Digital Assembly for Wing (DAWN) will develop and innovatively apply digital solutions and software tools to demonstrate end-to-end digitalisation for a high production rate aircraft wing assembly and systems installation manufacturing system utilising the Wing of Tomorrow demonstrator wingboxes. The aim is to improve process control, reduce the amount of concessions and inspections, and reduce cycle time by connecting the supply chain, operational workers and support functions to manufacturing assets and assembly processes. Airbus will utilise the results of DAWN to enable a Digital Smart Factory_._

The Smarter Testing project aims to develop a novel testing and certification process for aeronautical structures through the use of an optimised test campaign that will combine virtual and physical tests to provide a step reduction in development lead-time and costs. This will be achieved through the development of a continuous digital thread between virtual and physical tests to increase the use of simulations that supports the whole lifecycle of the product, from early design to type-certification. Simulations will be validated using advanced measurements, quantitative data correlation methods and exploited through data analytics in order to increase credibility and maturity.

This project will reduce vehicle emissions by developing (i) a novel ferrite motor technology for a passenger vehicle application, and (ii) electro-mechanical analysis tools enabling high levels of system integration. Permanent magnet (PM) machines are most common for EV/HEV due to superior efficiency and power density. Rare-earth types are prevalent but suffer from supply chain issues, which can be removed by using ferrite PMs. Initial studies show that significant increase in efficiency and power density is possible, achieving values similar to rare-earth machines. The project will develop analysis tools to optimise system performance - efficiency, NVH, durability, thermal performance, cost, and lightweighting. The structural design of a ferrite motor is challenging, hence this topology will form the basis for the analysis tool development, with results transferable to other topologies. Co-simulation of state of the art electromagnetic, thermal and structural physics will be used to derive novel, faster, yet accurate, reduced order models which capture electro-mechanical interactions as early as possible to improve process efficiency and achieve true system optimisation. Testing of material properties (laminations and magnets) will improve the structural and electromagnetic models. The prototype drivetrain will be tested to demonstrate system interactions and vehicle-level efficiency improvements.

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