Automated Production of Photovoltaic Arrays for Satellites

Transcription

1 Autmated Prductin f Phtvltaic Arrays fr Satellites Elie DAWIDOWICZ / Daniel BOURIC Innv'actinAerspace 4.0 1

2 Outline PVA Factry4.0 Presentatin f space slar panels as a prduct Space f the Future When Factry f the Future meets Space industry Cnclusin 2

3 PVA Factry4.0 TAS in Belgium What are we ding? H A S S E L T CHARLEROI LEUVEN HASSELT L E U V E N C H A R L E R O I Develpment, Manufacturing and Marketing f electrnic prducts and sftware fr satellite market Telecmmunicatin ; Defense ; Observatin ; Explratin ; Navigatin ; Science fr Eurpean launchers(ariane, Syuz and Vega) Micrelectrnic slutin Avinicelectrnic prducts and sftware Opened since June sq Autmated manufacturing f phtvltaic assemblies (PVA) Industry 4.0 Smart data Opening and start f prductin: Q sq sq Clean rms : sq 3

4 PVA Factry4.0 Prduct Definitin Prduct = PhtVltaic Assembly = Slar Panel Pwer generatin fr satellites ( kw) Lifetime: 3 15 years Design drivers: W / / kg / m² / m³ PVA = mechanical assembly CIC bnded t the substrate CIC welding Harnessing Heavily cnstrained by space envirnment: Temperature range: -175 C C Thermal cycling: up t s f cycles Radiatins Very sensitive t manufacturing prcess changes Out f industrialr space spec. 4

5 PVA Factry4.0 Prduct Definitin There is vlume in space! Fr 1 large gestatinary satellite: ~10000 SCAs ~X welds 2 wings 12 panels X0 000 glue depsitins ~ kmsf cables + Mst f prcesses are cmmn t all satellite slar panels Transversal analysis and crrelatins 5

6 Space f the Future General View and diagnsis Purpse f Industry4.0: setup a prductin envirnment t enable knwledge management and prcess cntrl Qualificatin Set a design standard Validate perfrmances One-sht demnstrating prduct repeatable perfrmances N demnstratin f prduct stability in time Acceptance Detect deviatins Prevent prpagatin Prcess cntrl Anticipate deviatins Identify rt causes Cnsumes end-prduct lifetime and requires precautins T ften perfrmance-riented target missed! Leads t cstly repairs Detectin & preventin f rt causes Measurable, cntrllable key prcess parameters Minimize impact n the end-prduct Prcess variance surveillance 6

7 Space f the Future Manufacturing Technlgies Heritage situatin Mst f manufacturing peratins are manual Prducts are systematically cntrlled and require sme repairs PVA Factry4.0: Autmatin f critical prcesses: glue dispense, lay-dwn, welding In-line testing, cntrl and traceability Aiding statins fr harnessing leveraging 4.0 technlgies «Augmented» peratr fcus n manufacturing peratins Autmatin f acceptance test executin Operatr added value = setup, cnfiguratin, pilting and results analysis Warning: autmatin nt a gal in itself 7

8 Space f the Future Digital Factry Cncept f digital cntinuity: single surce f infrmatin accessible with different views Infrmatin in a central database in explitable digital frmat Database is addressed with specific tls accrding t the applicatin Purpse: ease and speed up prcess/prduct changes and heritage capitalizatin Fact-based technical prpsals, design analysis, heritage management Engineering Custmer Design fr manufacturing Design fr test Techn Push Generatin f End-Item Datapackages Guaranteed cnsistency Increased V&V traceability Industrialisatin & Prductin Test & Cntrl 8 Margin ptimizatin, Trend analysis, Anmaly management

9 Space f the Future End-t-End Engineering EXAMPLE Digital cntinuity prmtes multi-disciplinary appraches and lessns learnt frm all stakehlders Hw t ensure utput pwer withut measuring utput pwer? Example f rute Design analysis Perfrmance standard Qualificatin Plan Custmer Custmer Design FMECA Prduct Key Chracteristics Prcess FMECA Cntrl Plan Prductin Industrial requirements Supplier Data 9

10 Space f the Future Smart Prductin Systems Same data is ruted t varius users fr different purpses Quality lps Prductin peratins In-line traceability as diagnsis tl Digital wrk instructins derived frm def. file Prcess cnfiguratin management Immediate inf impacting 1 prduct Prductin supervisin Smart Data Statistical Prcess Cntrl (SPC) Materials & cnsumables autmated mnitring Flw, cycle time and capability assessement Explitatin and crrelatin f prductin data Feedback fr cntinuus imprvement Feedback fr design imprvement Shrt-term cntrl impacting n-site prducts Lng-term imprvement impacting future prducts 10

11 Space f the Future Smart Prductin Systems EXAMPLE Hw t ensure gluing peratin quality? Glue / Cell Fill in Full syringe assembly f PVA Glue with (gluing, #N intercnnectin, ) syringe #N T late! Glue with syringe #N+1 Materials Witness Trac. sample Lg brwsing SPC tracking Pull test Anmaly cnfined Repair affected cells Repair affected cells (if any) Query(Cell withgluex) Envirnment Multi-parameters Crrelatin Temperature variatins within tlerance Defect at T < X Defect at Hygrmetry > Y Multi- rt causes identificatin Crrective actins fr glue preparatin step Crrective actins fr cleanrm mnitring Lng-termcrrective actins 11

12 Cnclusins Industry4.0 = setup f an efficient prductin envirnment Applicable t any prcess r prduct Game changer fr 21st century: DATA Capture the right data, centralize it and distribute it t different users Enable data exchange between all actrs (supply chain, custmer, ) Digitalizatin and data management is key raw material fr industrial perfrmance Guidelines t enable a «Space Industry4.0» G beynd qualificatin and acceptance t ensure prduct quality Vlumesare t be sught at prcess level, nt prduct level Industrial perfrmance fr the custmer Take the pprtunity t re-thinkprduct quality based n «What infrmatin is relevant fr whm?» 12