Transcript Document

2004 Coordinate Measurement System Committee
July 2004
Presented by
Geraint Jones
Airbus UK
Scott Sandwith
New River Kinematics
Lead Metrology Engineer
Metrology Software Engineer
Integrated CAD-Metrology and Alignment
of Key Features of A380 Wings
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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
© AIRBUS UK LTD 2002. All rights reserved. Confidential and proprietary document.

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

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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)
© AIRBUS UK LTD 2002. All rights reserved. Confidential and proprietary document.
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
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Measured features on an A380 Wing set
OVERWING PANEL x 2
ENGINE PYLONS x 4
UNDERWING PANEL x 2
FLAP BEAMS x 10
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AILERONS x 6
WING ROOT x 2
Laser
tracker
Laser
Radar
WING TWIST x 2
FLAP TRACK
FAIRINGS X 48
FALSEWORK X 4
SPOILERS x 16
A total of 96 planned measurement tasks per wing set!
60% involve building routines as well as inspection
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Measured features on an A380 Wing set
Engine Pylon Geometry
Forks
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Thrust Spigot
Aft fitting
Aims:
-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
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Measured Features on an A380 Wing set
Wing Tip Falsework
Z
Y
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X
Surface B
Surface A
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.
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Stage 02 Measurement requirement
Wing Root Measurement
= Datum reference points
Top skin profile
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Front spar
Centre spar
LR200
Rear spar
Bottom skin profile
Aims:
To measure top and bottom skin surface profiles and to
measure spar orientation with respect to the CAD model
Junction to Wing box/fuselage
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Stage 02 Measurement requirement
Wing Incidence
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Incidence
primary datum
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
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Future metrology software requirements at Airbus
LEAST SQUARES
FITTING
SKILLFULL
OPERATORS
REQUIRED
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HINGE LINE
FITTING TODAY
MULTIPLE SOLUTIONS
EASIER
AND
POSITIVE
SCRIPTING
OPTIONS &
OUTCOME
S
ATTRIBUTEY
EYES/NO
SOLUTION
REQUIRED
HINGE LINE
FITTING OPTIMISED
ELECTRONI
C GAUGING
SOLUTION
=
ELECTRONIC GAUGING
FITTING
RESIDUALS
STORED
FOR LATER
USE
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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
© AIRBUS UK LTD 2002. All rights reserved. Confidential and proprietary document.
• Quality Procedures
Reports  improves communication
SPC Charting yields process control
Unified Spatial Metrology Network to ensure process
capabilities
Graphical
• Feature based alignment strategies
Fitting  direct alignment of measurements and
instruments to model
Relationship
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Model Driven Verification with Integrated Metrology
Automated inspection of critical
interface features with Laser
Scanner
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Model Driven Assembly
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Kinematics mechanism alignment directly to CAD
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Hinge Line Alignment Reporting
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Working Frame
Bull's-eye Charts Showing Hinge Line Tolerances and Results
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Integrating Measurement Technologies - USMN
•
USMN – Network Optimization



•
Multiple Instrument Network  Scanner + Tracker

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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


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)
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Metrology Confidence with USMN on Wing Survey
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Hinge Line Targeting Uncertainty
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Extrapolation Pt Targeting
Expands Uncertainty
Uncertainty
Expanded by 23%
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Hinge Line Targeting Uncertainty
Mid Pt Targeting Reduces Uncertainty
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Uncertainty
Reduced by 16%
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Relationship Fitting Methodology
• Align critical features within the A380 wing system:
interdependence
Relative importance with weighting
Interaction between key kinematic mechanisms and critical
interface features
Each relationship has an inherent local reporting frame
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Model
• 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
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Relationship Fitting: Interface Feature Alignment
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Scanner Survey Optimized to CAD
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Relationship Fitting: Hinge Line Kinematics
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Optimize Hinge Line Configuration + Build to Nominal
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Q & A session
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