Use menu "View - Header & Footer" for Presentation title - Siglum - Reference

July 2004

Integrated CAD-Metrology and Alignment of Key Features of A380 Wings

2004 Coordinate Measurement System Committee

Presented by

Geraint JonesAirbus UK Lead Metrology Engineer

Scott SandwithNew River Kinematics

Metrology Software Engineer

Month 200X 2004 Coordinate Measurement System Committee Page 2

© A

IRB

US

UK

LTD

200

2. A

ll rig

hts

rese

rved

. Con

fiden

tial a

nd p

ropr

ieta

ry d

ocum

ent.

Introduction – A380 Metrology at Broughton

• Measurement Systems Laser Trackers

– Alignments of kinematic mechanisms Laser Radar Scanner

– Direct measurement of performance and interface features• Assembly of the Airbus A380 Wing

Build and Inspect directly to features• Integrate Metrology Systems and CAD• Optimize Build and Inspection of Wing Performance

Features• Software Platform

Graphical environment and reports Relationship Fitting optimize part alignment to CAD Confident product configuration and communication

Month 200X 2004 Coordinate Measurement System Committee Page 3

© A

IRB

US

UK

LTD

200

2. A

ll rig

hts

rese

rved

. Con

fiden

tial a

nd p

ropr

ieta

ry d

ocum

ent.

LSM systems used on A380 and why

Current systems used on the A380 Project at Airbus Broughton are

Laser trackers (7) and a laser radar (1)

The laser tracker instrument was procured because:-

• It is highly versatile

• It’s performance is commensurate with the range of design specifications

• It’s ability to track and therefore build

The Laser radar was procured because:-

• It’s ability to measure in a targetless fashion

• It’s ability to mostly automate the data gathering process

• It’s ability to measure large amounts of data quickly

• It’s performance is commensurate with the range of design specifications

Month 200X 2004 Coordinate Measurement System Committee Page 4

© A

IRB

US

UK

LTD

200

2. A

ll rig

hts

rese

rved

. Con

fiden

tial a

nd p

ropr

ieta

ry d

ocum

ent.

Measured features on an A380 Wing set

A total of 96 planned measurement tasks per wing set!60% involve building routines as well as inspection

SPOILERS x 16

AILERONS x 6

FLAP BEAMS x 10

ENGINE PYLONS x 4

OVERWING PANEL x 2

UNDERWING PANEL x 2

WING ROOT x 2

WING TWIST x 2

FALSEWORK X 4 FLAP TRACK FAIRINGS X 48

LaserRadar

Lasertracker

Month 200X 2004 Coordinate Measurement System Committee Page 5

© A

IRB

US

UK

LTD

200

2. A

ll rig

hts

rese

rved

. Con

fiden

tial a

nd p

ropr

ieta

ry d

ocum

ent.

Measured features on an A380 Wing set

Engine Pylon Geometry

Forks

Thrust Spigot

Aft fittingAims:-To inspect the position of the Forks in the X direction-To inspect the position of the Aft fitting in the Y direction-To inspect the orientation of the Forks to the engine thrust line

Month 200X 2004 Coordinate Measurement System Committee Page 6

© A

IRB

US

UK

LTD

200

2. A

ll rig

hts

rese

rved

. Con

fiden

tial a

nd p

ropr

ieta

ry d

ocum

ent.

Measured Features on an A380 Wing set

Wing Tip Falsework

X

Z

Y

Surface A

Surface B

Aim:To blend profile of surface A into surface BFrom an initial alignment the relationshipsfunction allows a fine adjustment of the translationin Z and rotation around X.

Month 200X 2004 Coordinate Measurement System Committee Page 7

© A

IRB

US

UK

LTD

200

2. A

ll rig

hts

rese

rved

. Con

fiden

tial a

nd p

ropr

ieta

ry d

ocum

ent.

Stage 02 Measurement requirement

LR200Rear spar

Front spar

Centre spar

Bottom skin profile

Top skin profile

Junction to Wing box/fuselage

Wing Root Measurement

Aims:To measure top and bottom skin surface profiles and tomeasure spar orientation with respect to the CAD model

= Datum reference points

Month 200X 2004 Coordinate Measurement System Committee Page 8

© A

IRB

US

UK

LTD

200

2. A

ll rig

hts

rese

rved

. Con

fiden

tial a

nd p

ropr

ieta

ry d

ocum

ent.

Stage 02 Measurement requirement

Wing Incidence

Aim:To understand the extent and sense of rotation of the aerofoil- Wing set as well as asymmetrical tolerance- Incidence is measured via 6 opposing pairs of points per wing =Measured points using hidden point device

Incidenceprimary datum

Incidence

Nose up tolerance

IncidenceNose down tolerance

Month 200X 2004 Coordinate Measurement System Committee Page 9

© A

IRB

US

UK

LTD

200

2. A

ll rig

hts

rese

rved

. Con

fiden

tial a

nd p

ropr

ieta

ry d

ocum

ent.

Future metrology software requirements at Airbus

HINGE LINEFITTING TODAY

LEAST SQUARESFITTING

MULTIPLE SOLUTIONS

SKILLFULL OPERATORS

REQUIRED

HINGE LINEFITTING OPTIMISED

ATTRIBUTEYEYES/NO

SOLUTION REQUIRED

FITTING RESIDUALS

STORED FOR LATER

USE

EASIER AND

POSITIVE SCRIPTING OPTIONS & OUTCOMES

ELECTRONIC GAUGING SOLUTION

= ELECTRONIC GAUGING

Month 200X 2004 Coordinate Measurement System Committee Page 10

© A

IRB

US

UK

LTD

200

2. A

ll rig

hts

rese

rved

. Con

fiden

tial a

nd p

ropr

ieta

ry d

ocum

ent.

