Subsequent Synchronization of Individual Monitoring Systems for Machining of Aircraft Structures via a Data Collector Using OPC UA

The European aviation industry is facing a groundbreaking phase of upheaval, not just because of the global COVID-19 pandemic, but also as result of increasing efforts to reduce greenhouse gases. Carbon neutral fuels that might be used in the future are more expensive than currently used fossil-based jet fuel. Due to these rising operating costs for airlines, travel costs for passengers might increase significantly. To counteract on this, essential cost optimization of today's aircraft production and aircraft operation are of crucial importance. This paper presents a concept for and the experimental analysis of a superimposed quality assurance based on an automated process monitoring system for machining of large aircraft structures to reduce non-productive secondary times. Based on monitoring systems for evaluation of machined edge quality, process forces and machine path, only a superimposed analysis of all information gives a reliable, automated statement whether the machining has been carried out within tolerances. To achieve this, a data collector, data synchronization and analysis of all available monitoring systems as well as a generic data exchange via the communication protocol OPC UA have been developed.