innovations and advanced technologies for the future cabin system

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


Corporate Division Diehl Aerosystems:

three Units


Customers and Platforms

Partner to the Aviation Industry


Product Portfolio


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


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


Agenda




4. Future Solutions



Picture: Airbus/Boeing/Lufthansa etc.

Cabin Interior State-of-the-art


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


Agenda




4. Future Solutions



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 ?


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.


Agenda




4. Future Solutions



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


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


Future Design Principles


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


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


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


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


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


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


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.


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


Agenda




4. Future Solutions

5. Summary for future cabin systems


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


Passion for Aviation


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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