AIoT Methodology for Retrofitting Aeronautical Manufacturing Systems

Artificial Intelligence of Things (AIoT) technologies shifted the structure of production systems, enabling the development of more intelligent, connected and sustainable manufacturing environments. However, some industrial sectors, such as aerospace manufacturing industry, fell behind in the adoption of these new technologies, mainly because of the high safety standards, strict reliability requirements and long lifespan of aircraft components. Due to low production volumes and complex manufacturing processes, this sector relies heavily on weakly automated legacy machines and production systems. This article proposes a methodology to ease the integration of AIoT technologies for retrofitting legacy industrial equipment in the aeronautical domain in order to achieve the requirements of modern industrial production systems, enabling the development of more flexible, efficient and interconnected manufacturing environments. The proposed methodology is validated through a case study where the Smart Retrofitting of a legacy aeronautical industrial machine is carried out. The case study focuses on the development of an AIoT-based architecture to implement a predictive maintenance system through vibration and infrared thermography monitoring. A three layer architecture is proposed based on Edge/Fog/Cloud Computing paradigms. A hybrid communication architecture is used, combining wired technologies for critical real-time control tasks and wireless technologies for enhanced flexibility and scalability. The results demonstrate the viability of the proposed methodology for retrofitting legacy aircraft manufacturing systems.