2004 Coordinate Measurement System Committee Presented by Geraint

2004 Coordinate Measurement System Committee 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 A 380 Wings Use menu "View - Header & Footer" for Presentation title - Siglum - Reference July 2004

Introduction – A 380 Metrology at Broughton • Measurement Systems 4 Laser Trackers – Alignments of kinematic mechanisms 4 Laser Radar Scanner – Direct measurement of performance and interface features • Assembly of the Airbus A 380 Wing © AIRBUS UK LTD 2002. All rights reserved. Confidential and proprietary document. 4 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 4 Relationship Fitting optimize part alignment to CAD 4 Confident product configuration and communication 4 2004 Coordinate Measurement System Committee Month 200 X 2

LSM systems used on A 380 and why Current systems used on the A 380 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 • © AIRBUS UK LTD 2002. All rights reserved. Confidential and proprietary document. • 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 2004 Coordinate Measurement System Committee Month 200 X 3

Measured features on an A 380 Wing set OVERWING PANEL x 2 ENGINE PYLONS x 4 UNDERWING PANEL x 2 FLAP BEAMS x 10 © AIRBUS UK LTD 2002. All rights reserved. Confidential and proprietary document. 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 2004 Coordinate Measurement System Committee Month 200 X 4

Measured features on an A 380 Wing set Engine Pylon Geometry Forks © AIRBUS UK LTD 2002. All rights reserved. Confidential and proprietary document. 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 2004 Coordinate Measurement System Committee Month 200 X 5

Measured Features on an A 380 Wing set Wing Tip Falsework Z Y © AIRBUS UK LTD 2002. All rights reserved. Confidential and proprietary document. 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. 2004 Coordinate Measurement System Committee Month 200 X 6

Stage 02 Measurement requirement Wing Root Measurement = Datum reference points Top skin profile © AIRBUS UK LTD 2002. All rights reserved. Confidential and proprietary document. Front spar Centre spar LR 200 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 2004 Coordinate Measurement System Committee Month 200 X 7

Stage 02 Measurement requirement Wing Incidence ce e iden oleranc c In pt se u No © AIRBUS UK LTD 2002. All rights reserved. Confidential and proprietary document. 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 2004 Coordinate Measurement System Committee Inc ide nce No se do wn t ole Month 200 X ran ce 8

Future metrology software requirements at Airbus LEAST SQUARES FITTING SKILLFULL OPERATORS REQUIRED © AIRBUS UK LTD 2002. All rights reserved. Confidential and proprietary document. HINGE LINE FITTING TODAY MULTIPLE SOLUTIONS EASIER AND POSITIVE SCRIPTING OPTIONS & OUTCOMES ATTRIBUTEY EYES/NO SOLUTION REQUIRED HINGE LINE FITTING OPTIMISED ELECTRONI C GAUGING SOLUTION = ELECTRONIC GAUGING FITTING RESIDUALS STORED FOR LATER USE 2004 Coordinate Measurement System Committee Month 200 X 9

Measurement Control • Measurement Control with CAD Model Driven Assembly 4 Build/Inspect direct to model definition produces common results Minimal secondary support tooling (e. g. Shop Aids and Targeting) 4 Model controls conformance 4 Tolerances are relative to features 4 Pragmatic GD&T with feature to feature relationships © AIRBUS UK LTD 2002. All rights reserved. Confidential and proprietary document. • Quality Procedures 4 Graphical Reports improves communication 4 SPC Charting yields process control 4 Unified Spatial Metrology Network to ensure process capabilities • Feature based alignment strategies 4 Relationship Fitting direct alignment of measurements and instruments to model 2004 Coordinate Measurement System Committee Month 200 X 10

© AIRBUS UK LTD 2002. All rights reserved. Confidential and proprietary document. Model Driven Verification with Integrated Metrology Automated inspection of critical interface features with Laser Scanner 2004 Coordinate Measurement System Committee Month 200 X 11

Model Driven Assembly © AIRBUS UK LTD 2002. All rights reserved. Confidential and proprietary document. Kinematics mechanism alignment directly to CAD 2004 Coordinate Measurement System Committee Month 200 X 12

Hinge Line Alignment Reporting © AIRBUS UK LTD 2002. All rights reserved. Confidential and proprietary document. Working Frame Bull's-eye Charts Showing Hinge Line Tolerances and Results 2004 Coordinate Measurement System Committee Month 200 X 13

Integrating Measurement Technologies - USMN • USMN – Network Optimization Determine real-world uncertainty fields for Points and Features 4 Characterize actual instrument uncertainty performance from Shop Floor Surveys 4 Take advantage of relative uncertainty of measurement components 4 • Multiple Instrument Network Scanner + Tracker Systems operate synchronously in a cooperative network aligned with USMN 4 USMN orientation produces optimal results 4 Traceable uncertainty estimates for Points, Instruments, and Features © AIRBUS UK LTD 2002. All rights reserved. Confidential and proprietary document. 4 • Manage Measurement Uncertainties – Confidence Graphical Reports Communicate Process Improvements 4 Geometric fitting uncertainty (sphere, line, plane, cylinder, etc) 4 2004 Coordinate Measurement System Committee Month 200 X 14

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

Hinge Line Targeting Uncertainty © AIRBUS UK LTD 2002. All rights reserved. Confidential and proprietary document. Extrapolation Pt Targeting Expands Uncertainty Expanded by 23% 2004 Coordinate Measurement System Committee Month 200 X 16

Hinge Line Targeting Uncertainty Mid Pt Targeting Reduces Uncertainty © AIRBUS UK LTD 2002. All rights reserved. Confidential and proprietary document. Uncertainty Reduced by 16% 2004 Coordinate Measurement System Committee Month 200 X 17

Relationship Fitting Methodology • Align critical features within the A 380 wing system: interdependence 4 Relative importance with weighting 4 Interaction between key kinematic mechanisms and critical interface features 4 Each relationship has an inherent local reporting frame © AIRBUS UK LTD 2002. All rights reserved. Confidential and proprietary document. 4 Model • Best-Fit Weighted Relationships 4 As-Built configuration is optimized to its nominal CAD model on the shop floor 4 Simultaneously fits the constraints defined by the relationships 4 Relative importance of each constraint is controlled using weights set by the production team 2004 Coordinate Measurement System Committee Month 200 X 18

Relationship Fitting: Interface Feature Alignment © AIRBUS UK LTD 2002. All rights reserved. Confidential and proprietary document. Scanner Survey Optimized to CAD 2004 Coordinate Measurement System Committee Month 200 X 19

Relationship Fitting: Hinge Line Kinematics © AIRBUS UK LTD 2002. All rights reserved. Confidential and proprietary document. Optimize Hinge Line Configuration + Build to Nominal 2004 Coordinate Measurement System Committee Month 200 X 20