Title: Craig Cramer
1 Dimensional Management of Composite Tooling for
the Worlds Largest One Piece, All Composite
Aircraft Fuselage
- Presented by
- Craig Cramer
- Boeing 787 Operations Mandrel Production
Readiness Leader
2Composite Solutions Applied Throughout the 787
3The 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).
4Completed Test Barrel
5Metrology 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
6STP - 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
Analyzers 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.
7Situation (Old Method)
NOM TOOL SURFACES
MACHINE THE TOOL
NOM NC PROGRAM
Catia
ENGINEERING SURFACES
Catia
STEP FILE TRANSLATOR
CREATE NOMINAL INSPECTION FILE
FORMULATE THE INSPECTION PLAN
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
8The 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.
9The 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).
10The 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.
11New Method Flow
NOM TOOL SURFACES
MACHINE THE TOOL
NOM NC PROGRAM
Catia
ENGINEERING SURFACES
INSTANT FEED BACK
Catia
FORMULATE THE INSPECTION PLAN
DRIVE FILE INSPECTION CREATION
DRAFT THE PLAN
GENERATE REPORTS
CHECK TOOL
Spatial Analyzer
Spatial Analyzer
Spatial Analyzer
Spatial Analyzer
PowerPoint
12Metrology 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
13Templates 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
14Template 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
15Measurement Plan Automation
- Automated Drive File Creation Feature Based
16MP Process Components
- 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
- Templates
- CAD Model
- Instruments
- Measurement plan
- Initialize (load template)
- Enhancements
- Data Collection
- Registration/Fit to Features
- Feature Extraction
- Query/Analysis
- Process Checks
17Completed Barrel with (3) LR200 Scanners Setup
1
3
2
18Manage 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
19Acknowledgments
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
20QUESTIONS?
21