ProMoH2 – End-to-end process chain and data monitoring for quality-assured liquid hydrogen storage systems

The “ProMoH2“ project focuses on developing an automated, end-to-end (E2E) process chain and data-monitoring network for the production of quality-assured liquid hydrogen (LH2) storage capsule systems. Serving as the core interface between the tank storage and the aircraft distribution system, the capsule requires ultra-precise, space-constrained joining operations (such as laser beam and orbital TIG welding) within an surrounding with limited accessibility.

To overcome tight space limitations and strict quality demands, ProMoH2 integrates compact joining end-effectors, real-time in-situ process monitoring, AI-assisted anomaly detection, and targeted automated nondestructive testing (NDT) into a centralized data pool. Furthermore, holistic distortion simulation and automated geometry acquisition ensure dimensional accuracy across all assembly steps. The entire concept will be physically built and validated via a demo process chain in Bremen, aiming to achieve higher manufacturing efficiency, reduced cycle times, lower defect rates, and an optimized carbon footprint for future zero-emission hydrogen-powered aircraft.

Challenge: Automation in LH2 storage capsule manufacturing

Manufacturing liquid hydrogen (LH2) storage capsule systems presents critical technical hurdles due to complex joint geometries and severely restricted spatial access. Conventional manual assembly fails to meet strict aviation quality standards (e.g., ISO 17927) for high weld integrity. Additionally, tight installation spaces limit accessibility for standard joining equipment, nondestructive testing (NDT), and geometry acquisition, while thermal distortion across complex pipe and dome assemblies creates high defect risks.

Solution: Automated E2E process chain and AI-based quality assurance

ProMoH2 resolves these manufacturing challenges by developing an automated, digitalized end-to-end (E2E) process chain with integrated quality assurance. The solution combines compact orbital laser and TIG welding end-effectors with real-time in-situ process monitoring, AI-driven anomaly detection, and targeted nondestructive testing (NDT) linked into a central data pool. Coupled with real-time geometry acquisition and predictive distortion simulations, the system replaces rigid tooling to ensure high precision, cut material waste, and streamline production cycle times.

Benefits: Efficiency gains in automated LH2 capsule production

By automating and digitalizing the process chain, ProMoH2 achieves key operational and sustainability milestones:

• Increased production efficiency: Achieving over 50 % automation in assembly operations while cutting quality inspection time and functional testing effort by over 60 %.
• Resource and waste reduction: Smart process control and precise distortion simulation reduce material and resource consumption by 20 % compared to conventional manual production.
• Enhanced quality and digital traceability: Digital capturing of 75 % of quality assurance data ensures full compliance with strict aviation standards (e.g., ISO 17927) for zero-emission aircraft manufacturing.

 

Project partners:

• Airbus Operations GmbH (Project lead and requester )
• Fraunhofer Gesellschaft
• BIAS - Bremen Institute of Applied Beam Technology
• ISEMP - Bremen Center for Computational Materials Science, University Bremen
• Nutech - Gesellschaft für Lasertechnik und Materialprüfung mbH