Serial heated air tube system Connected tube elements 19