innovations and advanced technologies for the future cabin system
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Innovations and Advanced Technologies
for the future Cabin System
5th European HyperWorks Technology Conference
November 7th-9th, Bonn, Germany
Wolf-Dieter Kuhnla, Diehl Aircabin
© Diehl Aircabin2HTC 2011, Kuhnla
Agenda
1. Diehl Aerosystem at a glance
2. State of the art cabin solutions
3. How to further improve the value added for the customer ?
4. Future Solutions
5. Summary for the future cabin system
© Diehl Aircabin3HTC 2011, Kuhnla
Corporate Division Diehl Aerosystems:
three Units
© Diehl Aircabin4HTC 2011, Kuhnla
Customers and Platforms
Partner to the Aviation Industry
© Diehl Aircabin5HTC 2011, Kuhnla
Product Portfolio
© Diehl Aircabin6HTC 2011, Kuhnla
1961
Laupheim History
… a 50 year history in development and manufacturing
of composite components for aircraft interiors
1960 1970 1980 1990 2000 2010
2003 20052000199919911971
1960
Foundation of
the Site
Laupheim
1970
Foundation of
AIRBUS
Industries
1987
1st time GmbH.
Diversification of
the products
portfolio
1995
„Dolores“
Program leads to
foundation of
Aircabin
2001
Foundation of
AIRBUS
integrated
company
2008
Diehl Aircabin
(Shareholders
Diehl & Thales)
1997
New strategy:
system supplier
with enginee-ring
capacity
2005
Reintegration of
Aircabin into
Airbus
2008
© Diehl Aircabin7HTC 2011, Kuhnla
Product Range
FIT CHECKS /
FAL SUPPORT
ENGINEERING
PROCESS
LEAN DRIVEN
PRODUCTION
CUSTOMER
SUPPORT
INDUSTRIAL
DESIGN
Lining / Floor to Floor Capabilities
Air DuctingCompartments & Monuments
Individual Cabins / Mock-Up
© Diehl Aircabin8HTC 2011, Kuhnla
Agenda
1. Diehl Aerosystem at a glance
2. State of the art cabin solutions
3. How to further improve the value added for the customer ?
4. Future Solutions
5. Summary for the future cabin system
© Diehl Aircabin9HTC 2011, Kuhnla
Picture: Airbus/Boeing/Lufthansa etc.
Cabin Interior State-of-the-art
© Diehl Aircabin10HTC 2011, Kuhnla
Diehl Aircabin on A350XWB
Floor to Floor
FCRC
Crew Rest Compartments Air Distribution
Diehl Aircabin as reliable First Tier Supplier on board of the A350.
FCRC
Dado Panels
Sidewall
PSC/unit
Bins
Ceilings
Doorframe Lining
Light systems
Cabin - Air Distribution -TemperatureControl - Air Extraction
Routing – Integration – Bracketing –Testing
Fwd & Bulk Cargo Compartment Ventilation
Different Ventilation Systems(Cockpit, G&T, FCRC, CRC, IFE, Avionic,Flight Deck and Individual Systems)
CCRC
© Diehl Aircabin11HTC 2011, Kuhnla
Agenda
1. Diehl Aerosystem at a glance
2. State of the art cabin solutions
3. How to further improve the value added for the customer ?
4. Future Solutions
5. Summary for the future cabin system
© Diehl Aircabin12HTC 2011, Kuhnla
Compared with the industrial good aircraft – the cabin is a consumer good
Business model of airlines will be widely spreadRef.: Airbus
How to further improve the customer valued added ?
© Diehl Aircabin13HTC 2011, Kuhnla
How to further improve the customer valued added ?
Future trendsPassenger landscapes is expected to
change considerably due to demographics,
gender and cultural diversity
Flying greenGreen consumption patters will impact
Corporate Social Responsibility(CSR) and
corporate travel policies
Ref.: Airbus, Blue Motion, Trends
New business opportunitiesConnectivity & social web increase the
information of passengers and their
productivity – seeking for better value for
money.
© Diehl Aircabin14HTC 2011, Kuhnla
Agenda
1. Diehl Aerosystem at a glance
2. State of the art cabin solutions
3. How to further improve the value added for the customer ?
4. Future Solutions
5. Summary for the future cabin system
© Diehl Aircabin15HTC 2011, Kuhnla
Division capability for integrated Packages
Division consists of two building blocks. Customers can opt either for
systems or cabin interior individually and for integrated packages.
Division Capabilities = Systems + Cabin Interior
Systems Cabin Interior
Co
ck
pit
Sys
tem
s
Fli
gh
t C
on
tro
l S
ys
tem
s
Avio
nic
s P
latf
orm
s
Uti
lity
Sys
tem
s
Inte
rio
r L
igh
tin
g S
ys
tem
s
Air
Du
cti
ng
Cre
w R
est
Co
mp
art
me
nts
Flo
or-
to-F
loo
r / L
inin
g
VIP
Fu
rnit
ure
Lava
tori
es
(Ga
lle
ys
to
be a
dd
ed
)
interactinteract interact
Sa
fety
& s
up
ply
sys
tem
s
inte
rac
t
inte
rac
t
inte
rac
t
© Diehl Aircabin16HTC 2011, Kuhnla
Future Design Principles
Modulized components
The module principle opens the possibility to
reduce weight. The idea is to combine
meanwhile separate functions in a reduced
amount of single parts.
