Dimensional Management of Composite Tooling for the World’s Largest One Piece, All Composite Aircraft Fuselage Presented by: Craig Cramer Boeing 787 Operations Mandrel Production Readiness Leader

Composite Solutions Applied Throughout the 787 Aluminum 20% Titanium 15% Fiberglass 10% Other 5% As you can see, the 787 uses a significant amount of composite materials in its primary structure. This is because composite materials are ideal for an airplane – they don’t corrode or fatigue as metal structure is prone to do. Carbon laminate Carbon sandwich Fiberglass Aluminum Aluminum/steel/titanium pylons

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]).

Completed Test Barrel This is one of the earlier experimental barrels build to test composite lay-up techniques. Our certification barrel will be larger than this one.

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

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.

Situation (Old Method) NOM TOOL SURFACES NOM NC PROGRAM MACHINE THE TOOL Catia ENGINEERING SURFACES Catia FORMULATE THE INSPECTION PLAN CREATE NOMINAL INSPECTION FILE STEP FILE TRANSLATOR CREATE DRIVE FILE CHECK TOOL Spatial Analyzer This is the flow that was used for the earlier experimental barrels. Note that we were not under schedule pressures that we will experience on the certification barrel Step 1: Gather as a team to formulate the build plan and communicate the plan to management via PowerPoint. This is a great way to illustrate what you will measure and to get team buying but it cannot be tied directly into the measurement instrument or analysis tools. Step 2: Create the nominal inspection file in CATIA V5 by building planes, points, intersects and vectors on the many surfaces in the engineering model. This will be the file used to create the drive file to run the scanner. Step 3: Send the nominal CATIA file through a translator like IGES of STEP. Step 4: Build the drive files done manually by our best Analysts. Done in Verisurf then converted to Excel for download to the measuring device. Step 5: Inspect the tool using the tracker and scanner run by Spatial Analyzer without a scripted measurement plan. Most of the routines are manually input by or most experienced operators. They are interpreting the plan published in PowerPoint. These are our best people so they do a great job of knowing how and what to measure but again, the input is mostly manual. Believe me these people are great but they have a lot of people trying to back seat drive during the measurement. Step 6: Okay, her is where is gets messy because we are asking our Analysts do crunch a whole lot of data. Our analysts are very good at what they do but they are asked to do a lot of work and are put under a great deal of pressure to kick out the reports. Inevitably, everyone wants a little different analysis or report so the Analyst is being pulled from every direction. Step 7: Generate the many reports that are asked for by the many organizations whishing to look at the data. A monumental task. PowerPoint Catia Catia Excel These processes may take several weeks because they are mostly manual input MEASURED DATA ANALYZED RESULTS REPORTED Excel

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.

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).

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. The goal here is to give the skilled workforce doing the assignment the tools to do their jobs more affectively and efficiently yielding confidence in the product being measured.

New Method Flow INSTANT FEED BACK NOM TOOL SURFACES NOM NC PROGRAM MACHINE THE TOOL Catia ENGINEERING SURFACES INSTANT FEED BACK Catia DRAFT THE PLAN DRIVE FILE & INSPECTION CREATION FORMULATE THE INSPECTION PLAN CHECK TOOL GENERATE REPORTS Step 1: Again, draft the plan using MS PowerPoint to communicate you intentions to everyone. Step 2: Create the inspection data and drive files in SA Step 3: Script the actual plan in SA Step 4: Run the devise and collect the data using the SA scripted Measurement Plan. Step 5: Generate the reports at the end of the data collection on the shop floor. Spatial Analyzer PowerPoint Spatial Analyzer Spatial Analyzer Spatial Analyzer

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 Overcome obstacles by employing metrology automation concepts and managing the process elements thru template and measurement plan creation.

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

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 Major Item #1 CAD Template Information transfer Step model Standardization of naming conventions, Lines Holes, Cylinders,Planes, Curves, etc Model cleanup, Automated Model check tools Points groups (associated by feature), Hole vectors

Measurement Plan Automation Automated Drive File Creation – Feature Based Once the script is written, drive file creation is basically automatic The pervious method that Boeing has used to create drive files was to construct them in CATIA V5. This method is very time consuming.

MP Process Components Reporting Data Export Templates CAD Model 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 Major Item #2 Measurement Plan Slides 3-5 talk elements and considerations of the Measurement plan creation. Element 1 Measurement, 2 Analysis, 3 Reporting System set up: Operator sets up system, enters part number Starts setup measurement plan, which prompts operator through system checks, Model download: CAD model loaded (.mdl, .step) Setup points can provide model layer criteria Measurement Plan Measurement: System checks, Operator instructions, build mode or check mode Criteria defined by QE ‘common measurement criteria file’ Analysis: Extraction/Creation of features, datum's, and fitting to Achieve analysis as defined by Cad Model Reporting: On screen feed back to user. Word/HTML for RB/Engineering, Text file of all analysis for database/SPC, Text file for rejection Storage:Database historical info, Rejection info and Job file containing all measurements (limited life) Post Analysis: Stored historical info, retrieved as needed for Engineering, SPC, Check orders, Supplier auditing

Completed Barrel with (3) LR200 Scanners Setup #1 #3 #2 The ability to run multiple devises is paramount. It allows the operator more freedom as well as reducing the uncertainty by taking the data from multiple view points. SA will collect the data from multiple machine simultaneously (not waiting for one devise to finish. We can run simulations prior to going to the shop floor to predict devise locations and line of site as well as breaking the data down into sets to streamline the measurement and organize the data that we will report out. The SA scripting commands will re-load the data missed by the pervious shot when the devise is re-positioned for line of site.

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

Acknowledgments Craig Neidig Scott Sandwith 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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