2004 Coordinate Measurement System Committee July 2004

Presented by

Geraint Jones Scott Sandwith

Airbus UK New River Kinematics
Lead Metrology Engineer Metrology Software Engineer

Integrated CAD-Metrology and Alignment

of Key Features of A380 Wings

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 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
© AIRBUS UK LTD 2002. All rights reserved. Confidential and proprietary document.

• 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

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 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
© AIRBUS UK LTD 2002. All rights reserved. Confidential and proprietary document.

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 Month 200X Page 3

 Measured features on an A380 Wing set
OVERWING PANEL x 2

ENGINE PYLONS x 4 UNDERWING PANEL x 2

FLAP BEAMS x 10 WING ROOT x 2

Laser Laser
tracker
AILERONS x 6 WING TWIST x 2
Radar
© AIRBUS UK LTD 2002. All rights reserved. Confidential and proprietary document.

FALSEWORK X 4 FLAP TRACK

FAIRINGS X 48

SPOILERS x 16

A total of 96 planned measurement tasks per wing set!

60% involve building routines as well as inspection

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 Measured features on an A380 Wing set
Engine Pylon Geometry

Forks

Thrust Spigot
© AIRBUS UK LTD 2002. All rights reserved. Confidential and proprietary document.

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 Month 200X Page 5

 Measured Features on an A380 Wing set
Wing Tip Falsework

Y Surface B

Surface A
X
© AIRBUS UK LTD 2002. All rights reserved. Confidential and proprietary document.

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 Month 200X Page 6

 Stage 02 Measurement requirement
Wing Root Measurement
= Datum reference points

Top skin profile

Front spar

Centre spar LR200

© AIRBUS UK LTD 2002. All rights reserved. Confidential and proprietary document.

Rear spar

Bottom skin profile

Aims: Junction to Wing box/fuselage

To measure top and bottom skin surface profiles and to
measure spar orientation with respect to the CAD model

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 Stage 02 Measurement requirement
Wing Incidence
i d ence an ce
In c tol er
e u p
Nos
Incidence
primary datum

Inc
© AIRBUS UK LTD 2002. All rights reserved. Confidential and proprietary document.

i de
No nc
se e
do
wn
Aim: tol
era
To understand the extent and sense of rotation of the aerofoil n ce
- Wing set as well as asymmetrical tolerance
- Incidence is measured via 6 opposing pairs of points per wing
=Measured points using hidden point device

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 Future metrology software requirements at Airbus

LEAST SQUARES
FITTING EASIER
AND
ATTRIBUTEY
POSITIVE
EYES/NO
SKILLFULL SCRIPTING
SOLUTION
OPERATORS OPTIONS &
REQUIRED
OUTCOMES
REQUIRED

HINGE LINE HINGE LINE

FITTING TODAY FITTING OPTIMISED = ELECTRONIC GAUGING
© AIRBUS UK LTD 2002. All rights reserved. Confidential and proprietary document.

FITTING
MULTIPLE SOLUTIONS ELECTRONI RESIDUALS
C GAUGING STORED
SOLUTION FOR LATER
USE

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 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
© AIRBUS UK LTD 2002. All rights reserved. Confidential and proprietary document.

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

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 Model Driven Verification with Integrated Metrology
© AIRBUS UK LTD 2002. All rights reserved. Confidential and proprietary document.

Automated inspection of critical

interface features with Laser
Scanner

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 Model Driven Assembly

Kinematics mechanism alignment directly to CAD

© AIRBUS UK LTD 2002. All rights reserved. Confidential and proprietary document.

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 Hinge Line Alignment Reporting

Working Frame
© AIRBUS UK LTD 2002. All rights reserved. Confidential and proprietary document.

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

2004 Coordinate Measurement System Committee Month 200X Page 13
 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
© AIRBUS UK LTD 2002. All rights reserved. Confidential and proprietary document.

 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)

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 Metrology Confidence with USMN on Wing Survey
© AIRBUS UK LTD 2002. All rights reserved. Confidential and proprietary document.

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 Hinge Line Targeting Uncertainty

Extrapolation Pt Targeting
Expands Uncertainty
© AIRBUS UK LTD 2002. All rights reserved. Confidential and proprietary document.

Uncertainty
Expanded by 23%

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 Hinge Line Targeting Uncertainty
Mid Pt Targeting Reduces Uncertainty

Uncertainty
Reduced by 16%
© AIRBUS UK LTD 2002. All rights reserved. Confidential and proprietary document.

2004 Coordinate Measurement System Committee Month 200X Page 17

 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

© AIRBUS UK LTD 2002. All rights reserved. Confidential and proprietary document.

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

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 Relationship Fitting: Interface Feature Alignment

Scanner Survey Optimized to CAD

© AIRBUS UK LTD 2002. All rights reserved. Confidential and proprietary document.

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 Relationship Fitting: Hinge Line Kinematics
Optimize Hinge Line Configuration + Build to Nominal
© AIRBUS UK LTD 2002. All rights reserved. Confidential and proprietary document.

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 © AIRBUS UK LTD 2002. All rights reserved. Confidential and proprietary document.

Q & A session

2004 Coordinate Measurement System Committee

Month 200X
Page 21