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New end-to-end digital framework for optimized manufacturing and maintenance of next generation aircraft composite structures

PROJECTS
Funding
European
European Union
Duration
-
Geo-spatial type
Other
Total project cost
€5 691 452
EU Contribution
€5 691 451
Project Acronym
GENEX
STRIA Roadmaps
Vehicle design and manufacturing (VDM)
Transport mode
Airborne icon
Transport policies
Safety/Security
Transport sectors
Passenger transport,
Freight transport

Overview

Call for proposal
HORIZON-CL5-2021-D5-01
Link to CORDIS
Background & Policy context

Composite materials are flying high and are dropping weight – in the aviation industry, that is. They provide structural strength but are light in weight.

Objectives

The EU-funded GENEX project will develop a novel end-to-end digital twin-driven framework based on enhanced computational models. These models incorporate the interdisciplinary knowledge of aircraft components and manufacturing/repair processes to support its optimization. Furthermore, they enable the development of health and usage monitoring and management system during continuous operation of aircraft to ensure aircraft safety and airworthiness. The digital twin-driven framework will be implemented into a common industrial internet of things (IIoT) platform to integrate the developed models.

GENEX project aims at developing a novel end-to-end digital twin-driven framework based on enhanced computational models, which embed the interdisciplinary knowledge of the aircraft components and the manufacturing/repairing processes, to support the optimized manufacturing of composites parts, enable the continuous operation of aircrafts and improve the composites repairing processes for ensuring aircraft´s safety and airworthiness.

Methodology

First, automated ATL process coupled with THz-based in-process monitoring together with hybrid-twin simulation methods will be developed for eco-efficient and advance manufacturing of innovative reprocessable-repairable-recyclable (3R)-resin-and state-of-the-art thermoplastic composites. Second, innovative data- and physics-based machine learning algorithms for damage detection and location combined with advanced high-performance computing (HPC)-based multi-physics and artificial intelligent-powered digital twin tools for fatigue life prediction, will be implemented to transform information from optimized onboard piezoresistive sensors data networks interfaced with low-power wireless communication platform to health and usage assessment and prognosis. Third, augmented reality tools together with novel laser-assisted methods for surface cleaning and monitoring , smart monitoring and in-situ tailored heating of composite repair blankets will be further developed to provide additional assistance in manual scarf repair operations , increasing reliability of repair process, while supporting the modification and virtual certification of MRO practices. Thus, a novel digital twin-driven framework will be implemented into a common IIoT platform to integrate the developed models and data acquired, providing bidirectional dataflow, and enabling the implementation of a holistic and comprehensive data management methodology ensuring to adequately create, capture, share, and reuse knowledge along the entire aircraft lifecycle.

Funding

Specific funding programme
HORIZON.2.5 - Climate, Energy and Mobility
HORIZON.2.5.7 - Clean, Safe and Accessible Transport and Mobility
HORIZON.2.5.6 - Industrial Competitiveness in Transport
Other Programme
HORIZON-CL5-2021-D5-01-06 Next generation digital aircraft transformation in design, manufacturing, integration and maintenance

Partners

Lead Organisation
Organisation
INSTITUTO TECNOLOGICO DE ARAGON
Address
MARIA DE LUNA 8, 50018 ZARAGOZA, Spain
EU Contribution
€816 875
Partner Organisations
Organisation
ECOLE NATIONALE SUPERIEURE D'ARTS ET METIERS
Address
BOULEVARD DE L HOPITAL 151, 75013 PARIS, France
EU Contribution
€243 746
Organisation
AKADEMIA GORNICZO-HUTNICZA IM. STANISLAWA STASZICA W KRAKOWIE
Address
AL ADAMA MICKIEWICZA 30, 30-059 KRAKOW, Poland
Organisation website
EU Contribution
€211 050
Organisation
KUNGLIGA TEKNISKA HOEGSKOLAN
Address
BRINELLVAGEN 8, 100 44 STOCKHOLM, Sweden
Organisation website
EU Contribution
€374 405
Organisation
Gmi Aero
Address
13 RUE GEORGES AURIC CAP 19, 75019 PARIS, France
Organisation website
EU Contribution
€371 250
Organisation
ASOCIACION DE INVESTIGACION METALURGICA DEL NOROESTE
Address
CALLE RELVA TORNEIROS 27A, 36410 PORRINO, Spain
Organisation website
EU Contribution
€719 375
Organisation
INNOVATION IN RESEARCH & ENGINEERING SOLUTIONS
Address
RUE KONINGIN ASTRIDLAAN 59B/9, 1780 WEMMEL, Belgium
EU Contribution
€320 000
Organisation
AERNNOVA ENGINEERING DIVISION SAU
Address
CALLE LEONARDO DA VINCI MINANO SN, 01510 VITORIA GASTEIZ, Spain
Organisation website
EU Contribution
€347 050
Organisation
DEUTSCHES ZENTRUM FUR LUFT - UND RAUMFAHRT EV
Address
LINDER HOHE, 51147 KOLN, Germany
EU Contribution
€498 908
Organisation
EASN TECHNOLOGY INNOVATION SERVICES BVBA
Address
TERWEIDENSTRAAT 28, 3440 BUDINGEN, Belgium
EU Contribution
€150 000
Organisation
SMART MATERIAL GMBH
Address
LOBTAUER STRASSE 69, 01159 DRESDEN, Germany
Organisation website
EU Contribution
€309 625
Organisation
RESEARCH CENTER FOR NON DESTRUCTIVE TESTING GMBH
Address
ALTENBERGER STRASSE 69 SCIENCE PARK 2/2 OG, 4040 LINZ, Austria
EU Contribution
€407 500
Organisation
FUNDACION CIDETEC
Address
PASEO MIRAMON 196 PARQUE TECNOLOGICO DE MIRAMON, 20014 SAN SEBASTIAN, Spain
Organisation website
EU Contribution
€365 000
Organisation
ALTRAN INNOVACION SL
Address
AVENIDA DIAGONAL 199, 08018 BARCELONA, Spain
EU Contribution
€556 667

Technologies

Technology Theme
Aircraft design and manufacturing
Technology
Aircraft design model
Development phase
Research/Invention

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