Presented by: Craig Cramer Boeing 787 Operations Mandrel Production Readiness Leader
Post on 19-Jan-2016
26 Views
Preview:
DESCRIPTION
Transcript
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!
top related