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Innovations and Advanced Technologies for the future Cabin System

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  • 1. Innovations and Advanced Technologiesfor the future Cabin System5th European HyperWorks Technology ConferenceNovember 7th-9th, Bonn, GermanyWolf-Dieter Kuhnla, Diehl Aircabin
  • 2. 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 systemHTC 2011, Kuhnla 2 © Diehl Aircabin
  • 3. Corporate Division Diehl Aerosystems:three UnitsHTC 2011, Kuhnla 3 © Diehl Aircabin
  • 4. Customers and Platforms Partner to the Aviation IndustryHTC 2011, Kuhnla 4 © Diehl Aircabin
  • 5. Product PortfolioHTC 2011, Kuhnla 5 © Diehl Aircabin
  • 6. Laupheim History 1961 1971 1991 1999 2000 2003 2005 2008 1997 2005 New strategy: Reintegration of system supplier Aircabin into with enginee-ring Airbus capacity 1960 1970 1987 1995 2001 2008 Foundation of Foundation of 1st time GmbH. „Dolores“ Foundation of Diehl Aircabin the Site AIRBUS Diversification of Program leads to AIRBUS (Shareholders Laupheim Industries the products foundation of integrated Diehl & Thales) portfolio Aircabin company 1960 1970 1980 1990 2000 2010 … a 50 year history in development and manufacturing of composite components for aircraft interiorsHTC 2011, Kuhnla 6 © Diehl Aircabin
  • 7. Product Range Lining / Floor to Floor Capabilities Individual Cabins / Mock-Up Compartments & Monuments Air Ducting INDUSTRIAL ENGINEERING LEAN DRIVEN FIT CHECKS / CUSTOMER DESIGN PROCESS PRODUCTION FAL SUPPORT SUPPORTHTC 2011, Kuhnla 7 © Diehl Aircabin
  • 8. 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 systemHTC 2011, Kuhnla 8 © Diehl Aircabin
  • 9. Cabin Interior State-of-the-art Picture: Airbus/Boeing/Lufthansa etc.HTC 2011, Kuhnla 9 © Diehl Aircabin
  • 10. Diehl Aircabin on A350XWB FCRC Floor to Floor Crew Rest Compartments Air Distribution Dado Panels Cabin - Air Distribution -Temperature Control - Air Extraction Sidewall Routing – Integration – Bracketing – PSC/unit Testing Bins FCRC CCRC Fwd & Bulk Cargo Compartment Ventilation Ceilings Different Ventilation Systems Doorframe Lining (Cockpit, G&T, FCRC, CRC, IFE, Avionic, Flight Deck and Individual Systems) Light systems Diehl Aircabin as reliable First Tier Supplier on board of the A350.HTC 2011, Kuhnla 10 © Diehl Aircabin
  • 11. 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 systemHTC 2011, Kuhnla 11 © Diehl Aircabin
  • 12. How to further improve the customer valued added ? Compared with the industrial good aircraft – the cabin is a consumer good Business model of airlines will be widely spread Ref.: Airbus HTC 2011, Kuhnla 12 © Diehl Aircabin
  • 13. How to further improve the customer valued added ? Future trends Passenger landscapes is expected to change considerably due to demographics, gender and cultural diversity Flying green Green consumption patters will impact Corporate Social Responsibility(CSR) and corporate travel policies New business opportunities Connectivity & social web increase the information of passengers and their productivity – seeking for better value for money. Ref.: Airbus, Blue Motion, Trends HTC 2011, Kuhnla 13 © Diehl Aircabin
  • 14. 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 systemHTC 2011, Kuhnla 14 © Diehl Aircabin
  • 15. Division Capabilities = Systems + Cabin Interior interact Division capability for integrated Packages interact interact Systems Cabin Interior Crew Rest Compartments Interior Lighting Systems Safety & supply systems Flight Control Systems Floor-to-Floor / Lining (Galleys to be added) Avionics Platforms interact interact interact Cockpit Systems Utility Systems VIP Furniture Air Ducting Lavatories Division consists of two building blocks. Customers can opt either for systems or cabin interior individually and for integrated packages.HTC 2011, Kuhnla 15 © Diehl Aircabin
