On November 4, an Ariane 6 rocket successfully launched the Earth observation satellite Sentinel-1D into space. In the future, launches of the new launch vehicle are to take place in close succession, so that Europe can remain an important player in space research. A perfectly synchronized production network that manufactures components with the highest precision is essential for aerospace applications. Sensing technology can play an important role, from the physical traceability of parts to condition monitoring and quality management. Additionally, powerful sensors make energy consumption in production more manageable.
After a successful pilot phase, Fraunhofer IWU and the European Space Agency ESA are now rolling out four sensor groups to all Ariane manufacturing sites as part of the SmartSENS project. 'The goal is to consolidate all data on a platform (ESA-Steam) and evaluate it for closed quality loops,' explains Dipl.-Ing. Albrecht Hänel, Head of Digital Production Twin at Fraunhofer IWU and project manager at the institute.
So-called asset trackers monitor the availability, condition, and location of production facilities and resources as well as essential manufacturing processes in real-time. Monitoring vibrations in the process allows for important conclusions about the stability of the processes and thus the product quality. GPS trackers enable complete traceability of parts and components on their way to the factories, during processing in the factories, and on their way to (final) assembly. A fourth category of sensors keeps an eye on energy consumption during production, helping to keep the manufacturing-related CO2 footprint as low as possible.
IMPROVE: Getting better
SmartSENS is part of the ESA program 'IMPROVE! – Technologies for Smart Manufacturing, Intelligent Logistics and Sustainability'. The initiatives of this program aim for a fully automated and intelligent end-to-end value chain for the Ariane 6 launch vehicle and the rocket engine P120C. The focus is on groundbreaking innovations in predictive maintenance, connected sensor networks, digital supply chain management, and sustainable production processes.
Living partnership
Fraunhofer IWU launched SmartSENS in May 2025 together with AS Consulting. In the first phase, the sensor technologies were tested and validated in a real production environment at MTA Augsburg. Energy and vibration sensors from ABB, systems from Brady for real-time tracking of equipment, and GPS trackers from Trusted A/S for transport monitoring are being used. Production partners where the rollout is now taking place include ArianeGroup (Vernon/France), Avio S.p.A. (Colleferro/Italy), GKN Aerospace Sweden AB (Trollhättan), and ATC Space s.r.o Klatovy (Czech Republic).
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