Project OPTIMUS

Start date: 2021

End date: 2024

Participants: Applus+ Laboratories serves as a consortium member, coordinated by AIRBUS Operations, S.L., along with contributions from various companies (Frimal Trading S.L., Inventia Kinetics S.L., Metromecanica S.L., Obuu Tech S.L., and Utingal S.L.), research centers (EURECAT), and universities (University of Girona).

Funding: This project has been subsidized by CDTI under the file number MIG-20211010 through the 2021 call of the Missions Science and Innovation program.

Context:

The objective of the OPTIMUS project (Optimization of Automated, Multifunctional, and Sustainable Industrial Technologies) is to develop disruptive technologies aimed at the transformation, digitalization, and competitiveness of the industry.

Upon completion of the project, significant advancements have been achieved, including the development of automated flexible manufacturing processes (multi-operational) for processing multi-material/multifunctional components with embedded sensors; the hybridization of physical and digital environments; collaborative environments between human-robot, robot-robot, and human-machine/productive systems, featuring modeling, simulation, and advanced programming of collaborative scenarios; and technologies for eco-design and sustainable, safe, and efficient industrial production across the entire supply chain.

Objectives:

• Research automation and industrial process simulation technologies for composite materials.
• Investigate technologies based on automated robotics and digital twins.
• Research new verification technologies using machine learning techniques.
• Reuse carbon fiber waste.

These developments represent a major technological leap in the carbon fiber aircraft manufacturing processes.

Methodology:

Applus+ participated with its patented A+ Glide Forming technology. Initially, simulation tools were developed for the A+ Glide Forming technology to analyze its application in female molds, aiming to reduce the number of development trials needed to achieve the desired quality and automation level. These tools were developed by Applus+ with the support of the University of Girona (Grupo Amade).

A new concept of heating blankets for forming with A+ Glide Forming was also developed. The goal was to provide greater deformability to better conform to the contour and radii of the tool without causing material accumulation defects (a critical feature for tools with negative cavities, such as female molds), while ensuring a robust and electrically safe product. Applus+ collaborated with Eurecat in developing this technology.

The engineering team at Applus+ Laboratories built a demonstrator of an automated machine, incorporating the aforementioned technologies and enhancing the previous A+ Glide Forming machine. This machine enables the manufacturing of any type of omega stringer within the project's scope, as well as other geometries with minimal or no hardware modifications.

Experimental testing sequences were conducted at Applus+ Laboratories to validate the developed concepts. A total of 32 demonstrator pieces were manufactured and assembled into a demonstrator panel for further analysis using microsections and structural tests.

Through structural testing, critical design details were validated, as well as the implementation of new types and formats of pre-impregnated composite materials. The boundary conditions applied to the test structures were precisely determined using our Applus Absolute Accurate Methodology. Additionally, our advanced methodology for quantitative comparison of data obtained through Digital Image Correlation and Acoustic Camera measurements was utilized.

For more information about the project, visit: https://research.airbus.com/es/optimus