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V-STARS AUTOMATED MEASUREMENT

V-STARS AUTOMATED MEASUREMENT. Measurement and Record of Connecting Rods Lengths (Struts) in the A380 Wing Box TR21 AIRBUS Nantes France. Speaker : N. ROMMAN. Synopsis. Struts in Wingbox A380 Former Mean of Measurement Tests of feasibility and comparisons with other systems

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V-STARS AUTOMATED MEASUREMENT

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  1. V-STARS AUTOMATED MEASUREMENT Measurement and Record of Connecting Rods Lengths (Struts) in the A380 Wing Box TR21 AIRBUS Nantes France Speaker : N. ROMMAN

  2. Synopsis Struts in Wingbox A380 Former Mean of Measurement Tests of feasibility and comparisons with other systems Measurement and Automation Additional features

  3. Synopsis Struts in Wingbox A380 Former Mean of Measurement Tests of feasibility and comparisons with other systems Measurement and Automation Additional features

  4. WingBox A380 • During assembly: • Volume and Maintain of Wingbox • Tooling Struts

  5. WingBox A380 • Tooling Struts : Front Part

  6. WingBox A380 • Tooling Struts : Rear Part

  7. WingBox A380 • Measurement of Connecting Rods Lengths : Manufacture Carbon Struts • 143 Struts : • 66 Front Part • 77 Rear Part

  8. // 19.042 à 22.217 H9 WingBox A380 • Measurement of Connecting Rods Lengths : • Lengths between 1050mm and 2350mm

  9. Synopsis Struts in Wingbox A380 Former Mean of Measurement Tests of feasibility and comparisons with other systems Measurement and Automation Additional features

  10. Former Measurement • « Caliper » :

  11. Former Measurement • Former Process (4 separate areas): • Remove the floor in the Measurement area • Remove the Tooling Struts in the Measurement area • Calibrate the caliper with a Reference Bar

  12. Former Measurement • Mesurement of Connecting Rods Lengths • Fill manually the results sheet • Re-install the Tooling Struts • Restart the same process for the 3 other areas • Fill all the results in an Excel file

  13. Former Measurement • Drawbacks : • Need to remove the floor • Need to divide the Measurement into 4 parts • Need to remove and install again all the Tooling Struts • Lead time: 8 hours for 2 operators • Caliper : heavy, bulky, difficult to handle

  14. Former Measurement • Drawbacks : • Need to calibrate the caliper • Risk of errors in the positioning of the caliper • Risk of errors when the operator reads or writes the values • Risk of errors when filling the Excel file

  15. Synopsis Struts in Wingbox A380 Former Mean of Measurement Tests of feasibility and comparisons with other systems Measure and Automation Additional features

  16. Tests and Comparisons • Measurement of WingBox’ Front Part • Adhesive targets to simulate all the struts position

  17. Tests and Comparisons • 14 accurate targets for a comparison between the four measurement systems : • V-STARS S8/ INCA3 • V-STARS E4X/ NIKON D2X • Laser Tracker LEICA (LTD500) • Caliper in service

  18. Tests and Comparisons • V-STARS Measurement :

  19. Tests and Comparisons • Comparison: • Values in millimeters

  20. Tests and Comparisons • Results : • Feasibility of the measurement with V-STARS shown (~ 50 pictures) • Rapidity and simplicity to set up the targets and to achieve the measurement

  21. Tests and Comparisons • System chosen by AIRBUS Nantes: • V-STARS E4X System / NIKON D2X

  22. Synopsis Struts in Wingbox A380 Former Mean of Measurement Tests of feasibility and comparisons with other systems Measurement and Automation Additional features

  23. Measurement and automation Targets Preparation of the measurement Taking pictures Automation with V-StarsCom Results

  24. Measurement - Targets • Two kinds of targets used : • for free holes • for holes with tooling struts free holes tooling strut

  25. Measurement - Targets TSOR with 3 Balls : balls

  26. Measurement - Targets • Target for free holes: • Tree balls mounted on spring • Auto-centres the target • Holds the target in the hole without constraint

  27. Measurement - Targets Target for holes with tooling strut : 3 balls to centre and maintain the target

  28. Measurement - Targets • The target is aligned to the centre of the hole mounted on the bar pin • Base of the target against the surface

  29. Measurement - Targets Target for holes with tooling strut : Feature Target is used to construct a point with the same offset than the TSOR

  30. Measurement - Targets • Coded targets : • for Feature Target • for Automation (Driver file is used) Right label Strut’s length automatically computed

  31. Measurement - Preparation • The measurement is done in 2 steps : • Wingbox Front Part (66 lengths) • Wingbox Rear Part (77 lengths) TSOR targets can be inserted in any free holes. Targets installed on tool struts have a specific position.

  32. Measurement - Preparation Each target is used in Front Part and Rear Part of the Wingbox.

  33. Measurement - Preparation Scale Bar :

  34. Measurement - Pictures Wingbox front part ready to be measured :

  35. Measurement Procedure Stations

  36. Measurement Procedure Stations

  37. Measurement - Pictures Measurement : 48 pictures Remove the memory card from the camera and insert it in the PC. Open “V-StarsCom” (automation software of V-STARS)

  38. Measurement – V-StarsCom

  39. Measurement – V-StarsCom

  40. Measurement – V-StarsCom

  41. Measurement – Excel File Result in Excel file

  42. Measurement – Excel File Results of Front Part are filled in the Excel file. The Excel file will be completed automatically with the measurement data of the Rear Part. After results validation, the Struts can be manufactured.

  43. Synopsis Struts in Wingbox A380 Former Mean of Measurement Tests of feasibility and comparisons with other systems Measure and Automation Additional features

  44. Additional Features Measurement of the Reference Plane :

  45. Additional Features Check the “ΔY” value for each Strut // with the Reference Plane within 2mm Point on Upper Panel Point on Lower Panel

  46. Additional Features A new Excel file will be automatically created with “ΔY” coordinates :

  47. One operator measurement for each part Front and Rear

  48. Users and Supplier • Airbus Nantes France • System Information Dept. Manager: Patrick GUERIN • Metrologist Expert: Thierry PAVAGEAU • FAL Wing Box Manager: Antoine BAUD • Engineering Supplier (G.M.S. France) • Manager : Nabil ROMMAN

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