The aerospace industry requires a lot of skill-based knowledge and is extremely dependent on human-based processes. As the aviation system becomes more complex, the design and training process becomes shorter and shorter, which makes the human-based process more error-prone. may. Therefore, in this highly competitive environment, using the available big data to achieve easier, faster and safer operation, saving time, cost and energy consumption will be a key winning factor.
Even a very advanced aircraft is inseparable from the most basic, oldest and most boring process of riveting. Even a large enterprise like Airbus cannot withdraw from the work of rivets. In order to deliver the aircraft in time, on the traditional aircraft assembly line, workers often need to use more than 1,100 different tools to install 400,000 rivets, bolts or other fasteners, heavy workload and installation due to human factors. Quality is difficult to unify.
Under such circumstances, augmented reality (AR) technology is one of the few solutions that can open up new perspectives in the industry. Mobile, lightweight, and inexpensive AR technology will enable workers to connect and access relevant big data, and access related on-demand. Digitize content to perform everyday tasks.
AR technology has already entered the manufacturing industry.
Airbus is now investigating tools that make this process smarter. The entire system consists of AR equipment and four tools for drilling, measuring, tightening and quality verification, such as using a camera tablet or head-mounted AR glasses. The video image captured by the camera is displayed on the display and superimposed with additional data information, and since the information just appears where it is needed, it provides a quick and economical reference, a technique that is used in aircraft assembly. The rivet step is of great significance.
In a further study, Airbus proposed its Future Factory (FOF) program, in which AR technology and the Internet of Things continue to be applied as basic application technologies to aircraft assembly lines, one of its main purposes. It is to improve the efficiency of workers installing aircraft fasteners. For the “Future Factoryâ€, the head of research and innovation of the Airbus Information and Communication Technology (ICT) department believes that “future factory†is not the same as “automation factoryâ€. The so-called “automation factory†is often made up of a large number of robots. Replacing workers, but the tradition of using robots on a large scale in the precision production process in the aircraft assembly line has probably not been seen in the foreseeable future. Therefore, Airbus needs a solution to achieve “future factoryâ€.
The future factory of the aircraft combined with the virtual and real.
Currently the solution is provided by PTC, which specializes in computer-aided design (CAD) software, product lifecycle management (PLM) software, service management software (SLM), and Internet of Things (IoT) solutions. The customer provides a solution for the "future factory". Mr. Chen Jizhong, technical director of PTC's China Defense and Northern Region, said that this method called CPS “cybo-physical†is a solution that Airbus calls “future factoryâ€, which can help the number of aircraft assembly lines. High-efficiency production with tens of thousands of processes.
The assembly line workshop site (top) and digital factory monitoring based on RFID technology (below).
Based on the concept of “Future Factoryâ€, Airbus has introduced a new business scene of “Rosie the Riveter 2.0â€. The whole plan is specifically to use the use of torque tools with the assistance of AR technology to define the application scenarios of future rivet workers. This technology means that you can use a tablet or smart glasses to scan the surface of the aircraft, identify the hole depth and the correct installation position, and display the specifications and installation requirements of the required rivets, bolts or other fasteners on the screen. Networking is passed to smart tools. The corresponding fasteners are then automatically installed by the tool root data.
"Riveting workers" has a long history.
Although it is difficult to achieve complete automation on the assembly line due to the complexity of the aircraft, this work will still bring revolutionary advancement to the final assembly of the aircraft and improve the accuracy and quality of the assembly. The IoT platform to be built by Airbus is based on PTC's ThingWorx build, integrates PLM/ERP/MES software, workers and tools, has 3D data, standards and work cards for easy access and browsing, and has plug-and-play openness. Platform and role-based user experience. In the future, due to the networking of these tools, the whole process is not only faster, but the reliability of the fasteners after installation is higher than that of manual installation, and a standardized knowledge base of solid parts installation is accumulated. In addition, with this technology, quality inspections can be performed quickly and anytime, and installation errors can be detected and corrected at an early stage, thereby reducing the cost of rework on a large scale.
In addition to rivets and bolts, another major direction of AR technology applications is to assist in the installation of hundreds of kilometers of cables and pipelines on the aircraft. The AR system guides workers step by step how to install water pipes, how to route them, where to go. Connecting cables is 30% faster and 90% more accurate than traditional guided installations. In the picture, Airbus's "Moon" (assembly-oriented authorized augmented reality) system guides the A400M wire installation.
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