Automated manufacturing of large composites utilizing a process orchestration system

Abstract The benefits of composite materials in aerospace applications are their low weight and high mechanical properties. The downsides are mainly economical due to high material costs and complex manufacturing processes. Since material costs are decreasing slowly the approach of reducing composite part costs is to automate the manufacturing process. In earlier studies an automated preforming process for a rear pressure bulkhead was established. However, the sub processes of cutting, transport, fixation, gripping, draping and quality assurance were triggered manually as well as the storage of process data and quality assurance measurements. In this work the system was further enhanced with the help of a process orchestration system and several databases. The system triggers the individual processes and monitors the status of execution. Process parameters, execution state, sensor data and quality assurance measurements were stored automatically in a database. In this paper the design and execution of the system, interfaces for sub process integration and changes in robot cell configuration and safety are described. With these improvements a monitored, reproducible and automated system could be established and tested on the draping of reinforcement plies for a rear pressure bulkhead.