Fraunhofer Institute for Production Technology IPTResearch project "Ready4RampUp"
Development of a digital start-up environment for engine production
In the "Ready4RampUp" project, the Fraunhofer IPT and its partners are developing a digital ramp-up environment for the efficient, resource-saving and flexible production of complex engine components for the aviation industry.
The aim of the sub-project within the Production Launch Center Aviation (PLCA) is to build an infrastructure that combines real machines and systems with an end-to-end digital architecture. A combined environment consisting of several CAx workstations, machining centers and various measuring equipment will be created at the Aachen site. This physical infrastructure will be supplemented by a networked IIoT architecture and digital services based on the existing digital framework "dPart".
As a result, the digital ramp-up environment should enable faster, more resource-efficient and higher-quality production by making better use of technological limits - an important contribution to efficient, environmentally friendly aviation. It is expected that this will increase the efficiency of production, planning and quality assurance by more than 50 percent and save around 25 percent on materials and resources compared to current processes. The project is also laying the foundations for new digital production approaches that can be used in predictive quality assurance or life cycle analyses, for example.
Digitally networked infrastructure for planning, production and quality assurance
The metalworking industry already uses numerous digital tools such as CAD/CAM systems, control systems, production facilities and measuring equipment. However, these systems work largely in isolation from one another, meaning that process data can only be reused to a limited extent and can only be networked with one another at great expense. This is precisely where Ready4RampUp comes in: The aim is to create a digitally networked environment in which planning, production and quality assurance share data and work together.
The underlying and already existing framework dPart combines model-based approaches for mapping complex physical processes with modern IT structures, including edge cloud-based data processing. In this way, dPart creates an end-to-end digital representation of manufacturing processes - from design to planning and processing through to quality assurance. The digital ramp-up environment that is to be created in the Ready4RampUp project not only maps individual aspects of the production of engine components, but also links all data that is also collected in the downstream processes to form a structured, cross-system digital twin.
Complete digital image of the entire process for series production
The focus is on two data concepts: the digital shadow records time and location-related production data that comes directly from machines and sensors. The digital twin expands this database to include geometric and material-related properties of the components and thus provides a complete digital image along the entire production process. In the future, both data concepts will be used not only for the production of individual prototypes in the Fraunhofer IPT's research environment, but also in series production at the participating companies.
By better exploiting technological limits, the complex and safety-critical engine components can be manufactured faster, more resource-efficiently and in higher quality - an important contribution to efficient, environmentally friendly aviation. In addition, the project creates further foundations for new digital production approaches, which in turn can also be used in predictive quality assurance or life cycle analyses.
Finally, the digital start-up environment developed is to be tested and validated as a prototype under real conditions in order to ensure an immediate transfer to industry. To this end, the project partners are developing a concept for scaling and industrial use. In this way, not only aviation companies, but also other sectors with similarly complex production systems should benefit from the results later on.
Close cooperation with industry and research institutions on engine production
The Fraunhofer IPT plays a central role in the project. It is supporting MTU Aero Engines AG with project coordination and is largely responsible for the technical implementation of the digital ramp-up environment. This includes the development of the physical infrastructure on site in Aachen, the design and implementation of the digital twin and the coordination of system integration. The Fraunhofer IPT is also contributing its expertise in standardization and data architecture in order to qualify the project results for use in industry. Ready4RampUp thus makes an important contribution to the technological advancement and sustainability of aviation production in Germany.
Project Consortium
- MTU Aero Engines AG, Munich/Aachen (Project coordinator)
- ModuleWorks GmbH
- Fraunhofer Institute for Production Technology IPT
- Manufacturing Technology Institute, MTI der RWTH Aachen
- Institut für Strahlantriebe und Turbomaschinen, IST der RWTH Aachen
Funding
The research project "Ready4RampUp - Development of a framework for the digital twin in the production of engine components" is funded by the Federal Ministry for Economic Affairs and Energy (BMWE) as part of the aviation research program VI-3.
Funding reference: 20N2206B