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

A380

1. 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 Kinematics
Metrology Software Engineer

2. Month 200X 2004 Coordinate Measurement System Committee Page 2
©

A
I
R
B
U
S

U
K

L
T
D

2
0
0
2
.
A
ll
r
ig
h
t
s

r
e
s
e
r
v
e
d
.

C
o
n
f
id
e
n
t
ia
l
a
n
d

p
r
o
p
r
ie
t
a
r
y

d
o
c
u
m
e
n
t
.
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

3. Month 200X 2004 Coordinate Measurement System Committee Page 3
©

A
I
R
B
U
S

U
K

L
T
D

2
0
0
2
.
A
ll
r
ig
h
t
s

r
e
s
e
r
v
e
d
.

C
o
n
f
id
e
n
t
ia
l
a
n
d

p
r
o
p
r
ie
t
a
r
y

d
o
c
u
m
e
n
t
.
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

4. Month 200X 2004 Coordinate Measurement System Committee Page 4
©

A
I
R
B
U
S

U
K

L
T
D

2
0
0
2
.
A
ll
r
ig
h
t
s

r
e
s
e
r
v
e
d
.

C
o
n
f
id
e
n
t
ia
l
a
n
d

p
r
o
p
r
ie
t
a
r
y

d
o
c
u
m
e
n
t
.
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

5. Month 200X 2004 Coordinate Measurement System Committee Page 5
©

A
I
R
B
U
S

U
K

L
T
D

2
0
0
2
.
A
ll
r
ig
h
t
s

r
e
s
e
r
v
e
d
.

C
o
n
f
id
e
n
t
ia
l
a
n
d

p
r
o
p
r
ie
t
a
r
y

d
o
c
u
m
e
n
t
.
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

6. Month 200X 2004 Coordinate Measurement System Committee Page 6
©

A
I
R
B
U
S

U
K

L
T
D

2
0
0
2
.
A
ll
r
ig
h
t
s

r
e
s
e
r
v
e
d
.

C
o
n
f
id
e
n
t
ia
l
a
n
d

p
r
o
p
r
ie
t
a
r
y

d
o
c
u
m
e
n
t
.
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.

7. Month 200X 2004 Coordinate Measurement System Committee Page 7
©

A
I
R
B
U
S

U
K

L
T
D

2
0
0
2
.
A
ll
r
ig
h
t
s

r
e
s
e
r
v
e
d
.

C
o
n
f
id
e
n
t
ia
l
a
n
d

p
r
o
p
r
ie
t
a
r
y

d
o
c
u
m
e
n
t
.
Stage 02 Measurement requirement
LR200
Rear 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

8. Month 200X 2004 Coordinate Measurement System Committee Page 8
©

A
I
R
B
U
S

U
K

L
T
D

2
0
0
2
.
A
ll
r
ig
h
t
s

r
e
s
e
r
v
e
d
.

C
o
n
f
id
e
n
t
ia
l
a
n
d

p
r
o
p
r
ie
t
a
r
y

d
o
c
u
m
e
n
t
.
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
I
n
c
i
d
e
n
c
e
N
o
s
e

d
o
w
n

t
o
l
e
r
a
n
c
e

9. Month 200X 2004 Coordinate Measurement System Committee Page 9
©

A
I
R
B
U
S

U
K

L
T
D

2
0
0
2
.
A
ll
r
ig
h
t
s

r
e
s
e
r
v
e
d
.

C
o
n
f
id
e
n
t
ia
l
a
n
d

p
r
o
p
r
ie
t
a
r
y

d
o
c
u
m
e
n
t
.
Future metrology software requirements at Airbus
HINGE LINE
FITTING TODAY
LEAST SQUARES
FITTING
MULTIPLE SOLUTIONS
SKILLFULL
OPERATORS
REQUIRED
HINGE LINE
FITTING OPTIMISED
ATTRIBUTEY
EYES/NO
SOLUTION
REQUIRED
FITTING
RESIDUALS
STORED
FOR LATER
USE
EASIER
AND
POSITIVE
SCRIPTING
OPTIONS &
OUTCOMES
ELECTRONI
C GAUGING
SOLUTION
=ELECTRONIC GAUGING

10. Month 200X 2004 Coordinate Measurement System Committee Page 10
©

A
I
R
B
U
S

U
K

L
T
D

2
0
0
2
.
A
ll
r
ig
h
t
s

r
e
s
e
r
v
e
d
.

C
o
n
f
id
e
n
t
ia
l
a
n
d

p
r
o
p
r
ie
t
a
r
y

d
o
c
u
m
e
n
t
.
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

11. Month 200X 2004 Coordinate Measurement System Committee Page 11
©

A
I
R
B
U
S

U
K

L
T
D

2
0
0
2
.
A
ll
r
ig
h
t
s

r
e
s
e
r
v
e
d
.

