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The conceptual model of a digital factory created at the University became the theoretical basis for the design of aerospace equipment pilot production facilities.
“A cyberphysical robotic factory for the development and production of cubesat nanosatellites is being created at the University campus in the interests of Roscosmos State Corporation. It is planned that the first pilot production site will open in December this year, now special equipment is being purchased and prepared for it. This is the first project to be realized within the framework of the conceptual model of the digital factory developed by the staff of the Advanced Aerospace Engineering School (AAES) of Samara University,” said Ivan Tkachenko, AAES Director.
According to him, the nanosatellites currently being developed in Samara University AAES will be intended for automatic robotic assembly by design. In the future it is planned to develop the technology of automated production of AIST-ST nanosatellites of 12U size intended for radar observation of the Earth’s surface in X-band. Right now, the University is developing the first satellite of this series together with St. Petersburg company “Specialized Technology Centre”; the launch into orbit is scheduled for 2024. The production volumes of the future cyberphysical factory have not yet been determined.
“The development of specific satellites is just one of the objectives of the cyberphysical factory that is currently under construction. And the main task is the development of standard robot-assembled structures, as well as technologies of robotic assembly, automated storage of components and materials, automated transportation of parts and product bodies, control and testing of satellites. At AAES, we have already established a significant scientific and technical foundation, tested a number of solutions related to robotization of the assembly process of nanoclass spacecraft, and are moving forward,” says Ivan Tkachenko.
Apart from AAES research fellows, students of the Advanced Aerospace Engineering School also participate in the development of robot-assembled structures and robotic manufacturing technologies; for them, this is part of the educational process. The infrastructural base on which the cyberphysics factory is now being established is the production and test complex for small spacecraft, which was created jointly by Samara University and SRC Progress under the Russian Government Resolution No. 218.
In the future, it is planned to open another cyberphysical factory in the territory of the University campus – for the development and production of small-sized gas turbine power units. This pilot production facility is also being created within the framework of the digital factory concept and will work in the interests of ODK-Kuznetsov (part of Rostec’s United Engine Corporation).
“The creation of the digital factory concept is one of the key point in the development of our Advanced Aerospace Engineering School. This is the core around which its scientific, organizational and educational activities are already being built. The focus of our attention is the intelligent production systems and technologies that are being implemented at our enterprises today and which they are in dire need of. We are educating engineering personnel who are competent in such technologies and are able to implement them in real production, and since the principle of our University is “Education through research”, first of all, we develop and implement these technologies at our university,” says Ivan Tkachenko.
About the digital factory concept
In the concept developed by AAES staff, the digital factory is presented as a cyberphysical system that combines informational (digital) and physical (real) components. Their joint work will ensure production flexibility, cost reduction, acceleration and increased efficiency of all processes for the development and manufacture of small spacecraft, small gas turbines and other aerospace equipment.
There are several basic principles on which the digital factory model is based. First of all, it is its hierarchical structure with several levels. The model is built on the use of end-to-end technologies – big data, artificial intelligence, and the Internet of Things. It incorporates the system’s ability for automatic learning. The model is presented as a multi-agent system in which intelligent production cells act as agents, and their robotization and automation should result in creation of a human-free production space.
The developers have identified three hierarchical levels in the structure of the digital factory: digital factory – smart factory – virtual factory. Higher-level factories include one or more lower-level factories according to the matryoshka doll principle.
The digital factory is the very first, initial level, where a new product and its production technology are born.
For instance, in the experimental cyberphysical production of cubesats, which AAES of Samara University is now creating at the campus, the digital factory will be engaged in designing nanosatellites, creating digital twins of materials and products, developing technological processes for assembling nanosatellites and their testing. One of the key products at this level is the digital product passport. It is a “live” electronic structure that reflects all the current characteristics of the spacecraft and accompanies it throughout its life cycle.
The second, higher structural level of the digital factory is the smart factory. Serial production is being organized here. A smart factory is a robotic production facility packed with state-of-the-art equipment. This equipment is monitored and controlled by an automated production system. Automation eliminates the influence of a human factor and improves product quality, but requires special approaches to product design.
The highest level in the digital factory structure is the virtual factory. It is an information and analytical system that manages the enterprise as a whole. All production, logistical and economic information flows to this level for analysis and preparation of management decisions. The difference of the conceptual model developed at AAES of Samara University is that in addition to digital and smart factories, third-party partner enterprises are included in the structure of the virtual factory.
“A key feature of our digital factory model is that it includes suppliers of equipment, components and materials at the input, and dealers and operators of manufactured products at the output. This is a fundamentally important point for aerospace enterprises, as the creation of aviation and space rocket equipment requires broad cooperation between enterprises, and the developers and manufacturers of such equipment accompany their products throughout the life cycle, ensure their improvement and modernization, as well as the replacement of units and assemblies,” says Ivan Tkachenko.
For reference:
Federal project “Advanced Engineering Schools” is being implemented as part of the state program “Scientific and Technological Development of the Russian Federation”. Samara National Research University passed the competitive selection and became one of the thirty participants of the federal project “Advanced Engineering Schools” in June 2022.
The activities of the Advanced Aerospace Engineering School (AAES) of Samara University include three interrelated areas: space engineering, aviation propulsion engineering and information technology. The frontier engineering challenge that the school is addressing is to develop integrated solutions that accelerate the creation and modernization of aerospace products, as well as the training of engineering personnel. The University’s industrial partners in the Advanced Engineering Schools project are SRC Progress (part of Roscosmos State Corporation) and ODK-Kuznetsov (part of Rostec’s United Engine Corporation).
Photo: Elizaveta Ivanisova
