Computer Aided Design, Manufacturing & Measurement Integration
August 13-17 2001Coordinate Measurement System Committee
Albuquerque, New MexicoRichey-McIvor-Sandwith
Computer Aided Design Manufacturing& Measurement Integration
Copyright © 2001 The Boeing Company
Michael Richey & Robb McIvor, Boeing Scott Sandwith, New River Kinematics
Computer Aided Design, Manufacturing & Measurement Integration
August 13-17 2001Coordinate Measurement System Committee
Albuquerque, New MexicoRichey-McIvor-Sandwith
•CAD Geometry•Data management•Local Area/Zone X-form from Part Attributes•Key Characteristics – FD&T Tolerances
•Factory demonstration•Major Assembly directly from CAD•Multiple Real-time Hybrid Measurement Systems•Integrated Dynamic Graphical Interface
•Applications•Determinate Assembly •Multiple Measurement Interfaces
•Bulkhead Assembly Simulation•Summary - Questions
Computer Aided Design, Manufacturing & Measurement Integration
August 13-17 2001Coordinate Measurement System Committee
Albuquerque, New MexicoRichey-McIvor-Sandwith
Design
Produce Measurement/Analysis
Reporting
Information back into Design
3D Cad Model Authority
Process Scope
Computer Aided Design, Manufacturing & Measurement Integration
August 13-17 2001Coordinate Measurement System Committee
Albuquerque, New MexicoRichey-McIvor-Sandwith
2D Drawing Authority
2D Drawing Interpretation
Digital Product Line Today
3D Design
3D Model Release
Product
Tool Oriented Detail Assembly
2D drawing Assembly Inspection
3D Measurement Equipment
MFG Engineering
NC Programming
Manufacturing
Quality Assurance
Tooling
Product
Integrated Digital Product Line
3D Model Assembly Inspection
3d Model Oriented Detail Assembly
And Authority
Computer Aided Design, Manufacturing & Measurement Integration
August 13-17 2001Coordinate Measurement System Committee
Albuquerque, New MexicoRichey-McIvor-Sandwith
Wing Spar Test Program
Aug 2000
Computer Aided Design, Manufacturing & Measurement Integration
August 13-17 2001Coordinate Measurement System Committee
Albuquerque, New MexicoRichey-McIvor-Sandwith
Overview of 3D Measurement Pilot•Create 3D CAD Models of components, sub-assemblies and major components
•CATIA Model with Embedded Tolerancing
•Local Area/Zone X-form from Part Attributes
•Key Characteristics
•FD&T Tolerances
•Measurement Systems
Computer Aided Design, Manufacturing & Measurement Integration
August 13-17 2001Coordinate Measurement System Committee
Albuquerque, New MexicoRichey-McIvor-Sandwith
Functional Dimensioning and Tolerancing (FDT)
Computer Aided Design, Manufacturing & Measurement Integration
August 13-17 2001Coordinate Measurement System Committee
Albuquerque, New MexicoRichey-McIvor-Sandwith
•Data Transfer between CAD system and metrology system
•STEP (Standard for the Exchange of Product)
•International Standard ISO 10303
•AP203, AP219, and XML-Express
•Boeing Standard for Data Exchange (Lifecycle)
•IGES (International Graphics Exchange Specification).
•The format used for this project was STEP
Computer Aided Design, Manufacturing & Measurement Integration
August 13-17 2001Coordinate Measurement System Committee
Albuquerque, New MexicoRichey-McIvor-Sandwith
Measurements System Integration Challenges
•Boeing uses different types of CAMS for tool construction and maintenance which are controlled by 2D drawings.
•Operators are not trained to operate all of the different measurement systems. Operating software and data analysis varies significantly between systems, even for like kind technologies.
Measurements System Integration Solution
•A key to the success of this project was software which provided a common instrument interface, simultaneous and synchronsis data acquisition from different measurement instruments.
Computer Aided Design, Manufacturing & Measurement Integration
August 13-17 2001Coordinate Measurement System Committee
Albuquerque, New MexicoRichey-McIvor-Sandwith
Common Measurement Systems Interface
Computer Aided Design, Manufacturing & Measurement Integration
August 13-17 2001Coordinate Measurement System Committee
Albuquerque, New MexicoRichey-McIvor-Sandwith
Measurement and Assembly
•Dynamic real time graphical interface shows the measured location of the part against the CAD model. Easy to make adjustments with confidence.
