Internet of things in

Aerospace

By

Alejandro Sánchez-Beato Semolino

Table of Contents
1. Introduction ...................................................................................................... 2
2. Industrial IoT at Airbus .................................................................................... 4
3. Data transmission and analysis ........................................................................ 4
3.1 Skywise………………………………………………………………..5
4. Digital Twins .................................................................................................... 8
5. Artificial intelligence...................................................................................... 10
6. Additive Manufacturing ................................................................................. 10
7. Maintenance ................................................................................................... 11
8. IoT in the Cabin: The Connected Cabin......................................................... 12
9. Bibliography ................................................................................................... 14
 1. Introduction

In 1999, Kevin Ashton, a technology pioneer at MIT, set out to optimize supply chain
operations using a network of smart devices that use radio frequency identification (RFID) tags.
Eventually, he succeeded in establishing a global standard system for RFID and other sensors.
However, one crucial question remained unanswered: what to call this new and exciting field?
Over time, the term "Internet of Things" (IoT) was chosen.
The Internet of Things ensures the interconnection and transmission of data and
information between devices without the need for human intervention. When we refer to IoT,
we encompass robotics, autonomous vehicles, drones, and smart home devices. Recent
advances in deep learning and artificial intelligence (AI) form the foundation of all IoT
applications.
19% of IoT application domains are dedicated to aerospace applications.
The industrial revolution has seen diverse generations, from steam-powered mechanization,
electricity-powered mass production, computer-based automated production, to the cyber-
physical systems (CPS) and Internet of Things (IoT) that power production today. Today's
evolution and availability of IoT is ushering in a new industrial revolution, where manufacturing
technologies and processes take advantage of intelligent automation, data sharing, and
connectivity.
This perspective implies that future industries will be considerably more automated and
intelligent, both in the execution of manufacturing processes and in business decision-making.
This intelligence can foresee various production scenarios and suggest the best solution for
each particular case, allowing production to be increased and customer demands and needs to
be met. Simultaneously, this intelligence optimizes manufacturing processes and improves
efficiency by providing clear information about processes, equipment, products, and operators.

Some of the key challenges that the sector will face in the coming years are:
1. Digital transformation: the adoption and use of computer systems is necessary
to streamline the different production, logistics and administrative processes.
2. Optimization: One of the main problems present in the industry is the inefficient
use of resources, such as waste of raw materials, inefficiency in process
scheduling, inefficiency in energy use, etc.

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 3. Cybersecurity: As industries become increasingly digital, the impact of a lack of
security measures on businesses can be devastating. Therefore, it is essential to
protect your systems and data from potential attacks.
4. Horizontal connectivity: Connectivity between organizations for transactional
purposes and value chains in the digital space is a major trend. Connecting
different systems increases collaboration between companies by sharing
services, resources, and data.
5. Automation: The manufacturing industry is increasingly using artificial
intelligence to automate tasks, automatically set parameters, optimize processes
and operations, plan production, and support decision-making with detailed data
analytics. Recently, several initiatives related to the development and application
of IoT and CPS systems have emerged, such as Industry 4.0

In the aerospace industry, the Internet of Things (IoT) is revolutionizing ground and air
operations. Real-time analytics powered by IoT are already delivering improvements in quality
and productivity, and passengers can expect a variety of new and exciting experiences on
board.
Next, we will show some of the advances that have been made in the aerospace sector
thanks to the Internet of Things, specifically we will focus on investigating how the industry has
evolved at Airbus, and how it has improved both in production times and methods as well as in
flight data analysis and aircraft maintenance techniques.

