End-to-End Process Chain and Data Monitoring for Quality-Assured Liquid Hydrogen Storage Systems
(ProMoH2)

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).

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 non-destructive 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.

Challange
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, non-destructive testing (NDT), and geometry acquisition, while thermal distortion across complex pipe and dome assemblies creates high defect risks.
Solution
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 non-destructive 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
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 & Waste Reduction: Smart process control and precise distortion simulation reduce material and resource consumption by 20% compared to conventional manual production.
• Enhanced Quality & 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.

__________

Bearbeitung: Verbundprojekt: BIAS GmbH zusammen mit Airbus Operations GmbH, Bremen Center for Computational Materials Science / University Bremen (ISEMP), Fraunhofer Gesellschaft (IZFP), NUTECH Gesellschaft für Lasertechnik und Materialprüfung mbH, assoziierter Partner Innojoin GmbH

Laufzeit: 07/2026-06/2029

Förderung: BMWE Bundesministerium für Wirtschaft und Energie