Robot preformed CFRP rear pressure bulkhead as an example for highly automated manufacturing of large carbon fibre aircraft parts

We present our approach to an automated solution for high quantity manufacturing of a Rear Pressure Bulkhead from carbon fibre reinforced plastics in one overall process using several robots in a single robotic cell. The process contains sub-processes such as cutting and delivering material, preforming cut-pieces and in-situ non-destructive testing. The focus is set on the sub-process of preforming, where many different plies (structure and reinforcing) are identified, picked-up, draped, transferred and laid-up into the mould. Online sensors as well as subsequent measurements of fibre angles and the exact position of the placed plies provide data for process monitoring and quality assurance documentation. The paper presents the design of the overall process and its possible implementation in factory environment as well as the latest stand of the development. We also discuss the comparison between our solution and the current manual manufacturing process.