Topics:
reduced lead time
weight reduction
highly integrated, preassembled cabin
modules
reduced numbers of single parts and
structure interfaces
optional installation of movable bins
Integrated Sensors
Integrated Power und Data Solutions
In line Decoration
Integrated Lighting
In line Modul assembly
© Diehl Aircabin17HTC 2011, Kuhnla
Future Design Principles
© Diehl Aircabin18HTC 2011, Kuhnla
Innovative Concepts
New lightweight design
Development of membrane based lining elements withintegrated lighting, air ventilation and enhanced acousticproperties to replace the well known sandwich structure.
Topics:
Membrane technology
Air distribution
Light integration
Design options
Part production
Picture: Airbus
© Diehl Aircabin19HTC 2011, Kuhnla
Cabin Comfort
Realisation of a displacement cabin air
ventilation and development new insulation
materials for air ducts to increase the cabin
comfort. This will increase the passenger
comfort by the reduction of annoying air
draughts inside the cabin. Further
improvements will be a lead-time reduction.
Topics:
Membrane technology
Homogeneous air distribution
Insulation concepts
Noise Reduction
Innovative Concepts
© Diehl Aircabin20HTC 2011, Kuhnla
Innovative Concepts
Diehl Vision:
The energy self-sufficient cabin
• Separation of essential and
non-essential loads
Approach:
– energy autonomous galley
– intelligent cabin power management
The ACARE obligations and the increasing demand of power consumption are requesting newapproaches and innovations with the aim to achieve a more efficient cabin operation
© Diehl Aircabin21HTC 2011, Kuhnla
System Integration
High production rates for future aircrafts
requires beside the module design the
integration of different components and
functions. In close cooperation with Diehl
Aerospace, DASELL and AoA new
solutions will be developed.
Innovative Concepts
Topics:
In Line Integration
Lightweight sandwichpanels with
integrated electronics (light, sensors,
data solutions and signs)
Rapid Manufacturing
Sealant Materials
In Line Decoration
Powder painted modules with highly
resistant and easy cleanable
surfacesIntegrated Sensors
Integrated Power und Data Solutions
In line Decoration
Integrated Lighting
In line Modul assembly
© Diehl Aircabin22HTC 2011, Kuhnla
Target for all future productdevelopments from Diehl Aircabin isthe continuous consideration of thepossible environmental impacts. Thismeans impact investigations during theproduction and especially during inservice and end of life. Meanwhile alldata basis is available to perform a LifeCycle Assessment (LCA) for ourproducts.
Current LCA Research Topics:
Natural fibre prepregs
Effective Toolheating
Enlargement of the data basis
Continuous weight reductions
Sustainable Design and Production
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
GWP AP EP POCP PE_fossil
Delivery
Facility HVAC
Assembly
Surface structure
Other
Honeycomb core
Prepreg
Crushed Core process
© Diehl Aircabin23HTC 2011, Kuhnla
Process Innovations
Diehl Aircabin succeeded in modifying
cabin interior parts made out of fiber
reinforced plastics, so that electrostatic
coating becomes possible. Furthermore,
scratch resistance, abrasion and cleaning
properties of the powder coating have
been optimized, so that all properties
exceed the normal standard of the liquid
coating or decorative foil.
Advantages
20 % weight reduction reachable
No VOC emissions during the
powder coating process
New decoration possibilities
© Diehl Aircabin24HTC 2011, Kuhnla
Further use of composite materials
Quelle: Entwicklung des Einsatzes von FVK im Flugzeugbau; Dr. W. Dudenhausen; Aspekte der automatisierten Fertigung von Faserverbundstrukturen; Deutsches Zentrum für
Luft- und Raumfahrt, Stuttgart; 2009.
© Diehl Aircabin25HTC 2011, Kuhnla
Weight Optimization
(i.e. recirculation fan bracket A350 ducting)
• Model 1 - basis
– Maximum Stress = 117 MPa
– Lowest frequency = 22,1 Hz
– Bracket weight = 5,40 Kg
• Model 2 - optimized
– Maximum Stress = 280 MPa
– Lowest frequency = 22,5 Hz
– Bracket weight = 2,0 Kg
Gain 3,40 Kg =
63%Ref: Olivier Lo Verso, Diehl Aircabin, Session 12 Aerospace, 9.Nov
A350 (Recirculation Fan) Bracket Optimization
© Diehl Aircabin26HTC 2011, Kuhnla
Agenda
1. Diehl Aerosystem at a glance
2. State of the art cabin solutions
3. How to further improve the value added for the customer ?
4. Future Solutions
5. Summary for future cabin systems
© Diehl Aircabin27HTC 2011, Kuhnla
Summary for future cabin systems
• High volatility and bias of customer
demands
• Added value in
- further integration of additional functions
- modularization for independent change
from aircraft
• Energy-self-sufficient and ECO-efficient
• Inline with OEM supplier development
Ref.: Boeing,Airbus
© Diehl Aircabin28HTC 2011, Kuhnla
Passion for Aviation
© Diehl Aircabin29HTC 2011, Kuhnla
Thank you …
… your questions, please.
Wolf-Dieter Kuhnla
Diehl Aircabin GmbH
Am Flugplatz
88471 Laupheim
Germany
Fon: + 49 7392 703 3150
E-Mail: [email protected]
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