Figure 1: IoT in Aviation

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 2. Industrial IoT at Airbus

Changing market needs and customer expectations are fundamentally changing the way
modern aircraft are designed and manufactured. To produce aircraft that meet the highest
standards of quality and performance, there must be a digital, intelligent and future-oriented
industrial ecosystem. The Industry Revolution 4.0 has put Airbus on the path to a complete
digital transformation across the entire product lifecycle.
In the operational area, automation of both production lines and processes is taking
place, with multidisciplinary integration and intelligent manufacturing systems that allow better
monitoring and traceability of all processes. This means that we are on the path to smart, self-
controlled factories.
In addition, thanks to IoT, improvements in manufacturing efficiency are being achieved
in the aerospace sector. Advanced analytics provide time-of-flight insights, allowing
manufacturers to quickly take action to address inefficiencies.
A key example would be IoT-enabled smart meters, which are able to provide
information on energy use in aircraft production, resulting in significant cost savings and more
sustainable operations. This would lead to savings of up to 20% in energy consumption.
The IoT is also capable of providing instant feedback on the performance of all machines
employed during the production process. At the Airbus factory in Saint Eloi, machine data is fed
into a live visual representation, thus creating a "digital shadow" of the entire assembly line.
Allowing users to track operations as well as perform highly accurate simulations to find the
most effective ways to improve operations.
IoT can also help monitor and control the amount of torque provided by a tool on the
assembly line, thereby improving quality and productivity. If too much or too little torque is
applied, the tool stops and the user is immediately notified. At Airbus, this approach has
improved efficiency by 20 to 30 percent.

3. Data transmission and analysis

Business decisions today rely heavily on the insights that big data can provide. However,
processing large volumes of complex and unstructured data requires high-throughput analytics
to extract value. Airbus is at the forefront of future technology in data analytics with the aim of
delivering the right information to the right people at the right time and in a context they can
understand.

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 The aerospace industry is constantly generating a staggering amount of data. Today's
commercial aircraft, for example, can generate more than 30 GB of data daily, measuring more
than 40,000 operating parameters for various components and systems. In addition, airlines
generate business data, scheduling data, and operational data recorded by pilots, flight
attendants, engineers, maintenance technicians, and airport representatives, among others.
Suppliers and OEMs are also a significant source of information.
The question is: is the aerospace industry effectively leveraging all this data?
Airbus strives to make sure that is the case. To achieve this, it has developed a platform
that connects and aggregates information across the aviation industry, enabling diverse
stakeholders to collaborate and share data efficiently.
On a daily basis, Airbus collects and processes large amounts of data from its air
operations, enabling it to achieve superior performance and add value in a variety of areas.
These benefits translate into:
1. Operational Excellence.
2. Improved product design, strategy, and marketing.
3. Increased operational performance and fleet reliability.
4. New business models and revenue streams.
5. Faster innovation rates.

3.1 Skywise

In 2017, Airbus officially launched Skywise with Palantir. Skywise is an open data
platform that collects vast amounts of data from Airbus, customers, and suppliers, offering a
greater amount of information, knowledge and potential for better decision-making and
greater cost savings.

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 Figure 2: Skywise around the world

Skywise has been conceived to manage the integration of business and operational
systems, addressing the processing of large data sets. This includes the manipulation of data
from aircraft sensors, as well as structured operations and maintenance data, and unstructured
data, such as white papers. In addition, Skywise offers tools that allow users to prepare,
aggregate, and analyze data, along with templates that make it possible to build applications
directly on the platform.
Since its launch in June 2017, Skywise has seen remarkable growth, consolidating data
not only from Airbus, but also from suppliers and more than 100 airlines. The platform adds
significant value to both airlines and providers by providing them with a powerful infrastructure
that integrates systems that, for most airlines, have historically remained disconnected. By
using Skywise's advanced analytical tools, airlines can generate insights in both code-based and
no-code environments.
Skywise has tackled a variety of projects and challenges, including decreasing
maintenance issues and preventing technical delays, identifying defect patterns, and predicting
failures through the application of artificial intelligence. In addition, it has contributed to
increasing fuel efficiency, optimizing parts replacement to reduce operating costs, minimizing
the impact of changes in flight schedules on passengers and complex flight network operations,
and automating reports linked to various regulatory documents.
Airlines have the ability to incorporate operational and analytical applications, in
addition to Skywise, to get the most out of their data. Since many airlines don't have the talent
or systems to develop a similar platform themselves, Skywise represents an opportunity for all
of them to access a state-of-the-art data management system.
Why does Airbus offer such a platform and how do you derive value from this initiative?