•Distributed Computing Capable (real-time multi-task measurement and analysis across multiple computers)
•Synchronous Measurement between Instruments (Master-Slave or Synchronous Polled Modes)
•TCP/IP interfaces to instruments to enable distributed processing
•Supports remote process control and monitoring.
Computer Aided Design, Manufacturing & Measurement Integration
August 13-17 2001Coordinate Measurement System Committee
Albuquerque, New MexicoRichey-McIvor-Sandwith
Project Specifics
• Using a 3D CAD model; build components onto a wing spar web in tolerance with minimal tooling and CAMS equipment
• CAMS equipment consisted of two different manufacturers laser trackers and a PCMM
• “Tooling” consisted of movable steel stanchions and wooden wedges
Computer Aided Design, Manufacturing & Measurement Integration
August 13-17 2001Coordinate Measurement System Committee
Albuquerque, New MexicoRichey-McIvor-Sandwith
Registration/Transformation Example:
• The tracker on the “wet” (i.e., fuel) side of the spar web measured reference holes on the spar and was best-fit transform to the spars coordinate frame.
• The tracker on the “dry” side of the web was oriented to the spar’s model by best fitting measurements of web, chord, and ribs features to the spar’s CAD model on the shop floor.
• The PCMM measurements of reference features on the spar were used to transform it into the spar system.
• The PCMM could of just as easily transformed into the coordinate system established by the tracker on the “wet” side.
Computer Aided Design, Manufacturing & Measurement Integration
August 13-17 2001Coordinate Measurement System Committee
Albuquerque, New MexicoRichey-McIvor-Sandwith
Computer Aided Design, Manufacturing & Measurement Integration
August 13-17 2001Coordinate Measurement System Committee
Albuquerque, New MexicoRichey-McIvor-Sandwith
After establishing the appropriate coordinate systems, the “dry” side tracker set a stiffener while the PCMM simultaneously set a hinge line assembly.
Computer Aided Design, Manufacturing & Measurement Integration
August 13-17 2001Coordinate Measurement System Committee
Albuquerque, New MexicoRichey-McIvor-Sandwith
Determinate Assembly Application
Design & Tool Reduction• Potential reduction and elimination of families of tools and their maintenance.• Multiple airplane models using one holding fixture and 3D data sets from
secured wireless server. (Rate adjustable)• Produce multiple airplane models, end to end within the same docking tool
station.
Benefits• Reduction in Tool designs, build, and maintenance cost.• Short design to build time.• Eliminate 2D release process.• Less factory floor space.• Rate sensitive production process.
Computer Aided Design, Manufacturing & Measurement Integration
August 13-17 2001Coordinate Measurement System Committee
Albuquerque, New MexicoRichey-McIvor-Sandwith
Aft Pressure Bulkhead Assembly Simulation
Computer Aided Design, Manufacturing & Measurement Integration
August 13-17 2001Coordinate Measurement System Committee
Albuquerque, New MexicoRichey-McIvor-Sandwith
CAD -> Design• By-pass the 2D drawing release process• Smart DA Tool applications and wireless real-time location of CAD data to factory • Use of full production part assembly tolerances “embedded CAD attributes” • Compress Design to Build cycle times
CAMS -> Produce & Measure Anywhere• Perform Tool Routines with the tool in the loaded condition for sustaining programs• Fleet Support and filed maintenance• Wireless data between the DB and factory floor• Rate adjustable Determinate Assembly Smart Tool docking stations• Integrate "Key Characteristics" from the production part, into the & build plans
CAD -> Analysis• Common web enabled database for Internal/External Supplier • Provide database foundation for reduction in product variability and work repetition• Statistical Process Control, focus on unstable features to drive out root cause• Information, Utilized by all organizations 24/7
Summary
Computer Aided Design, Manufacturing & Measurement Integration
August 13-17 2001Coordinate Measurement System Committee
Albuquerque, New MexicoRichey-McIvor-Sandwith
References:Boeing Team Members:Michael Richey, CATIA LEAD InstructorRob McIvor 777 Tool ConstructionNew River Kinematics Team Members:Scott Sandwith