Case study

Dassault Aviation optimizes
the mounting-assembly of Rafale wings

Industry : Aeronautics

Dassault Aviation uses the Digital-Assisted Operations solution to reduce non-conformities during complex mounting-assembly operations of aero structures, thus minimizing errors risks and improving quality and productivity.

ROI

• Error risk minimized 

• Optimized cycle time

• Ergonomics 

Products used

DiotaPlayer

Projective system

Introduction

Requiring numerous and variable tasks, mounting-assembly operations of aero structures (riveting, drilling, fasteners laying…) present a high complexity, source of errors for operators. In order to help operators to make no mistake, Dassault Aviation uses the Digital-Assisted Operations solution that minimizes errors risks and improves quality and productivity. Focus on the implementation and benefits of this solution in the case of pinning operation on Rafale wings.

Challenges

Before robots start drilling and milling on the Rafale wing, operators need to position different pins at specific locations to ensure the wing is well fixed on the structure. A long preparation process with a risk of error due to the complexity of the task and the changing configuration from one operation to the other. 

In this context, how to efficiently guide operators in the pinning operation and reduce risk of errors?

Solution

Diota implemented its Digital-Assisted Operator solution with a configuration leveraging the capabilities of the projective system.

Digital and interactive work instructions are projected directly on the Rafale wing surface, guiding the operator in the pinning tasks. Reference and position of each pin are visualized on the structure, helping operators to avoid errors. 

Results & Benefits

Quality:

  • Simple identification and reliable execution of the tasks 
  • Error risk reduced

Productivity:

  • Tasks without added value avoided (information search, count, marking…) 
  • Optimized cycle time

Ergonomics:

  • Integrated solution to users workspace
  • Focused operators on their expertise

Building on this success, Dassault Aviation plans to implement the solution on other workspaces.

The Story

A process combining human and robotic interventions

The process of mounting and assembly of Rafale aerofoils implies, among others, successive and complementary interventions of robot and human operator for pinning, drilling and milling operations.

Indeed, to allow the robot to carry out suitable drilling and milling on the wing, beforehand, operators ensure that the sail is well fixed on its framework, without interfering with the robot’s trajectory.

To that end, they put pins with various sizes at specific localization on the sail before each robot’s intervention. The pinning configuration (localization and references of the pins) changes following the phase of the process. 

A high complexity for the operator

The variability of the pinning configuration is a source of complexity for operators. To identify localization and references of the pins for their pose on the wing, operators are constantly comparing the real wing with papers and draw markers with pens, scotch, pieces of paper…

With this method localization and references errors are inevitable, even for the most experienced. 

Therefore, Dassault Aviation was looking for a solution able to help operators to avoid errors, in particular facilitating instruction understanding.

Pinning instructions directly projected on the Rafale wingsassistance

To guide their operators, Dassault Aviation chose to implement Diota’s Digital-Assisted Operations solution through which pinning instructions (references and localizations), directly prepared in Dassault Systems PLM, are comprehensively projected on the sail.

Thereby, operators visualize right in front of them, directly on the sail, the pinning configuration and only have to put the pins following the references and localizations indicated according to the process phase.

Thanks to this solution we know exactly where to carry out the right tasks and we cannot go wrong anymore. This tool is the future.

– Operator, Dassault Aviation

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