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Dimensional Management of Composite Tooling for the World’s Largest One Piece, All Composite Aircraft Fuselage PowerPoint Presentation
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Dimensional Management of Composite Tooling for the World’s Largest One Piece, All Composite Aircraft Fuselage. Presented by: Craig Cramer Boeing 787 Operations Mandrel Production Readiness Leader. Composite Solutions Applied Throughout the 787. Other 5%. Fiberglass 10%. Carbon laminate.

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Dimensional Management of Composite Tooling for the World’s Largest One Piece, All Composite Aircraft Fuselage

Presented by:

Craig Cramer

Boeing 787 Operations Mandrel Production Readiness Leader

composite solutions applied throughout the 787
Composite Solutions Applied Throughout the 787

Other

5%

Fiberglass

10%

Carbon laminate

Composites50%

Titanium15%

Carbon sandwich

Fiberglass

Aluminum

Aluminum20%

Aluminum/steel/titanium pylons

the project
The Project
  • Build a complete Test and Certification Barrel of the Boeing 787 Dreamliner fuselage (The 787 Fuselage team).
  • Construct this all composite fuselage as a One Piece Skin-Stinger Bond Assembly.
  • The Barrel, when completely assembled with doors, windows, floors, etc., will be fatigue tested for FAA Certification.
  • Maintain commonality between Boeing, the world wide Partners and the Suppliers (The Production Readiness Team [PRT]).
metrology application
Metrology Application
  • Metrology challenge: inspect the many surfaces of the Tools to optimize the as-built condition of each Sub-Assembly when the entire Tool is assembled
  • Model Preparation: Develop models, drive files and tolerances
  • Measurement Tasks:

(using laser radar scanner and laser trackers)

      • Inspect Tools for Quality Assurance
      • Use As-Built data to optimally assemble the tool
      • Measure IML and OML after fuselage is cured
  • Provide collection data to optimize the manufacturing process
  • Data used in certification and validation of the manufacturing processes for the FAA
stp metrology
STP - Metrology
  • Situation:

New manufacturing processes with shortened flow times require new methods for quickly analyzing data and generating feedback.

  • Target:

The proposed test program must have fast feedback loops of the survey data.

  • Proposal:

Use scripted measurement plans with Spatial Analyzer’s common interfaces to metrology systems, thus providing a closed loop control system with critical component features to automated product assembly. A Big Button interface for running the scripts simplifies shop floor implementation while enabling close process flow control. Embedded process checks and tolerances enable the script to handle real-world production assembly processes.

situation old method
Situation (Old Method)

