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.

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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
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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).

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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
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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

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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

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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

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Measurement Plan Automation

• Automated Drive File Creation Feature Based

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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

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Completed Barrel with (3) LR200 Scanners Setup
1
3
2
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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
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QUESTIONS?
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• Thank you!