Falcon | Fully automated, controlled and versatile system for low cost, high rate and energy efficient production of highly loaded aeronautical structural parts

Summary
The main objective of the FALCON project is the design and manufacturing a versatile tooling system (reduction of tooling by up 40%) for the effective (30% reduction in time, 20% in cost and 20% in energy) and high quality (Aeronautic Quality Standards) production of CFRP frames for different fuselage sections subjected to different level of loads. The FALCON system will include two interrelated components (press-forming tooling and curing tooling) which will be supported through laser tracker technologies and robotic positioning/placement equipment.

The press-forming tooling consists of flexible and adaptable modules designed for different frame geometries that will increase the number and typologies of produced parts. These modules have plug and produce connectors for fast and accurate connexion and individual hydraulic cylinders for a precise controlling of the kinematics of the process. In addition, the cooling/heating system will be also especially designed for improving part quality and process energy efficiency. This cooling/heating is adapted to part geometries through the combination of metallisation technologies with embedded channels and metallic additive 3D technologies applied to trickiest geometries.

In other hand, the curing tooling is designed for including all the required reinforcements into the frame during the curing process independently to the face of the part in which should be placed. This will be achieved by means of positioning tooling which are produced according to each part requirements through the utilisation of high accuracy mechanising equipment.

Finally, the process is continuously controlled and optimised thanks to a real time monitoring system in order to be robust and repeatable. The monitoring system is feed through integrated sensors (strain and temperature gauges) and external equipment (laser tracker) in order to obtain soundness data related to deformation, displacements and temperature at micro and macro levels.
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More information & hyperlinks
Web resources: https://cordis.europa.eu/project/id/754274
Start date: 01-06-2017
End date: 30-11-2019
Total budget - Public funding: 496 250,00 Euro - 496 250,00 Euro
Cordis data

Original description

The main objective of the FALCON project is the design and manufacturing a versatile tooling system (reduction of tooling by up 40%) for the effective (30% reduction in time, 20% in cost and 20% in energy) and high quality (Aeronautic Quality Standards) production of CFRP frames for different fuselage sections subjected to different level of loads. The FALCON system will include two interrelated components (press-forming tooling and curing tooling) which will be supported through laser tracker technologies and robotic positioning/placement equipment.

The press-forming tooling consists of flexible and adaptable modules designed for different frame geometries that will increase the number and typologies of produced parts. These modules have plug and produce connectors for fast and accurate connexion and individual hydraulic cylinders for a precise controlling of the kinematics of the process. In addition, the cooling/heating system will be also especially designed for improving part quality and process energy efficiency. This cooling/heating is adapted to part geometries through the combination of metallisation technologies with embedded channels and metallic additive 3D technologies applied to trickiest geometries.

In other hand, the curing tooling is designed for including all the required reinforcements into the frame during the curing process independently to the face of the part in which should be placed. This will be achieved by means of positioning tooling which are produced according to each part requirements through the utilisation of high accuracy mechanising equipment.

Finally, the process is continuously controlled and optimised thanks to a real time monitoring system in order to be robust and repeatable. The monitoring system is feed through integrated sensors (strain and temperature gauges) and external equipment (laser tracker) in order to obtain soundness data related to deformation, displacements and temperature at micro and macro levels.

Status

CLOSED

Call topic

JTI-CS2-2016-CFP04-LPA-01-23

Update Date

27-10-2022
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Horizon 2020
H2020-EU.3. SOCIETAL CHALLENGES
H2020-EU.3.4. SOCIETAL CHALLENGES - Smart, Green And Integrated Transport
H2020-EU.3.4.5. CLEANSKY2
H2020-EU.3.4.5.1. IADP Large Passenger Aircraft
H2020-CS2-CFP04-2016-02
JTI-CS2-2016-CFP04-LPA-01-23 Low Cost, Smart Tooling for Composites