Measurement Control

• Measurement Control with CAD Model Driven AssemblyBuild/Inspect direct to model definition produces common

results Minimal secondary support tooling (e.g. Shop Aids and Targeting)

Model controls conformanceTolerances are relative to featuresPragmatic GD&T with feature to feature relationships

• Quality ProceduresGraphical Reports improves communicationSPC Charting yields process controlUnified Spatial Metrology Network to ensure process

capabilities• Feature based alignment strategies

Relationship Fitting direct alignment of measurements and instruments to model

Month 200X 2004 Coordinate Measurement System Committee Page 11

© A

IRB

US

UK

LTD

200

2. A

ll rig

hts

rese

rved

. Con

fiden

tial a

nd p

ropr

ieta

ry d

ocum

ent.

Model Driven Verification with Integrated Metrology

Automated inspection of critical interface features with Laser Scanner

Month 200X 2004 Coordinate Measurement System Committee Page 12

© A

IRB

US

UK

LTD

200

2. A

ll rig

hts

rese

rved

. Con

fiden

tial a

nd p

ropr

ieta

ry d

ocum

ent.

Model Driven Assembly

Kinematics mechanism alignment directly to CAD

Month 200X 2004 Coordinate Measurement System Committee Page 13

© A

IRB

US

UK

LTD

200

2. A

ll rig

hts

rese

rved

. Con

fiden

tial a

nd p

ropr

ieta

ry d

ocum

ent.

Hinge Line Alignment Reporting

Working Frame

Bull's-eye Charts Showing Hinge Line Tolerances and Results

Month 200X 2004 Coordinate Measurement System Committee Page 14

© A

IRB

US

UK

LTD

200

2. A

ll rig

hts

rese

rved

. Con

fiden

tial a

nd p

ropr

ieta

ry d

ocum

ent.

Integrating Measurement Technologies - USMN

• USMN – Network Optimization Determine real-world uncertainty fields for Points and Features Characterize actual instrument uncertainty performance from

Shop Floor Surveys Take advantage of relative uncertainty of measurement

components• Multiple Instrument Network Scanner + Tracker

Systems operate synchronously in a cooperative network aligned with USMN

USMN orientation produces optimal results Traceable uncertainty estimates for Points, Instruments, and

Features• Manage Measurement Uncertainties – Confidence

Graphical Reports Communicate Process Improvements Geometric fitting uncertainty (sphere, line, plane, cylinder, etc)

Month 200X 2004 Coordinate Measurement System Committee Page 15

© A

IRB

US

UK

LTD

200

2. A

ll rig

hts

rese

rved

. Con

fiden

tial a

nd p

ropr

ieta

ry d

ocum

ent.

Metrology Confidence with USMN on Wing Survey

Month 200X 2004 Coordinate Measurement System Committee Page 16

© A

IRB

US

UK

LTD

200

2. A

ll rig

hts

rese

rved

. Con

fiden

tial a

nd p

ropr

ieta

ry d

ocum

ent.

Hinge Line Targeting Uncertainty

Extrapolation Pt Targeting Expands Uncertainty

Uncertainty Expanded by 23%

Month 200X 2004 Coordinate Measurement System Committee Page 17

© A

IRB

US

UK

LTD

200

2. A

ll rig

hts

rese

rved

. Con

fiden

tial a

nd p

ropr

ieta

ry d

ocum

ent.

Hinge Line Targeting Uncertainty

Mid Pt Targeting Reduces Uncertainty

Uncertainty Reduced by 16%

Month 200X 2004 Coordinate Measurement System Committee Page 18

© A

IRB

US

UK

LTD

200

2. A

ll rig

hts

rese

rved

. Con

fiden

tial a

nd p

ropr

ieta

ry d

ocum

ent.

Relationship Fitting Methodology

• Align critical features within the A380 wing system:Model interdependenceRelative importance with weightingInteraction between key kinematic mechanisms and critical

interface featuresEach relationship has an inherent local reporting frame

• Best-Fit Weighted RelationshipsAs-Built configuration is optimized to its nominal CAD model

on the shop floorSimultaneously fits the constraints defined by the

relationshipsRelative importance of each constraint is controlled using

weights set by the production team

Month 200X 2004 Coordinate Measurement System Committee Page 19

© A

IRB

US

UK

LTD

200

2. A

ll rig

hts

rese

rved

. Con

fiden

tial a

nd p

ropr

ieta

ry d

ocum

ent.

Scanner Survey Optimized to CAD

Relationship Fitting: Interface Feature Alignment

Month 200X 2004 Coordinate Measurement System Committee Page 20

© A

IRB

US

UK

LTD

200

2. A

ll rig

hts

rese

rved

. Con

fiden

tial a

nd p

ropr

ieta

ry d

ocum

ent.

Relationship Fitting: Hinge Line Kinematics

Optimize Hinge Line Configuration + Build to Nominal

Month 200X 2004 Coordinate Measurement System Committee Page 21

© A

IRB

US

UK

LTD

200

2. A

ll rig

hts

rese

rved

. Con

fiden

tial a

nd p

ropr

ieta

ry d

ocum

ent.

Q & A session