The research project “SeMoSys” addresses complex challenges in the assembly of aircraft fuselage sections. Its primary objective is to enhance high-rate production capabilities to meet the growing demands of the aerospace sector. By innovating assembly processes, SeMoSys aims to reduce process cycle times and incorporate system installations, such as supply modules and galleys, at earlier stages. Traditionally, such integrations occur later, often leading to inefficiencies. Through strategic planning and innovative assembly concepts with high degree of automation, the project seeks to streamline operations, optimizing production throughput while maintaining quality standards.

A key aspect of SeMoSys is the advanced assembly concept based on the Ring Station model. In this concept, the component carriers with the fuselage shells are sequentially positioned in a circular assembly station. An Automated Guided Vehicle (AGV) system is utilized for logistics, enhancing precision and reducing congestion on the assembly line while optimizing ergonomic aspects. Collaborative efforts with Fraunhofer and project partners have been crucial in developing this innovative approach. The integration of 3D optical measurement technology is essential for tolerance management and quality assurance in aircraft manufacturing.

The project emphasizes the strategic early integration of system installations to mitigate challenges from later-stage installations. Using advanced simulation environments, the assembly process of the galley has been visualized to identify bottlenecks and optimize steps. This aligns with broader trends in the aerospace industry, focusing on increased automation and digital twin technologies. By adopting these methodologies, SeMoSys is paving the way for future innovations in aircraft assembly, ensuring manufacturers can meet global demands for efficiency, speed, and quality. The implementation of advanced system architectures plays an important role in optimizing manufacturing systems in aircraft construction. Standardized OPC UA communication protocols are used for machine interfaces, and the digital mapping of production systems along with real-time data monitoring offers new opportunities for increasing efficiency and resource utilization.