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 The main reason behind Airbus' offering of this platform lies in its design, which allows
airlines and suppliers to share some of their data directly and instantly with Airbus. The
centralization of data and collaboration between different stakeholders enable Airbus to
address and support critical operational issues faster. In addition, this collaboration can help
airlines and suppliers prevent problems before they cause delays or other disruptions to their
operations, thus generating significant value.

Figure 3: Skywise internal organization

In the long term, access to some airline operational data will allow Airbus to understand
the actual behaviour of its aircraft across various geographies and business models, helping to
improve the design of new aircraft models. Improving their aircraft will not only result in
greater reliability, but it will also reduce operating costs and increase safety in the aviation
industry. This approach ultimately translates into an improved experience for passengers,
generating a positive feedback loop where all collaborative parties will be interested in data
sharing.
Simultaneously, by providing some of their data to Airbus, airlines benefit from having
access to anonymous benchmark metrics. The ability to benchmark their performance against
the rest of the industry provides crucial information that allows airlines to identify
opportunities for improvement in their processes, fleets, components, airports, and more.
For example:
Today, the engines of the most modern aircraft incorporate sensors that generate a
large amount of data per flight, reaching up to 787 terabytes per trip. This data includes various
information, such as the altitude, latitude, longitude, and speed of the aircraft. However,
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through the predictive capabilities of IoT, the aim is to ensure that this data does not need to
be downloaded after the flight for later analysis but can be transmitted in real time. This
strategy has the potential to reduce the need to disassemble engines during periods between
inspections, leveraging the data to forecast and improve aircraft performance. The final
implementation would require the creation of a connected and collaborative IoT network,
supported by artificial intelligence and machine learning algorithms, aspects that demand
scalability of algorithms and availability of computing resources for their execution.
This will be possible thanks not only to the sensors installed in the engines, but also to
the reduction in production costs that has driven the increasingly frequent launch of satellites
into space. These satellites, which collect terrestrial information, make it possible to obtain
meteorological data to create weather patterns. This, in turn, ensures flight safety and enables
reliably replanning of trajectories.

4. Digital Twins

As far as cyber-physical systems are concerned, the presence of a "digital twin", which
consists of a virtual model of a process, product or service derived from information collected
by sensors or automations, would enable intelligent data analysis and effective monitoring of
systems. In the context of the aerospace sector, this application could result in a reduction of
more than 50% in production times, by anticipating and avoiding problems before they occur,
thus preventing downtime and facilitating the planning of the production chain through
simulation. This approach, which is especially crucial in a high-investment sector, would lead to
significant savings, as any unforeseen error results in a substantial loss of financial resources.
Consequently, prediction and prevention will be prioritized rather than addressing problems
after they appear.

Figure 4: Digital Twin on Airbus

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Design engineers create a virtual model that serves as the basis for generating manufacturing
instructions in an automated manner. This allows operators to assemble components using
tablets and augmented reality glasses following the instructions provided by these devices. A
concrete example is the A330, where the implementation of this technology has significantly
reduced the time needed to assemble wiring harnesses, becoming five times more efficient.
Thanks to virtual models, the additive manufacturing of some parts is also facilitated,
generating a decrease in costs.
For Airbus, the adoption of Digital Twins and 3D technology is presented as a strategic
decision. These elements help streamline the manufacturing process. The ability to have virtual
representations of aircraft allows for virtual testing to be conducted, thus reducing the time
required for physical testing. This makes it possible to identify and correct errors before
production, improving design and services. Ultimately, a noticeable reduction in overall
development time is achieved.
Augmented reality, on the other hand, will experience implementations in various areas,
one of the most significant being the field of training. In this sense, it will be used to show
operators engines, parts or processes in a realistic and detailed way, thus improving their
learning process significantly. In addition, it will be used to guide operators in industrial
processes, especially in complex tasks that require the consultation of extensive manuals. The
use of augmented reality applications will make it possible to show step-by-step instructions on
the execution of tasks, reducing the time needed and improving the competitiveness of the
company. This approach will also be applied in job management and in products such as smart
glasses, which will help optimize production activities.

