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Craig Cramer

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Dimensional Management of Composite Tooling for the World s Largest One Piece, All Composite Aircraft Fuselage Presented by: Craig Cramer Boeing 787 Operations ... – PowerPoint PPT presentation

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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

2
Composite Solutions Applied Throughout the 787
3
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).

4
Completed Test Barrel
5
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)
  • 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

6
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
    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.

7
Situation (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
8
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.

9
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).

10
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.

11
New 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
12
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

13
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

14
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

15
Measurement Plan Automation
  • Automated Drive File Creation Feature Based

16
MP 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

17
Completed Barrel with (3) LR200 Scanners Setup
1
3
2
18
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

19
Acknowledgments
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
20
QUESTIONS?
21
  • Thank you!
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