July 2004 Use menu "View - Header & Footer" for Presentation title - Siglum - Reference Integrated CAD-Metrology and Alignment of Key Features of A380 Wings 2004 Coordinate Measurement System Committee Presented by Geraint Jones Airbus UK Lead Metrology Engineer Scott Sandwith New River Kinematics Metrology Software Engineer

© AIRBUS UK LTD All rights reserved. Confidential and proprietary document. Month 200X2004 Coordinate Measurement System CommitteePage 2 Introduction – A380 Metrology at Broughton Measurement Systems  Laser Trackers –Alignments of kinematic mechanisms  Laser Radar Scanner –Direct measurement of performance and interface features Assembly of the Airbus A380 Wing  Build and Inspect directly to features Integrate Metrology Systems and CAD Optimize Build and Inspection of Wing Performance Features Software Platform  Graphical environment and reports  Relationship Fitting  optimize part alignment to CAD  Confident product configuration and communication

© AIRBUS UK LTD All rights reserved. Confidential and proprietary document. Month 200X2004 Coordinate Measurement System CommitteePage 3 LSM systems used on A380 and why Current systems used on the A380 Project at Airbus Broughton are Laser trackers (7) and a laser radar (1) The laser tracker instrument was procured because:- It is highly versatile It’s performance is commensurate with the range of design specifications It’s ability to track and therefore build The Laser radar was procured because:- It’s ability to measure in a targetless fashion It’s ability to mostly automate the data gathering process It’s ability to measure large amounts of data quickly It’s performance is commensurate with the range of design specifications

© AIRBUS UK LTD All rights reserved. Confidential and proprietary document. Month 200X2004 Coordinate Measurement System CommitteePage 4 Measured features on an A380 Wing set A total of 96 planned measurement tasks per wing set! 60% involve building routines as well as inspection SPOILERS x 16 AILERONS x 6 FLAP BEAMS x 10 ENGINE PYLONS x 4 OVERWING PANEL x 2 UNDERWING PANEL x 2 WING ROOT x 2 WING TWIST x 2 FALSEWORK X 4 FLAP TRACK FAIRINGS X 48 Laser Radar Laser tracker

© AIRBUS UK LTD All rights reserved. Confidential and proprietary document. Month 200X2004 Coordinate Measurement System CommitteePage 5 Measured features on an A380 Wing set Engine Pylon Geometry Forks Thrust Spigot Aft fitting Aims: -To inspect the position of the Forks in the X direction -To inspect the position of the Aft fitting in the Y direction -To inspect the orientation of the Forks to the engine thrust line

© AIRBUS UK LTD All rights reserved. Confidential and proprietary document. Month 200X2004 Coordinate Measurement System CommitteePage 6 Measured Features on an A380 Wing set Wing Tip Falsework X Z Y Surface A Surface B Aim: To blend profile of surface A into surface B From an initial alignment the relationships function allows a fine adjustment of the translation in Z and rotation around X.

© AIRBUS UK LTD All rights reserved. Confidential and proprietary document. Month 200X2004 Coordinate Measurement System CommitteePage 7 Stage 02 Measurement requirement LR200 Rear spar Front spar Centre spar Bottom skin profile Top skin profile Junction to Wing box/fuselage Wing Root Measurement Aims: To measure top and bottom skin surface profiles and to measure spar orientation with respect to the CAD model = Datum reference points

© AIRBUS UK LTD All rights reserved. Confidential and proprietary document. Month 200X2004 Coordinate Measurement System CommitteePage 8 Stage 02 Measurement requirement Wing Incidence Aim: To understand the extent and sense of rotation of the aerofoil - Wing set as well as asymmetrical tolerance - Incidence is measured via 6 opposing pairs of points per wing =Measured points using hidden point device Incidence primary datum Incidence Nose up tolerance Incidence Nose down tolerance

© AIRBUS UK LTD All rights reserved. Confidential and proprietary document. Month 200X2004 Coordinate Measurement System CommitteePage 9 Future metrology software requirements at Airbus HINGE LINE FITTING TODAY LEAST SQUARES FITTING MULTIPLE SOLUTIONS SKILLFULL OPERATORS REQUIRED HINGE LINE FITTING OPTIMISED ATTRIBUTEY EYES/NO SOLUTION REQUIRED FITTING RESIDUALS STORED FOR LATER USE EASIER AND POSITIVE SCRIPTING OPTIONS & OUTCOME S ELECTRONI C GAUGING SOLUTION = ELECTRONIC GAUGING

