Three typical examples of aviation intelligent manufacturing under the new industrial revolution

Abstract : The new industrial revolution represented by German Industry 4.0 and the US Industrial Internet has swept the world. As the world leader in industrial technology development, the aviation industry is actively practicing the concept of intelligent manufacturing, with intelligence as the main line, towards leaner and more flexible. , agile, to people...
Abstract: The new industrial revolution led by German Industry 4.0 and the US Industrial Internet has swept the world. As the world leader in industrial technology development, the aviation industry is actively practicing the concept of intelligent manufacturing, with intelligence as the main line, towards leaner, more flexible, Agile, people-oriented, sustainable and low-cost. In intelligent manufacturing, digitalization, networking, informationization, and automation are further upgraded to model, interconnected, mutual understanding, and autonomy. On the basis of the four upgrades after the upgrade, the European and American aviation industries are showing the world's three typical examples of aviation intelligent manufacturing under the new industrial revolution—adaptive processing, autonomous assembly, and intelligent artificial reinforcement.
        Keywords: Industry 4.0; Industrial Internet; Intelligent Manufacturing; Aviation Industry

Introduction: The new industrial revolution led by German Industry 4.0 and the US Industrial Internet swept the world. As the world leader in industrial technology development, the aviation industry is actively practicing the concept of intelligent manufacturing, with intelligence as the main line, towards leaner, more flexible, Agile, people-oriented, sustainable and low-cost. Intelligent Manufacturing is a process of “Data Perception and Analysis->Information Processing and Push->Knowledge Sharing and Reuse->Smart Creation and Sublimation”. Digitalization, networking, informationization, and automation are further upgraded to: Modeling—Products, Comprehensive modeling of resources and processes; interconnectedness--human-machine-object interconnection, and real-time acquisition of state data; interoperability and mutual knowledge-data interoperability, and any state is known through model-based simulation analysis; autonomy-automation The device can make autonomous decision based on the state information, and the artificial intelligence and human intelligence combine to achieve optimal execution. On the basis of the upgraded four-year-old, European and American aviation manufacturers are showing the world's three typical examples of aviation intelligent manufacturing under the new industrial revolution—adaptive processing, autonomous assembly, and intelligent artificial reinforcement.

I. Aviation intelligent manufacturing under the new industrial revolution
        On March 2, 2016, representatives of the Industry 4.0 platform and the Industrial Internet Alliance reached a broad consensus on cooperation and became a major event in the wave of the new industrial revolution. Industry 4.0 proposed by Germany is a national plan aimed at realizing the transformation and upgrading of the manufacturing industry. It seeks a way out for the future development of many small and medium-sized German manufacturing companies from a service-oriented perspective. GE's industrial Internet is an industrial vision that aims to make full use of industry. The Internet of Things, to achieve more interoperability and mutual understanding, to create more data value through the use of advanced software analysis through distributed intelligent devices.
        1. New industrial revolution in the aviation industry
        From a focus point of view, Industry 4.0 focuses on a detailed model of manufacturing value chains for the next generation; Industrial Internet focuses on cross-domain and interoperability in industrial IoT.
        Specific to the aerospace industry, Industry 4.0 deals with big data in aerospace manufacturing, such as molecular dynamics in aero-engine turbine blade processing, moving the manufacturing industry vertically to the micro level, improving product quality and market efficiency; Industrial Internet processing aviation products Big data in operation, such as turbine blade operation and structural status, integrates manufacturing with a wide range of service industries to improve operational quality and service efficiency.
        2. A New Industrial Revolution Paradigm in Aviation Intelligent Manufacturing
        The German Artificial Intelligence Research Center has proposed three examples of “Industry 4.0” – smart products, intelligent machine tools, and enhanced operators; GE has proposed three examples of industrial Internet – smart devices, advanced analysis, and connections with people. . These examples form the basic paradigm of aerospace intelligence manufacturing.

Figure 1 Example of Industrial Internet and Industry 4.0
        Now, the Industrial Internet is infiltrating into aerospace manufacturing through the Industrial Internet of Things, such as the manufacturing system IoT being built by Airbus, which wirelessly connects smart devices such as measuring devices, riveting devices and tightening devices to central control in aircraft assembly. The station and the factory database automatically deploy mission programs through location information to ensure job quality through real-time analysis and operational control of location and measurement data.
        At the same time, through the interaction between RFID and the cyber physics system in the Industry 4.0 concept, the Airbus factory's production process can realize 3D real-time visualization and become a veritable digital factory, using digital twin technology to predict and monitor bottlenecks and conflicts in the factory. Guaranteed efficient operation.
        In addition, the current augmented reality/virtual reality (AR/VR) technology is both an important supporting technology for “enhanced operators” and an important application basis for “connecting with people”, playing an important role in connecting people and aviation intelligent manufacturing. Character.

