Abstract The digital twin (DT) concept, value-adding connecting the real and digital world, has been a rising trend in recent years, while the implementation and observation of challenges are still subject to research. Implementations of holistic Digital Twins of tangible and intangible assets of complex products or processes are often ideal-theoretic; instead, only subsystems and processes are replicated, which digital representations serve specific, meaningful applications. Specifically, with its distinct characteristics, the aviation industry and its production show various future application scenarios, which we use case-driven outline in this work. Therefore, we first summarize common, industry-neutral challenges of implementing Digital Twins and give an overview of aircraft production characteristics. Then, we will outline different fields of utilizing the Digital Twin concept and highlight integrational, organizational, and compliance-related challenges as well as opportunities in the context of aircraft production and Maintenance, Repair, and Overhaul (MRO). The use cases are located at different aircraft life cycle phases, from production system development, production supplying logistics, and Quality Assurance (QA) up to retrofit. 

Digital twins in aircraft production and MRO: challenges and opportunities

The article explores methods for detecting and tracking air targets in radar with an artificially reduced radar cross-section (RCS). A technique for control the radar antenna system using an adaptive method is presented, which is based on adapting the system to the conditions of information uncertainty due to fluctuations in the excitation signal of the radar target's radar-absorbing coating. Known methods of radar aircraft (active and passive, which do not take into account the structure of the coating of the aircraft) do not allow obtaining information about an air target with an artificially reduced RCS. The main contribution of this article is the development of radar and control methods based on the resonant frequency-phase interaction of the microwave electromagnetic field with the crystal structure of the radar absorbing coating of the aircraft. The stages of antenna system control based on the "frequency-phase detection method", "passive-active" tracking method, and "adaptive method" of antenna control have been studied. To test the proposed methods, an experiment was conducted to determine the transient process in the control system under conditions of information uncertainty. As a result of the experiment, the probability of tracking the target is increased by 14-19%. The findings will be useful for developers of radar and control systems for modern air facilities with an artificially reduced RCS.

Methodology for the Development of Radar Control Systems for Flying Targets with an Artificially Reduced RCS

Contrary to classic document-based engineering, model-based systems engineering (MBSE) is an approach that focuses on the definition of engineering artifacts as formal information models. In complex engineering projects, such as the design of automated aircraft production systems, MBSE is a means to control complexity and support interdisciplinary collaboration. To implement MBSE in industry, ready-to-use modeling workflows that guide and support system engineers are required to minimize overhead workload. System Modeling Language (SysML), a general purpose modeling language derived from Unified Modeling Language (UML), is widely accepted as the standard modeling language in MBSE and therefore supported by industry-leading software. In this paper, we propose a SysML-based modeling workflow that supports the conceptual engineering of automated production systems. The system engineer is guided through a multi-layer modeling workflow, which is based on the Software Platform Embedded Systems (SPES) method. The modeling workflow is validated by applying it in the engineering of an automated production system that is used in aircraft manufacturing.

MBSE Modeling Workflow for the Development of Automated Aircraft Production Systems

In the aircraft manufacturing industry, the process plans created for tasks such as automated drilling and riveting are lengthy and require prior testing and validation using Virtual Commissioning (VC), which can be time-consuming. The introduction of a new process plan requires the complete plan to be tested and validated again, exacerbating the challenge of testing and validating several plans or sequences in advance using VC. This research paper proposes using process mining and footprints conformance checking to reduce VC time for robotic systems. By integrating these techniques, differences in process plans can be detected, and only the new sequences or changes from an old to a new process plan need to be tested, significantly reducing the time needed to perform VC. This research implies that the developed approach can improve the efficiency of VC and ultimately enhance the performance of automated manufacturing systems. 

Optimizing Virtual Commissioning of a Robotic System using Process Mining and Footprints Conformance Checking

A key aspect in creating models of production systems with the use of model-based systems engineering (MBSE) lies in the description of system functions. These functions should be described in a clear and standardized manner.The VDI/VDE 3682 standard for Formalised Process Description (FPD) provides a simple and easily understandable representation of processes. These processes can be conceptualized as functions within the system model, making the FPD particularly well-suited for the standardized representation of the required functions. Hence, this contribution focuses on the development of a Domain-Specific Modeling Language (DSML) that facilitates the integration of VDI/VDE 3682 into the Systems Modeling Language (SysML). The presented approach not only extends classical SysML with domain-specific requirements but also facilitates model verification through constraints modeled in Object Constraint Language (OCL). Additionally, it enables automatic serialization of process descriptions into the Extensible Markup Language (XML) using the Velocity Template Language (VTL). This serialization enables the use of process modeling in applications outside of MBSE. The approach was validated using an collar screwing use case in the major component assembly in aircraft production. 

A SysML Profile for the Standardized Description of Processes during System Development

Civil Aircraft development and production are facing significant challenges in future. On the one hand, the flight-path to carbon neutral aviation, like using liquid hydrogen, will require game changing technologies. Simultaneously, competition, especially on the single aisle market, is evolving fast and puts pressure on market shares and margins. The necessity of an adaptable and highly efficient production becomes more evident than ever. One contribution to achieve this goal is the research project “Intelligent Modular Robotics and Integrated Production System Design for Aircraft Manufacturing” (iMOD). Namely, it will analyze challenges regarding (1) an integrated and Digital Twin-based system design approach, (2) flexible and modular robotics to support workers with unergonomic tasks and (3) a flexible intralogistics based on Automated Guided Vehicles (AGVs). Those three aspects will be integrated into an approach that uses semantic technologies to connect the different components across different levels of functionality and different life cycle phases. 

Challenges in Automated Commercial Aircraft Production

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Challenges in Automated Commercial Aircraft Production