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

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July 2004

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Integrated CAD
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Metrology and Alignment
of Key Features of A380 Wings

2004 Coordinate Measurement System Committee


Presented by





Geraint Jones

Airbus UK

Lead Metrology Engineer


Scott Sandwith

New River Kinematics

Metrology Software Engineer

© AIRBUS UK LTD 2002. All rights reserved. Confidential and proprietary document.

Month 200X


2004 Coordinate Measurement System Committee

Page
2

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

© AIRBUS UK LTD 2002. All rights reserved. Confidential and proprietary document.

Month 200X


2004 Coordinate Measurement System Committee

Page
3

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


© AIRBUS UK LTD 2002. All rights reserved. Confidential and proprietary document.

Month 200X


2004 Coordinate Measurement System Committee

Page
4

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

Laser

Radar

Laser

tracker

© AIRBUS UK LTD 2002. All rights reserved. Confidential and proprietary document.

Month 200X


2004 Coordinate Measurement System Committee

Page
5

Measured features on an A380 Wing set

Engine Pylon Geometry

Forks

Thrust Spigot

Aft fitting

Aims:

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To inspect the position of the Forks in the X direction

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To inspect the position of the Aft fitting in the Y direction

-
To inspect the orientation of the Forks to the engine thrust line

© AIRBUS UK LTD 2002. All rights reserved. Confidential and proprietary document.

Month 200X


2004 Coordinate Measurement System Committee

Page
6

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 B

From an initial alignment the relationships

function allows a fine adjustment of the translation

in Z and rotation around X.

© AIRBUS UK LTD 2002. All rights reserved. Confidential and proprietary document.

Month 200X


2004 Coordinate Measurement System Committee

Page
7

Stage 02 Measurement requirement

LR200




Rear 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 to

measure spar orientation with respect to the CAD model



= Datum reference points

© AIRBUS UK LTD 2002. All rights reserved. Confidential and proprietary document.

Month 200X


2004 Coordinate Measurement System Committee

Page
8

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



Incidence

primary datum

© AIRBUS UK LTD 2002. All rights reserved. Confidential and proprietary document.

Month 200X


2004 Coordinate Measurement System Committee

Page
9

Future metrology software requirements at Airbus




HINGE LINE

FITTING TODAY

LEAST SQUARES

FITTING

MULTIPLE SOLUTIONS

SKILLFULL

OPERATORS

REQUIRED

HINGE LINE

FITTING OPTIMISED

ATTRIBUTEY
EYES/NO
SOLUTION
REQUIRED

FITTING
RESIDUALS
STORED
FOR LATER
USE

EASIER
AND
POSITIVE
SCRIPTING
OPTIONS &
OUTCOME
S

ELECTRONI
C GAUGING
SOLUTION

=

ELECTRONIC GAUGING

© AIRBUS UK LTD 2002. All rights reserved. Confidential and proprietary document.

Month 200X


2004 Coordinate Measurement System Committee

Page
10

Measurement Control


Measurement Control with CAD Model Driven Assembly


Build/Inspect direct to model definition produces common
results

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


Model controls conformance


Tolerances are relative to features


Pragmatic GD&T with feature to feature relationships


Quality Procedures


Graphical Reports


improves communication


SPC Charting yields process control


Unified Spatial Metrology Network to ensure process
capabilities


Feature based alignment strategies


Relationship Fitting


direct alignment of measurements and
instruments to model


© AIRBUS UK LTD 2002. All rights reserved. Confidential and proprietary document.

Month 200X


2004 Coordinate Measurement System Committee

Page
11

Model Driven Verification with Integrated Metrology

Automated inspection of critical
interface features with Laser
Scanner

© AIRBUS UK LTD 2002. All rights reserved. Confidential and proprietary document.

Month 200X


2004 Coordinate Measurement System Committee

Page
12

Model Driven Assembly

Kinematics mechanism alignment directly to CAD

© AIRBUS UK LTD 2002. All rights reserved. Confidential and proprietary document.

Month 200X


2004 Coordinate Measurement System Committee

Page
13

Hinge Line Alignment Reporting

Working Frame

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

© AIRBUS UK LTD 2002. All rights reserved. Confidential and proprietary document.

Month 200X


2004 Coordinate Measurement System Committee

Page
14

Integrating Measurement Technologies
-

USMN


USMN


Network Optimization


Determine real
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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


C
ommunicate


Process Improvements


Geometric fitting uncertainty (sphere, line, plane, cylinder, etc)

© AIRBUS UK LTD 2002. All rights reserved. Confidential and proprietary document.

Month 200X


2004 Coordinate Measurement System Committee

Page
15

Metrology Confidence with USMN on Wing Survey

© AIRBUS UK LTD 2002. All rights reserved. Confidential and proprietary document.

Month 200X


2004 Coordinate Measurement System Committee

Page
16

Hinge Line Targeting Uncertainty

Extrapolation Pt Targeting

Expands Uncertainty

Uncertainty
Expanded by 23%

© AIRBUS UK LTD 2002. All rights reserved. Confidential and proprietary document.

Month 200X


2004 Coordinate Measurement System Committee

Page
17

Hinge Line Targeting Uncertainty

Mid Pt Targeting Reduces Uncertainty

Uncertainty
Reduced by 16%

© AIRBUS UK LTD 2002. All rights reserved. Confidential and proprietary document.

Month 200X


2004 Coordinate Measurement System Committee

Page
18

Relationship Fitting Methodology


Align critical features within the A380 wing system:


Model interdependence


Relative importance with weighting


Interaction between key kinematic mechanisms and critical
interface features


Each relationship has an inherent local reporting frame


Best
-
Fit Weighted Relationships


As
-
Built configuration is optimized to its nominal CAD model
on the shop floor


Simultaneously fits the constraints defined by the
relationships


Relative importance of each constraint is controlled using
weights set by the production team

© AIRBUS UK LTD 2002. All rights reserved. Confidential and proprietary document.

Month 200X


2004 Coordinate Measurement System Committee

Page
19

Scanner Survey Optimized to CAD

Relationship Fitting: Interface Feature Alignment

© AIRBUS UK LTD 2002. All rights reserved. Confidential and proprietary document.

Month 200X


2004 Coordinate Measurement System Committee

Page
20

Relationship Fitting: Hinge Line Kinematics


Optimize Hinge Line Configuration + Build to Nominal

© AIRBUS UK LTD 2002. All rights reserved. Confidential and proprietary document.

Month 200X


2004 Coordinate Measurement System Committee

Page
21

Q & A session