Integrated CAD-Metrology and Alignment of Key Features of A380 Wings
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Transcript of Integrated CAD-Metrology and Alignment of Key Features of A380 Wings
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 Jones
Airbus UK Lead Metrology Engineer
Scott Sandwith
New River KinematicsMetrology Software Engineer
Month 200X 2004 Coordinate Measurement System Committee Page 2
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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 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
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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)
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
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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
Month 200X 2004 Coordinate Measurement System Committee Page 5
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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
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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.
Month 200X 2004 Coordinate Measurement System Committee Page 7
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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 to
measure spar orientation with respect to the CAD model
= Datum reference points
Month 200X 2004 Coordinate Measurement System Committee Page 8
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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
Incidence
Nose up tolerance
IncidenceNose down tolerance
Month 200X 2004 Coordinate Measurement System Committee Page 9
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Future metrology software requirements at Airbus
HINGE LINE
FITTING TODAY
LEAST SQUARES
FITTING
MULTIPLE SOLUTIONS
SKILLFULL
OPERATORS
REQUIRED
HINGE LINE
FITTING 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
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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 strategiesRelationship Fitting direct alignment of measurements and
instruments to model
Month 200X 2004 Coordinate Measurement System Committee Page 11
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Model Driven Verification with Integrated Metrology
Automated inspection of critical interface features with Laser Scanner
Month 200X 2004 Coordinate Measurement System Committee Page 12
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Model Driven Assembly
Kinematics mechanism alignment directly to CAD
Month 200X 2004 Coordinate Measurement System Committee Page 13
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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
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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
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Metrology Confidence with USMN on Wing Survey
Month 200X 2004 Coordinate Measurement System Committee Page 16
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Hinge Line Targeting Uncertainty
Extrapolation Pt Targeting Expands Uncertainty
Uncertainty Expanded by 23%
Month 200X 2004 Coordinate Measurement System Committee Page 17
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Hinge Line Targeting Uncertainty
Mid Pt Targeting Reduces Uncertainty
Uncertainty Reduced by 16%
Month 200X 2004 Coordinate Measurement System Committee Page 18
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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
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Scanner Survey Optimized to CAD
Relationship Fitting: Interface Feature Alignment
Month 200X 2004 Coordinate Measurement System Committee Page 20
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Relationship Fitting: Hinge Line Kinematics
Optimize Hinge Line Configuration + Build to Nominal
Month 200X 2004 Coordinate Measurement System Committee Page 21
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Q & A session