C
o
n
f
id
e
n
t
ia
l
a
n
d

p
r
o
p
r
ie
t
a
r
y

d
o
c
u
m
e
n
t
.
Model Driven Verification with Integrated Metrology
Automated inspection of critical
interface features with Laser
Scanner

12. Month 200X 2004 Coordinate Measurement System Committee Page 12
©

A
I
R
B
U
S

U
K

L
T
D

2
0
0
2
.
A
ll
r
ig
h
t
s

r
e
s
e
r
v
e
d
.

C
o
n
f
id
e
n
t
ia
l
a
n
d

p
r
o
p
r
ie
t
a
r
y

d
o
c
u
m
e
n
t
.
Model Driven Assembly
Kinematics mechanism alignment directly to CAD

13. Month 200X 2004 Coordinate Measurement System Committee Page 13
©

A
I
R
B
U
S

U
K

L
T
D

2
0
0
2
.
A
ll
r
ig
h
t
s

r
e
s
e
r
v
e
d
.

C
o
n
f
id
e
n
t
ia
l
a
n
d

p
r
o
p
r
ie
t
a
r
y

d
o
c
u
m
e
n
t
.
Hinge Line Alignment Reporting
Working Frame
Bull's-eye Charts Showing Hinge Line Tolerances and Results

14. Month 200X 2004 Coordinate Measurement System Committee Page 14
©

A
I
R
B
U
S

U
K

L
T
D

2
0
0
2
.
A
ll
r
ig
h
t
s

r
e
s
e
r
v
e
d
.

C
o
n
f
id
e
n
t
ia
l
a
n
d

p
r
o
p
r
ie
t
a
r
y

d
o
c
u
m
e
n
t
.
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)

15. Month 200X 2004 Coordinate Measurement System Committee Page 15
©

A
I
R
B
U
S

U
K

L
T
D

2
0
0
2
.
A
ll
r
ig
h
t
s

r
e
s
e
r
v
e
d
.

C
o
n
f
id
e
n
t
ia
l
a
n
d

p
r
o
p
r
ie
t
a
r
y

d
o
c
u
m
e
n
t
.
Metrology Confidence with USMN on Wing Survey

16. Month 200X 2004 Coordinate Measurement System Committee Page 16
©

A
I
R
B
U
S

U
K

L
T
D

2
0
0
2
.
A
ll
r
ig
h
t
s

r
e
s
e
r
v
e
d
.

C
o
n
f
id
e
n
t
ia
l
a
n
d

p
r
o
p
r
ie
t
a
r
y

d
o
c
u
m
e
n
t
.
Hinge Line Targeting Uncertainty
Extrapolation Pt Targeting
Expands Uncertainty
Uncertainty
Expanded by 23%

17. Month 200X 2004 Coordinate Measurement System Committee Page 17
©

A
I
R
B
U
S

U
K

L
T
D

2
0
0
2
.
A
ll
r
ig
h
t
s

r
e
s
e
r
v
e
d
.

C
o
n
f
id
e
n
t
ia
l
a
n
d

p
r
o
p
r
ie
t
a
r
y

d
o
c
u
m
e
n
t
.
Hinge Line Targeting Uncertainty
Mid Pt Targeting Reduces Uncertainty
Uncertainty
Reduced by 16%

18. Month 200X 2004 Coordinate Measurement System Committee Page 18
©

A
I
R
B
U
S

U
K

L
T
D

2
0
0
2
.
A
ll
r
ig
h
t
s

r
e
s
e
r
v
e
d
.

C
o
n
f
id
e
n
t
ia
l
a
n
d

p
r
o
p
r
ie
t
a
r
y

d
o
c
u
m
e
n
t
.
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

19. Month 200X 2004 Coordinate Measurement System Committee Page 19
©

A
I
R
B
U
S

U
K

L
T
D

2
0
0
2
.
A
ll
r
ig
h
t
s

r
e
s
e
r
v
e
d
.

C
o
n
f
id
e
n
t
ia
l
a
n
d

p
r
o
p
r
ie
t
a
r
y

d
o
c
u
m
e
n
t
.
Scanner Survey Optimized to CAD
Relationship Fitting: Interface Feature Alignment

20. Month 200X 2004 Coordinate Measurement System Committee Page 20
©

A
I
R
B
U
S

U
K

L
T
D

2
0
0
2
.
A
ll
r
ig
h
t
s

r
e
s
e
r
v
e
d
.

C
o
n
f
id
e
n
t
ia
l
a
n
d

p
r
o
p
r
ie
t
a
r
y

d
o
c
u
m
e
n
t
.
Relationship Fitting: Hinge Line Kinematics
Optimize Hinge Line Configuration + Build to Nominal

21. Month 200X 2004 Coordinate Measurement System Committee Page 21
©

A
I
R
B
U
S

U
K

L
T
D

2
0
0
2
.
A
ll
r
ig
h
t
s

r
e
s
e
r
v
e
d
.

C
o
n
f
id
e
n
t
ia
l
a
n
d

p
r
o
p
r
ie
t
a
r
y

d
o
c
u
m
e
n
t
.
Q & A session