NOM TOOL

SURFACES

MACHINE

THE TOOL

NOM NC

PROGRAM

Catia

ENGINEERING

SURFACES

Catia

STEP FILE

TRANSLATOR

FORMULATE

THE

INSPECTION

PLAN

CREATE

NOMINAL

INSPECTION

FILE

CHECK

TOOL

CREATE

DRIVE FILE

Spatial

Analyzer

Excel

Catia

PowerPoint

Catia

These processes may take several weeks because they are mostly manual input

RESULTS

REPORTED

MEASURED

DATA

ANALYZED

Excel

the target
The Target
  • Seamless integration of measurement requirements in the Design/Quality Engineering and Production processes for 787 Fuselage Test Barrels.
  • Accurate and concise analysis of the data collected, verified directly to the digital model.
  • Rapid turn-around of collected data to support decision making.
  • Understandable reporting of the data to all participating parties, delivered in a timely/consistent manner.
  • Make the measurement results available enterprise-wide on the internet.
  • Future application for partner use on production airplane (digital portable solution).
  • All partners/suppliers use the same digital thread: common tie-in and verification method yield product consistency across the supplier/partner chain.
the proposal
The Proposal
  • Form a team of metrology experts to script Measurement Plans.
  • Script measurement plans and assist in the surveys as needed (the team).
  • Use the same software throughout the process to avoid misinterpretation of data.
  • Use real time analysis capabilities, on screen, so the operator will know immediately if the data is valid.
  • Inspection buy-off can be done ‘on-the-spot’ as the survey is being taken, or hand stamped on the paper copy of the report, directly to the design model.
  • Generate reports ‘on-the-spot’ and/or send results to a server for instant observation upon survey completion (avoid delay).
  • Share reports enterprise-wide via the internet.
  • Use existing tools if possible (SA is currently accredited software in the Boeing Company).
the plan new method
The Plan(New Method)
  • Write integrated Scripted Measurement Plans and Analysis Tasks to avoid misinterpretation of data.
  • Use the same software to write Measurement Plans, perform the survey and provide analysis.
  • Reduce, or eliminate, the time consumed by manual analysis.
  • Rapid turn-around of analysis after data collection is complete.
  • Work directly with the CAD model.
  • Instrument observations, reference tie-in, and measurement uncertainties are captured, documented and communicated consistently, establishing a level of confidence in production deliveries.
new method flow
New Method Flow

NOM TOOL

SURFACES

MACHINE

THE TOOL

NOM NC

PROGRAM

Catia

ENGINEERING

SURFACES

INSTANT

FEED BACK

Catia

DRAFT THE

PLAN

DRIVE FILE &

INSPECTION

CREATION

FORMULATE

THE

INSPECTION

PLAN

CHECK

TOOL

GENERATE

REPORTS

Spatial

Analyzer

Spatial

Analyzer

Spatial

Analyzer

Spatial

Analyzer

PowerPoint

metrology automation concepts
Metrology Automation Concepts
  • Communication between components, including across process and network boundaries
  • Shared measurement process components (e.g., Locate Instrument, AutoMeasure, MeasureMode)
  • Quick error and status reporting
  • Conditional Branching, Looping, and Interactive Queries
  • Dynamic loading of components
  • Constructs for instrument control, compound documents, automation, data transfer, storage and naming
templates and measurement plans
Templates and Measurement Plans
  • SA Template Files
    • CAD Model and Settings
    • Instruments Location and Settings
  • MP  Script of Measurement Process
    • Load Template
    • Start Instrument Interface
    • Data Collection  Drive Scanner & Rotate the Tool
    • Auto-Alignment to CAD
    • Feature Detection  Extraction
    • Feature Analysis
    • Generate Report
    • Save and Archive Inspection
template creation
Template Creation
  • Model information transfer
    • Getting the drawing intent into the graphics software
      • Elements; Surfaces, Holes, Lines
      • Features; Datum's, Tolerances
  • Creation of tags
    • Modify design standards
      • Standard labeling methods
      • Defined Model layers
measurement plan automation
Measurement Plan Automation
  • Automated Drive File Creation – Feature Based
mp process components
Templates

CAD Model

Instruments

Measurement plan

Initialize (load template)

Enhancements

Data Collection

Registration/Fit to Features

Feature Extraction

Query/Analysis

Process Checks

Reporting

Data Export

Step (AP203,214)

Documents: Word,Excel,AVI,HTML

User feed back

Pass Fail

Graphics

Tabular

Save & Archive

Operator interface

Inputs (User info)

Run

Output

MP Process Components
manage process elements
Data Exchange

Model

Tolerances

Feature relationships

Instrument Interface

Drive Instrument

Field checks

Initial Instrument Alignment

Process time

Multiple instruments

Translation/Rotation stages

Integrating different Metrology Devices

% of applications need two diff metrologies

Master slave control

Process triggers

Examples:

Robot & Scanner

Scanner with Tracker

Manage Process Elements
acknowledgments
Acknowledgments

Craig Neidig

Boeing Commercial Airplanes

787 Tool Engineering

File Creation

David B. Holm

Karl W. Kunst

Boeing Management

Scott Sandwith

New River Kinematics

Technical support

M.J. Fjellestad

Boeing Commercial Airplanes

777 Program

Editing