Optimization of Assembly Processes by Heated - CFK

CFK Convenetion 2014
CoC Manufacturing Engineering
Jens Winkler, Dipl. Ing.
Optimization of
Assembly Processes
by
Heated Air Technology
CFK Convenetion 2014
Content
• Introduction and Motivation
• Tolerance Compensation
• Curing of Sealant and Shim using Heated Air
• Summary and Conclusion
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CFK Convenetion 2014
Introduction and Motivation
•Vertical tail plane (VTP) of an Airbus single aisle aircraft
Aerodynamic
fairings
Rudder
Center box and rudder hinge fittings
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CFK Convenetion 2014
Introduction and Motivation
costs of tolerance
compensation in
assembly
costs of single
parts
tolerance of CFRP single parts
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assembly costs
due to tolerance compensation
manufacturing costs
of CFRP single parts
Optimum regarding single part manufacturing costs and
assembly costs due to tolerance compensation
CFK Convenetion 2014
Content
• Introduction and Motivation
• Tolerance Compensation
• Curing of Sealant and Shim using Heated Air
• Summary and Conclusion
5
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
CFK Convenetion 2014
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
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CFK Convenetion 2014
Tolerance Compensation
resin-based materials are used for
shimming:
polysulfide materials are used for sealing:
Liquid materials
Liquid materials
Long Curing times (depending on
Long curing times (depending on
temperature and air humidity)
Liquid shim material
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temperature and air humidity)
CFK Convenetion 2014
Tolerance Compensation
Current rate increase leads to "bottle necks" in production
=> time to do something (otherwise duplication of station necessary)!
Station leadtime
Aerodynamic
sealing
Shimming
stations
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© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
CFK Convenetion 2014
Tolerance Compensation
Curing time of the used shimming and sealant material in dependence of the
curing temperature
(Henkel EA 9394 AB)
Shim material
9h @ room temperatur
(Chemetall MC780 B1/2)
sealant material
8h @ room temperatur
9
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
CFK Convenetion 2014
Content
• Introduction and Motivation
• Tolerance Compensation
• Curing of Sealant and Shim using Heated Air
• Summary and Conclusion
10
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
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Month 2014
Curing of Sealant and Shim using Heated Air
Known processes:
- Heating lamps
- Heating mats
Heated air tubes for
aerodynamic sealant
Page 11
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Warm air box project
Shim heated curing system
SA VTP assembly
Prototype heated air
tubes for sealant
CFK Convenetion 2014
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
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© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
CFK Convenetion 2014
Curing of Sealant and Shim using Heated Air
- Shimming of gaps •Serial heated air system for rapid curing of shim
Control unit
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CFK Convenetion 2014
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)
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© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
CFK Convenetion 2014
Curing of Sealant and Shim using Heated Air
- Aerodynamic Sealing •heated air tube system
Heat distribution
inside air tube
15
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
CFK Convenetion 2014
Content
• Introduction and Motivation
• Tolerance Compensation
• Curing of Sealant and Shim using Heated Air
• Summary and Conclusion
16
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
CFK Convenetion 2014
Summary and Conclusion
•Curing time of the used shim and sealant material in dependence of the
curing temperature
(Chemetall MC780 B1/2)
(Henkel EA 9394 AB)
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
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CFK Convenetion 2014
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Thanks for your attention.
Page 18
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CFK Convenetion 2014
Curing of Sealant and Shim using Heated Air
- Aerodynamic Sealing •Serial heated air tube system
Connected tube
elements
19
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