The work done during the first 18 months of the CALITO project specified the re-design of cabin lining parts (sidewall and ceiling), hatracks, and cargo lining parts, including revolutionary automated fastening concepts. To detail the conceptual redesign, the lining part and its linked brackets were developed. This detailed design is adaptable within the cabin to all other use-cases.
For the cargo interior parts, a simplified detailed design was developed, taking into account that there are less aesthetic design requirements. Analysis of cutting-edge designs and technologies, as well as simulations of various creative installation scenarios and the concept of automation specifications, were all completed. For the sidewall and ceiling panels, the latest materials (Solvay Tegracore) and a weight-optimized automation design were used. During the second 18 months, prototypes for the first practical tests were developed. For the development of the lining components, three companies' expertise was acquired: SFS intec as an expert in the development and manufacture of fastening solutions, Solvay as an expert in high-performance aerospace materials and Bertrandt as a subcontracting partner as an expert in development and design services, in particular with regard to the detailing of aircraft cabin lining components. Functional testing was used to confirm that the new concept was suitable for an automated cabin installation. The parts were tested using the topic manager's existing automation technologies, and final changes to the comprehensive design data and parts were made. Following that, the consortium members demonstrated and disclosed that all necessary tests had been conducted and that the necessary modifications had been incorporated into the detailed design data as a result of the tests.
In addition, the prototypes' adaptation to the design data was confirmed, and a new design evaluation was included to meet all requirements for an automated cabin installation.
The following are the major accomplishments during the reporting period:
Smart Fasteners: Simple linear installation movements optimized for automation are made possible by smart easy snap fasteners. Complex positioning is eliminated thanks to the integration of self-adjusting functionality. For a cleaner look, the design eliminates the,,Schwalbennester" and hides the gap between the hatrack and sidewall.
Integrated cargo lining fastening concept: Due to fewer cargo lining requirements, we created a simplified sandwich panel design with a Solvay TegraCore foam core and an integrated smart bracket solution that is optimized for automation.
Test of self-adjusting bracket system: Installing a sidewall in under 10 seconds is possible with only three parts: LED cover, window funnel, and bottom rail, as opposed to the traditional installation process, which requires screwing. Smart tolerance compensation and adjustment functionality, as well as a simplified lining design optimized for fully automated installation.
Weight reduction: Due to the new material and design, the lining parts will be 20% lighter than the traditional lining components. This not only decreases the cost but also reduces the pollution.
Cost reduction: Overall, foam sidewall and hatrack are around 15% less expensive than honeycomb due to lower labor costs (honeycomb requires a lot of rework after applying the phenolic due to the holes in the structures) and lower equipment costs (no or lower need for insulation). In addition, the dado panel and cove light panel are already built into the CALITO sidewall. This eliminates the production process of these two components which has a positive effect on the production costs.