© AIRBUS UK LTD All rights reserved. Confidential and proprietary document. Month 200X2004 Coordinate Measurement System CommitteePage 10 Measurement Control Measurement Control with CAD Model Driven Assembly  Build/Inspect direct to model definition produces common results Minimal secondary support tooling (e.g. Shop Aids and Targeting)  Model controls conformance  Tolerances are relative to features  Pragmatic GD&T with feature to feature relationships Quality Procedures  Graphical Reports  improves communication  SPC Charting yields process control  Unified Spatial Metrology Network to ensure process capabilities Feature based alignment strategies  Relationship Fitting  direct alignment of measurements and instruments to model

© AIRBUS UK LTD All rights reserved. Confidential and proprietary document. Month 200X2004 Coordinate Measurement System CommitteePage 11 Model Driven Verification with Integrated Metrology Automated inspection of critical interface features with Laser Scanner

© AIRBUS UK LTD All rights reserved. Confidential and proprietary document. Month 200X2004 Coordinate Measurement System CommitteePage 12 Model Driven Assembly Kinematics mechanism alignment directly to CAD

© AIRBUS UK LTD All rights reserved. Confidential and proprietary document. Month 200X2004 Coordinate Measurement System CommitteePage 13 Hinge Line Alignment Reporting Working Frame Bull's-eye Charts Showing Hinge Line Tolerances and Results

© AIRBUS UK LTD All rights reserved. Confidential and proprietary document. Month 200X2004 Coordinate Measurement System CommitteePage 14 Integrating Measurement Technologies - USMN USMN – Network Optimization  Determine real-world uncertainty fields for Points and Features  Characterize actual instrument uncertainty performance from Shop Floor Surveys  Take advantage of relative uncertainty of measurement components Multiple Instrument Network  Scanner + Tracker  Systems operate synchronously in a cooperative network aligned with USMN  USMN orientation produces optimal results  Traceable uncertainty estimates for Points, Instruments, and Features Manage Measurement Uncertainties – Confidence  Graphical Reports  Communicate  Process Improvements  Geometric fitting uncertainty (sphere, line, plane, cylinder, etc)

© AIRBUS UK LTD All rights reserved. Confidential and proprietary document. Month 200X2004 Coordinate Measurement System CommitteePage 15 Metrology Confidence with USMN on Wing Survey

© AIRBUS UK LTD All rights reserved. Confidential and proprietary document. Month 200X2004 Coordinate Measurement System CommitteePage 16 Hinge Line Targeting Uncertainty Extrapolation Pt Targeting Expands Uncertainty Uncertainty Expanded by 23%

© AIRBUS UK LTD All rights reserved. Confidential and proprietary document. Month 200X2004 Coordinate Measurement System CommitteePage 17 Hinge Line Targeting Uncertainty Mid Pt Targeting Reduces Uncertainty Uncertainty Reduced by 16%

© AIRBUS UK LTD All rights reserved. Confidential and proprietary document. Month 200X2004 Coordinate Measurement System CommitteePage 18 Relationship Fitting Methodology Align critical features within the A380 wing system:  Model interdependence  Relative importance with weighting  Interaction between key kinematic mechanisms and critical interface features  Each relationship has an inherent local reporting frame Best-Fit Weighted Relationships  As-Built configuration is optimized to its nominal CAD model on the shop floor  Simultaneously fits the constraints defined by the relationships  Relative importance of each constraint is controlled using weights set by the production team

© AIRBUS UK LTD All rights reserved. Confidential and proprietary document. Month 200X2004 Coordinate Measurement System CommitteePage 19 Scanner Survey Optimized to CAD Relationship Fitting: Interface Feature Alignment

© AIRBUS UK LTD All rights reserved. Confidential and proprietary document. Month 200X2004 Coordinate Measurement System CommitteePage 20 Relationship Fitting: Hinge Line Kinematics Optimize Hinge Line Configuration + Build to Nominal

© AIRBUS UK LTD All rights reserved. Confidential and proprietary document. Month 200X2004 Coordinate Measurement System CommitteePage 21 Q & A session