Integrated cad metrology and alignment of key features of a380 wings
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2004 Coordinate Measurement System Committee. Presented by. Integrated CAD-Metrology and Alignment of Key Features of A380 Wings. Introduction – A380 Metrology at Broughton. Measurement Systems Laser Trackers Alignments of kinematic mechanisms Laser Radar Scanner

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

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Integrated cad metrology and alignment of key features of a380 wings

2004 Coordinate Measurement System Committee

Presented by

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

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Introduction a380 metrology at broughton

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

2004 Coordinate Measurement System Committee


Lsm systems used on a380 and why

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

2004 Coordinate Measurement System Committee


Measured features on an a380 wing set

Measured features on an A380 Wing set

OVERWING PANEL x 2

ENGINE PYLONS x 4

UNDERWING PANEL x 2

FLAP BEAMS x 10

Laser

tracker

WING ROOT x 2

Laser

Radar

AILERONS x 6

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


Measured features on an a380 wing set1

Measured features on an A380 Wing set

Engine Pylon Geometry

Forks

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


Measured features on an a380 wing set2

Measured Features on an A380 Wing set

Z

Y

X

Wing Tip Falsework

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


Stage 02 measurement requirement

Stage 02 Measurement requirement

Wing Root Measurement

= Datum reference points

Top skin profile

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

2004 Coordinate Measurement System Committee


Stage 02 measurement requirement1

Stage 02 Measurement requirement

Wing Incidence

Incidence

Nose up tolerance

Incidence

primary datum

Incidence

Nose down tolerance

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


Future metrology software requirements at airbus

Future metrology software requirements at Airbus

LEAST SQUARES

FITTING

EASIER AND POSITIVE SCRIPTING OPTIONS & OUTCOMES

ATTRIBUTEYEYES/NO SOLUTION REQUIRED

SKILLFULL

OPERATORS

REQUIRED

HINGE LINE

FITTING TODAY

HINGE LINE

FITTING OPTIMISED

ELECTRONIC GAUGING

=

MULTIPLE SOLUTIONS

FITTING RESIDUALS STORED FOR LATER USE

ELECTRONIC GAUGING SOLUTION

2004 Coordinate Measurement System Committee


Measurement control

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

2004 Coordinate Measurement System Committee


Model driven verification with integrated metrology

Model Driven Verification with Integrated Metrology

Automated inspection of critical interface features with Laser Scanner

2004 Coordinate Measurement System Committee


Model driven assembly

Model Driven Assembly

Kinematics mechanism alignment directly to CAD

2004 Coordinate Measurement System Committee


Hinge line alignment reporting

Hinge Line Alignment Reporting

Working Frame

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

2004 Coordinate Measurement System Committee


Integrating measurement technologies usmn

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)

2004 Coordinate Measurement System Committee


Metrology confidence with usmn on wing survey

Metrology Confidence with USMN on Wing Survey

95.46% Confidence Interval (2-sigma)

2004 Coordinate Measurement System Committee


Hinge line targeting uncertainty

Hinge Line Targeting Uncertainty

Extrapolation Pt Targeting Expands Uncertainty

Uncertainty Expanded by 23%

2004 Coordinate Measurement System Committee


Hinge line targeting uncertainty1

Hinge Line Targeting Uncertainty

Mid Pt Targeting Reduces Uncertainty

Uncertainty Reduced by 16%

2004 Coordinate Measurement System Committee


Relationship fitting methodology

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

2004 Coordinate Measurement System Committee


Relationship fitting interface feature alignment

Relationship Fitting: Interface Feature Alignment

Scanner Survey Optimized to CAD

2004 Coordinate Measurement System Committee


Relationship fitting hinge line kinematics

Relationship Fitting: Hinge Line Kinematics

Optimize Hinge Line Configuration + Build to Nominal

2004 Coordinate Measurement System Committee


Q a session

Q & A session

2004 Coordinate Measurement System Committee


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