Figure 5: Augmented reality on Airbus

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 5. Artificial intelligence

Currently, Artificial Intelligence is being implemented in various cross-cutting areas of

companies, such as human resources, purchasing and finance. This process is carried out
through applications such as Bots, Chatbots, and computer services equipped with artificial
intelligence. As a result, many tasks that require a specific cognitive level are now executed by
computer systems. Examples of this include the adaptation of invoices to the legislation of
other countries, the selection of personnel using tools that use "Big Data" or the digital network
monitoring of the processes of awarding orders to suppliers, among others. All this
development is leading to a process of recentralization of functions and the restructuring of
various areas within companies.

6. Additive Manufacturing

Another technology that helps the aerospace industry on its path to digitalization is
additive or component manufacturing, which is one of the pillars of Industry 4.0. It is based on
integrating new technologies to improve aspects such as speed, precision, competitiveness, and
energy efficiency. This technology makes it possible to convert digital models into solid three-
dimensional objects, without the need for molds or tools of any kind. Because the exact
manufacturing of each component is critical in this industry, additive manufacturing makes it
possible to seamlessly design almost any type of complex structure with advanced functionality.

Figure 6: Additive manufacturing machinery

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 It can bring numerous advantages when manufacturing all types of parts, such as faster
production or a much more sustainable manufacturing process by using resources efficiently.
In an interconnected world, additive manufacturing makes it possible to work on
demand and adapts to new production criteria.
Its name comes from the fact that the material is added sequentially (by addition), as
opposed to traditional manufacturing in which material is subtracted from a solid block until
the part is finished (by subtraction).
Although they are sometimes used synonymously, it should not be confused with 3D
printing, which is becoming more and more widespread. 3D printing is just another type of
additive manufacturing, although it has certain limitations.
Additive manufacturing makes it possible to combine different techniques, with
different production volumes and more quickly; and even with materials, such as certain
metals, that 3D printing does not use.

7. Maintenance

As the manufacturing processes and creation of new tools are evolving, so must their
maintenance methods. To this end, new technologies are already being integrated, such as the
use of drones to inspect and detect damage to the surface of aircraft, reducing average
inspection time and freeing up workers to perform other tasks.
At Airbus, aircraft inspection is carried out about 30 times a year, every 100 flight hours.
The average time it takes to inspect an aircraft can last several days and can last up to a week,
and a detailed inspection can involve more than five people, while a drone can do it 20 to 50
percent faster. For this reason, the application of this type of technology, such as the use of
drones in aircraft inspection, reduces costs, as well as the time spent. The 'Airbus Inspection
Drone' is a drone used by Airbus to inspect aircraft, increasing the quality of inspections and
shortening the time spent on it, as well as reducing costs. A drone can reduce the time of an
inspection from one day to three hours. As for the mode of use, the operators fly the drone
around the aircraft, and the drone follows the marked route autonomously thanks to a laser
radar that is able to detect obstacles and modify the route or stop the flight if necessary. During
the flight, the drone takes high-resolution photographs since they have built-in thermographic
sensors and operators can view these images in real time from a tablet. Subsequently, these
images are analyzed by a computer algorithm that locates any type of damage that the surface
of the aircraft may be suffering and are compared with the 3D model of the aircraft. On the
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other hand, drones are also used to create databases that help improve tracking, forecasting
and damage reduction in aircraft and future models.