Figure 2 Manufacturing system Internet of Things concept

Figure 3 3D real-time visualization of the production process
        Second, the three typical examples of aviation intelligent manufacturing
        Processing and assembly are the core of aerospace manufacturing. The three typical examples of aerospace intelligent manufacturing include: adaptive processing based on big data, lean-oriented autonomous assembly, and human-oriented intelligent artificial enhancement. In these three manufacturing situations, the traditional processing and assembly modes were subverted, the role of the operators was completely changed, and the characteristics of the new industrial revolution were concentrated.
        1. Adaptive processing based on big data
        Adaptive processing based on big data further enables enhanced machine tools with integrated sensors to become intelligent machine tools. The machine tool reads the CAD/CAM data directly from the CNC system through the object-oriented STEP-NC standard, and automatically generates the NC code based on the "super model" containing the part geometry, tool path generation, tool selection and other information. In this process, CAD/CAM/CNC/CMM is seamlessly connected to achieve dynamic process planning.
        As for big data, it can come from products, processes, machine tools, sensors, drives, positioners, NC controllers, machine tools, workpieces, clamping devices, as well as workflow, information carrier (RFID), ERP, PDM, MES and Process model. Knowledge of the process can be obtained by real-time analysis of position, vibration, force, torque, lubricant, shape, temperature and other data. For example, automatic model calibration and model-based automated process control are available for data from sensors and models.

Figure 4 Data from an enhanced machine tool
        Taking the Pratt & Whitney GTF engine as an example, the current process modeling simulation is based on a horizontal process chain, such as “milling-grinding-polishing” of high-pressure turbine blades, and in the future it is focused on the vertical process chain, ie process modeling at different scales. The more microscopic, the larger the amount of data, the big data appears in finite element analysis, micro kinematics and molecular dynamics. For the grinding of the reduction gear, the vertical process chain starts from the grinding particle modeling, and completely reproduces the microscopic mechanism of grinding to obtain the best results. Multi-physics modeling and online process simulation can also be performed through big data and high-performance computing, even for complex processes such as high-pressure gas-electric mechanical spark machining.

Figure 5 Gear grinding tool system modeling
        2. Lean-oriented autonomous assembly
        Lean-oriented autonomous assembly is not simply the use of rigid programming robots, AGV, but under the support of advanced measurement, Internet of Things, mobile technology to fully reflect the lean manufacturing concept, to achieve independent decision-making of these devices. In Boeing's concept of “networking/reconfigurable/autonomous assembly”, the assembly shop integrates wireless communication system, motion control system and intelligent power unit. All kinds of robots can dynamically sense the manufacturing environment and analyze the task situation. Independent cooperation.

Figure 6 "Networked / Reconfigurable / Autonomous Assembly" concept
        Boeing’s “Full Automated Manufacturing Factory” patent demonstrates the concept of a toolless factory and mobile intelligence proposed by the US Air Force’s “Future Factory” program. The shop floor is RFID-coded with six assembly units, drill-and-saw robots, and flexible simple tooling. It is mobile and is usually stored in the waiting area. The central console assigns tasks based on production speed and order, and the AGV controls the work and movement time by the AGV of the transport component. The AGV can autonomously move the robot and tooling between the waiting area and each unit according to the task.
        Autonomy is not unmanned, and the Airbus-certified human-machine collaboration robot confirms this. It can operate autonomously, move independently in the workshop and avoid collisions based on advanced tactile and optical sensing devices. This robot works in the same area as people, and can perform a variety of tasks, helping operators to reduce heavy pressure and monotonous work and inspection tasks.
        3. People-oriented intelligent artificial enhancement
        People are the core assets of the aviation intelligent manufacturing transformation road. Intelligent artificial reinforcement comprehensively utilizes AR/VR technology and combines with industrial Internet of Things, smart wearables and mobile devices to enhance people's ability to access information and use knowledge, making people better. Incorporate in a smart environment to better understand and perform tasks.
        The complex pipelines in the aircraft and the hundreds of kilometers of wires, tens of thousands of brackets and connector plug-ins are the main battlefields for intelligent and artificial reinforcement. The AR system can be guided step by step through a powerful user interface display. The operator performs these tasks accurately and quickly detects the quality of the installation. At present, AR technology is further moving towards aircraft component assembly, and Airbus operators are wearing Google glasses to complete the A330 cabin seat installation.

Figure 7 Smart Tablet Guide A400M Wire Installation
        Airbus is working on a tool that makes the manual drilling process more intelligent. The whole system consists of AR equipment and four tools: drilling, measuring, tightening and quality verification. The core part of the AR equipment includes a high-definition camera embedded in the operator's glasses. Dive into the processor of the operator's clothes and embedded image processing software. The entire system is built on a process environment with visual algorithms. Each tool has a range of functions and is capable of performing automated checks and corrections. The relevant information will be made known to the operator through the AR device to make the best follow-up. action.

Figure 8 AR-based intelligent drilling tool
        The aviation industry needs a lot of skill-based knowledge and is very dependent on human-based processes. The aviation system is becoming more and more complex, and the development and training cycle is getting shorter and shorter. Intelligent artificial reinforcement makes it easier, faster and safer to operate, thus saving time, cost and energy consumption. It is a key winning factor, which is also the European and American aviation industry. A great interpretation of the people-oriented smart manufacturing concept.

Third, the conclusion
        Adaptive processing, autonomous assembly, and intelligent artificial reinforcement in aviation intelligent manufacturing are the most important aspects of big data, lean thinking, and people-oriented concepts. At present, China's aviation industry is neglected and under-built. Under the new industrial revolution, the three typical paradigms of aviation intelligent manufacturing bring about an understanding, that is, to generate and use big data to master the mechanism knowledge from the micro-scale, to maximize the transformation of existing equipment to achieve a win-win situation of lean and intelligent, and to fully play the role of human beings. Enhancing its operational and innovative capabilities will be the three key factors for the future of China's aviation industry to compete with the European and American aviation industry, and it is worthy of our careful consideration. (Author: Liu Yawei)

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