research projects

RESEARCH PROJECTS AS THE BASIS FOR INNOVATIVE TECHNOLOGIES AND PRODUCTS

As a global technology leader, FFT is involved in a large number of national and international research projects, where it also takes the lead in collaborative research. Together with industrial and academic project partners, the foundations for future innovative technologies and products are developed here. FFT's research and development department is represented at several locations throughout Germany. In addition to the FFT locations in Fulda, Bremen and Hamburg, FFT is also present in various technology centres, including the Centre for Applied Aeronautics Research (ZAL) Hamburg, the Center for Eco-efficient Materials and Technologies (ECOMAT) Bremen, the Technology Centre Nordenham (TZN), the Research Centre CFK North Stade and the planned Innovation and Technology Centre (ITZ) North for hydrogen technologies.

Archive

Already completed research projects can be found in the archive.

To archive

Project

 

Aton

Metal hull technologies ecologically sustainable

The aim of the project is to develop ecologically sustainable metal technologies and new joining processes for the joining of aircraft fuselage structures. For this purpose, digitalisation solutions are to be integrated sensibly into the production and manufacturing process. Among other things, this should reduce the amount of resources required. In addition, the bonding of metal structures is to be implemented with a high degree of automation while achieving a high level of technical maturity and high economic efficiency. Furthermore, the weight of the structure is to be reduced, which has a direct influence on fuel consumption and thus also on the CO2 emissions of the aircraft.

Project duration: 2019 to 2023

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Project

 

DHiiP

DFP TRAY, HOT TOOL INTEGRATION & INMOULD PRIMERS FOR FUTURE WING SHELLS

The aim of the research project is to develop suitable process steps for the production of repeatably reproducible and cost-effective stringer-stiffened wing shells in the RTM process. At the same time, this process is to be digitised for the production of wing shells for short and medium-haul aircraft of the next generation.

Project duration : 2020 until 2023

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Project

 

MultiFAL

Multifunctional automation system for Fuselage Assembly Line

The main objective of the MultiFAL research project is to develop and prototype a system in which thermoplastic aircraft fuselage shells are welded fully automatically. The focus will be on robot-controlled production and central monitoring. The virtual commissioning should save up to 20 % commissioning time.

Project duration: 2019 until 2022

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Project

 

SeMoSys

Section assembly and system installation

The overall objective of the project is the development of automation solutions for the assembly of various aircraft fuselage sections. The focus of the developments is on a high production cadence as well as flexible and automated production technologies. For the system pre-installation, human-robot collaborations (HRC) for force-guided assembly operations are being tested. Safety and ergonomic aspects are being considered. A digital plant planning tool is also being developed for the planning of future production plants, with which customers and suppliers can intuitively make adjustments in the plant planning. In addition, the new tool will include a digital learning world with a 3D environment for training purposes for workers.

Project duration: 2021 until 2024

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Project

 

Unifix

Universal mobile component clamping and fixing device for the processing of fiber composite structures

The aim of this research project is to realise a fully integrated test facility for mobile component production on a 1:1 scale. This will be implemented by combining technological building blocks to meet the application specifications for innovative processing of large composite structures under the overriding requirement of flexibility and agility.

Project duration: 2018 until 2021

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Project

 

WISDOM

Development of a modular and hybrid integration platform for the analysis and validation of highly dynamic flight control systems

Within the joint project WISDOM, a validation platform is being developed and built with which future, highly dynamic and intelligent flight control systems for elongated airfoils can be investigated in a hybrid test environment. Innovative and safety-critical functions such as active load reduction or flutter suppression will be implemented and analysed. The aim of the project is to evaluate the new systems in terms of their interaction and performance and thus draw conclusions about the maturity of the technology.

Project duration: 2022 to 2025

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Project

 

IntelWi

DECENTRALISED AND AUTONOMOUS MEASUREMENT AND CONTROL MODULES FOR A SMART WING

In the IntelWi project, an intelligent, highly stretched, flexible and ultra-efficient wing is being investigated that is capable of recording environmental parameters and information on its condition by means of intelligent sensor technology. In combination with flight control systems, external influences such as gusts and manoeuvre loads should be able to be mitigated independently and actively. To optimise and shorten the development process, digital design chains from the field of MBSE will also be used and further developed within the project.

Project duration: 2020 to 2023

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Project

 

IoT4Test

Efficient test environments through the use of IoT

The funding project IoT4Test aims to realise a scalable, mobile and wirelessly communicating infrastructure for test data acquisition. In order to be able to adapt the IoT4Test system to a variety of different test and measurement tasks, the sensor technology and software in particular must be adapted to the corresponding requirements. Among other things, this process is to be realised by means of a cross-module operating system. In addition, the automatic creation of test documentation and the archiving of test data as well as human-machine interaction for visualisation and control through the use of mobile devices are further focal points of the IoT4Test approach.

Project duration: 2021 to 2022

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PLATEAU

Development of innovative system and avionics test technologies using the Liebherr FCS platform as an example

In the PLATEAU project, suitable methods that enable the testing and verification process for embedded systems in avionics in general and for flight control system platforms in particular are being investigated.  In addition to automation aspects, the focus is on two scenarios, distributed testing for locally distributed system parts and modern test methods in connection with the verification of a lean flight control platform. The aim of the project is to further develop and apply modern test processes and methods to increase the efficiency of the certification process and to shorten integration and development times.

Project duration: 2018 to 2022

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Optimum

Economical car door In MUlti material construction

The aim of this research project is to develop a car door in multi-material lightweight construction as well as the associated manufacturing processes and construction methods. Since the lightweight construction of doors plays a significant role in reducing vehicle weight, the central component is a glass-fibre reinforced inner door shell with a high level of functional integration. The car door must fulfil the static, dynamic and thermal load cases as well as the package requirements of common vehicle doors available on the market, whereby the stable connection between the composite material and the already KLT-coated metal component is crucial. FFT makes a significant contribution here in the field of roller hemming and automation technology.

Project duration: 2019 bis 2022

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Project

 

H2Giga – QT 4.2 FertiRob

Series production of hydrogen electrolysers - QT 4.2 Manufacturing and robotics

The "H2Giga - QT 4.2 FertiRob" project is a research project spanning the FFT sites in Fulda, Bremen and Hamburg. The aim is to develop and prototype a modular production plant for hydrogen electrolysers in the gigawatt range. The cross-sectional topic QT 4.2 - FertiRob deals with automation solutions for the various sub-problems in the production, assembly and disassembly of stacks and electrolysers. To ensure efficient and flexible applicability and easy scalability, a modular automation system is being developed. The aim is to link optimised manufacturing technologies and digital solutions into a complete system to ensure high-quality electrolyser production.

Project duration: 2021 bis 2025

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Contact

KUNO JANDAUREK

Head of Research & Development

FFT Produktionssysteme GmbH & Co. KG
Airbus-Allee 2
28199 Bremen

Tel.: +49 421 3770-8812
Mobil: +49 151 2625 4005
E-Mail: kuno.jandaurek(at)fft.de

JOACHIM SCHELLER

Manager Business & Technology Development

c/o ZAL TechCenter
Hein-Saß-Weg 22
21129 Hamburg

Mobil: +49 171 1018 641
E-Mail: joachim.scheller(at)fft.de

TOBIAS HOHMANN

Research & Development Coordinator Fulda 

FFT Produktionssysteme GmbH & Co. KG
Schleyerstraße 1
36041 Fulda

Tel.: +49 (661) 2926-4112   
Mobil: +49 (151) 68862576    
E-Mail: tobias.hohmann(at)fft.de