  • 16. 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: Integrated Power und Data Solutions  reduced lead time  weight reduction In line Decoration  highly integrated, preassembled cabin modules In line Modul assembly  reduced numbers of single parts and structure interfaces Integrated Lighting  optional installation of movable bins Integrated SensorsHTC 2011, Kuhnla 16 © Diehl Aircabin
  • 17. Future Design PrinciplesHTC 2011, Kuhnla 17 © Diehl Aircabin
  • 18. Innovative ConceptsNew lightweight designDevelopment 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 Picture: Airbus  Design options  Part productionHTC 2011, Kuhnla 18 © Diehl Aircabin
  • 19. Innovative Concepts 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 ReductionHTC 2011, Kuhnla 19 © Diehl Aircabin
  • 20. Innovative Concepts The ACARE obligations and the increasing demand of power consumption are requesting new approaches and innovations with the aim to achieve a more efficient cabin operation Diehl Vision: The energy self-sufficient cabin • Separation of essential and non-essential loads Approach: – energy autonomous galley – intelligent cabin power managementHTC 2011, Kuhnla 20 © Diehl Aircabin
  • 21. Innovative Concepts 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. Integrated Power und Data Solutions Topics: In Line Integration In line Decoration  Lightweight sandwichpanels with integrated electronics (light, sensors, data solutions and signs)  Rapid Manufacturing In line Modul assembly  Sealant Materials In Line Decoration Integrated Lighting  Powder painted modules with highly resistant and easy cleanable surfaces Integrated SensorsHTC 2011, Kuhnla 21 © Diehl Aircabin
  • 22. Sustainable Design and Production 100% Delivery 90% Facility HVAC 80% Target for all future product 70% Assembly 60% developments from Diehl Aircabin is Surface structure 50% the continuous consideration of the Other 40% possible environmental impacts. This 30% Honeycomb core 20% means impact investigations during the Prepreg 10% production and especially during in Crushed Core process 0% service and end of life. Meanwhile all GWP AP EP POCP PE_fossil data basis is available to perform a Life Cycle Assessment (LCA) for our products. Current LCA Research Topics:  Natural fibre prepregs  Effective Toolheating  Enlargement of the data basis  Continuous weight reductionsHTC 2011, Kuhnla 22 © Diehl Aircabin
  • 23. 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 possibilitiesHTC 2011, Kuhnla 23 © Diehl Aircabin
  • 24. 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.HTC 2011, Kuhnla 24 © Diehl Aircabin
  • 25. Weight Optimization(i.e. recirculation fan bracket A350 ducting) • Model 1 - basis • Model 2 - optimized – Maximum Stress = 117 MPa – Maximum Stress = 280 MPa – Lowest frequency = 22,1 Hz – Lowest frequency = 22,5 Hz – Bracket weight = 5,40 Kg – 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 OptimizationHTC 2011, Kuhnla 25 © Diehl Aircabin
  • 26. 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 systemsHTC 2011, Kuhnla 26 © Diehl Aircabin
  • 27. 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 developmentRef.: Boeing,Airbus HTC 2011, Kuhnla 27 © Diehl Aircabin
  • 28. Passion for AviationHTC 2011, Kuhnla 28 © Diehl Aircabin
  • 29. Contacts Thank you … … your questions, please. Wolf-Dieter Kuhnla Diehl Aircabin GmbH Am Flugplatz 88471 Laupheim Germany Fon: + 49 7392 703 3150 E-Mail: Dieter.Kuhnla@diehl-aircabin.deHTC 2011, Kuhnla 29 © Diehl Aircabin

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