Figure 7: Aircraft maintenance with a drone

Airbus carries out Maintenance, Repair and Operations using drones, AI and Augmented
Reality, as explained above, once the drone performs the inspection and has collected the
information, the Airbus System performs a digital analysis and a technician visualises on a
computer the possible defects that the drone has captured, According to a database in such a
way that the drone compares the damage of the plane, even being able to measure and detail
the possible defects. This is where AI comes in, as the images and data that are contained in a
database are used as mathematical algorithms with the aim of increasing the accuracy of the
drone, creating complex and autonomous systems. In addition, the AI ensures that the system
is trained as a result of carrying out inspections, since it learns what is a defect and what is not,
making it more intelligent.

8. IoT in the Cabin: The Connected Cabin

The Internet of Things (IoT) is also making inroads into the cabin, giving airlines and
passengers the ability to enjoy new and exciting travel experiences. This involves creating a
more personalized environment, powered by new applications that enable enhanced

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interactions with passengers' immediate surroundings, such as personalized entertainment and
dining options.
To bring this innovative cabin experience to life, Airbus has launched its Connected
Experience solution. Developed in collaboration with a number of leading partners, this open
ecosystem will facilitate real-time connections between key cabin components such as the
galley, bathroom, food carts, seats and overhead bins. Cabin crews will have access to digital
services, and real-time consolidated data during flight, analysed on Airbus' Skywise platform,
will improve predictive maintenance, cabin operations and reliability.
Connected seats will allow the crew to instantly access valuable information, such as
whether passengers are buckled up, whether the armrest is lowered, and whether the backrest
is upright. In addition, post-flight analytics will provide airlines with valuable insights into
passenger behavior, allowing them to continuously improve service in the future.
As IoT becomes an increasingly common standard across all aircraft, innovation in
various areas becomes essential. In the case of Airbus, it is anticipated that numerous projects
will contribute to a broader cabin concept, with the aim of improving the flexibility and services
offered in the cabin.

Figure 8: Connected cabin

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 9. Bibliography

Clavijo Romero, Maria (2021). Industry 4.0 in the aeronautical sector. Retrieved from
https://biblus.us.es/bibing/proyectos/abreproy/93426/fichero/TFG3426+ROMERO+CLAVIJO%
2C+MAR%C3%8DA.pdf
Berges Basáñez, Elena (2020). Implementation and improvement of the digitalization of
the production progress monitoring system within the framework of Industry 4.0 within the
aerospace sector. Retrieved from https://idus.us.es/bitstream/handle/11441/105167/TFG-3165-
BERGES%20BASA%C3%91EZ.pdf?sequence=1&isAllowed=y
Land, Ian; Niatas, Janson and Marc Serughetti. (18/10/2022). How Digital Twins are
Transforming Aerospace and Defense. Retrieved from https://www.synopsys.com/blogs/chip-
design/digital-twins-transform-aerospace-defense.html
Labrogére, Paul (03/10/2022). Digital Twins in companies. Digital Twins in companies.
Retrieved from https://www.protect.airbus.com/blog/digital-twins-in-companies/
Xu, KK; Gong, YD and Qiang, Z ( 05/07/2023). Comparison of traditional processing and
additive manufacturing technologies in various performance aspects. Retrieved from
https://www.webofscience.com/wos/woscc/full-record/WOS:001019966800001
Ramirez, Lorena (06/03/2023). Additive Manufacturing, a growing sector. Retrieved from
https://www.iebschool.com/blog/fabricacion-aditiva-que-es-aplicaciones-tecnologia/
Fendt, Martin (11/09/2019). Airbus commences in-flight trials of connected cabin
technologies. Retrieved from: https://www.airbus.com/en/newsroom/press-releases/2019-09-
airbus-commences-in-flight-trials-of-connected-cabin-technologies
Infodron (17/04/2018). Airbus will use autonomous drones to inspect its planes. Retrieved
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inspeccionar-aviones
RPASdrones (22/03/2019). The Airbus project that revolutionizes aircraft maintenance.
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Airbus. How Skywise Works? Skywise Ecosystem
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