CMSC 2005

Presented by:Craig CramerBoeing 787 Operations Mandrel Production Readiness Leader

Dimensional Management of

Composite Tooling for the World’s

Largest One Piece, All Composite

Aircraft Fuselage

CMSC 2005Composite Solutions Applied Throughout the 787

Carbon laminate

Carbon sandwich

Fiberglass

Aluminum

Aluminum/steel/titanium pylons

Composites50%

Aluminum20%

Titanium15%

Fiberglass10%

Other5%

CMSC 2005 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]).

CMSC 2005 Completed Test Barrel

CMSC 2005 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)

a. Inspect Tools for Quality Assurance

b. Use As-Built data to optimally assemble the tool

c. 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

CMSC 2005 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.

CMSC 2005 Situation (Old Method)

ENGINEERINGSURFACES

NOM TOOLSURFACES

CREATE NOMINAL

INSPECTIONFILE

CREATEDRIVE FILE

NOM NCPROGRAM

Catia

Catia

Catia Excel

MACHINETHE TOOL

CHECKTOOL

SpatialAnalyzer

STEP FILETRANSLATOR

FORMULATETHE

INSPECTIONPLAN

PowerPoint Catia

RESULTSREPORTED

Excel

MEASUREDDATA

ANALYZED

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

CMSC 2005 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.

CMSC 2005 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).

CMSC 2005 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.

CMSC 2005 New Method Flow

ENGINEERINGSURFACES

NOM TOOLSURFACES

FORMULATETHE

INSPECTIONPLAN

NOM NCPROGRAM

Catia

Catia

MACHINETHE TOOL

SpatialAnalyzer

GENERATEREPORTS

DRIVE FILE &INSPECTIONCREATION

Spatial Analyzer

Spatial Analyzer

Spatial Analyzer

INSTANT FEED BACK

CHECKTOOL

DRAFT THE PLAN

PowerPoint

CMSC 2005 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

CMSC 2005 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

CMSC 2005 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

CMSC 2005 Measurement Plan Automation

Automated Drive File Creation – Feature Based

CMSC 2005

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

CMSC 2005 Completed Barrel with (3) LR200 Scanners Setup

#1

#3

#2

CMSC 2005

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

CMSC 2005 Acknowledgments

Craig NeidigBoeing Commercial Airplanes787 Tool EngineeringFile Creation

David B. Holm Karl W. KunstBoeing Management

Scott SandwithNew River KinematicsTechnical support

M.J. FjellestadBoeing Commercial Airplanes 777 ProgramEditing

CMSC 2005

QUESTIONS?

CMSC 2005

Thank you!