V-STARS AUTOMATED MEASUREMENT Measurement and Record of Connecting Rods Lengths (Struts) in the A380 Wing Box TR21 AIRBUS Nantes France Speaker : N. ROMMAN

Synopsis I.Struts in Wingbox A380 II.Former Mean of Measurement III.Tests of feasibility and comparisons with other systems IV.Measurement and Automation V.Additional features

Synopsis I.Struts in Wingbox A380 II.Former Mean of Measurement III.Tests of feasibility and comparisons with other systems IV.Measurement and Automation V.Additional features

WingBox A380 During assembly: Volume and Maintain of Wingbox Tooling Struts

WingBox A380 Tooling Struts : Front Part

WingBox A380 Tooling Struts : Rear Part

WingBox A380 Measurement of Connecting Rods Lengths : Manufacture Carbon Struts 143 Struts : 66 Front Part 77 Rear Part

WingBox A380 Measurement of Connecting Rods Lengths : //  à H9 Lengths between 1050mm and 2350mm

Synopsis I.Struts in Wingbox A380 II.Former Mean of Measurement III.Tests of feasibility and comparisons with other systems IV.Measurement and Automation V.Additional features

Former Measurement « Caliper » :

Former Measurement Former Process (4 separate areas): 1. Remove the floor in the Measurement area 2. Remove the Tooling Struts in the Measurement area 3. Calibrate the caliper with a Reference Bar

Former Measurement 4.Mesurement of Connecting Rods Lengths 5.Fill manually the results sheet 6.Re-install the Tooling Struts 7.Restart the same process for the 3 other areas 8.Fill all the results in an Excel file

Former Measurement Drawbacks : Need to remove the floor Need to divide the Measurement into 4 parts Need to remove and install again all the Tooling Struts Lead time: 8 hours for 2 operators Caliper : heavy, bulky, difficult to handle

Former Measurement Drawbacks : Need to calibrate the caliper Risk of errors in the positioning of the caliper Risk of errors when the operator reads or writes the values Risk of errors when filling the Excel file

Synopsis I.Struts in Wingbox A380 II.Former Mean of Measurement III.Tests of feasibility and comparisons with other systems IV.Measure and Automation V.Additional features

Tests and Comparisons Measurement of WingBox’ Front Part Adhesive targets to simulate all the struts position

Tests and Comparisons 14 accurate targets for a comparison between the four measurement systems :  V-STARS S8/ INCA3  V-STARS E4X/ NIKON D2X  Laser Tracker LEICA (LTD500)  Caliper in service

Tests and Comparisons V-STARS Measurement :

Tests and Comparisons Comparison: Values in millimeters

Tests and Comparisons Results : Feasibility of the measurement with V-STARS shown (~ 50 pictures) Rapidity and simplicity to set up the targets and to achieve the measurement

Tests and Comparisons System chosen by AIRBUS Nantes: V-STARS E4X System / NIKON D2X

Synopsis I.Struts in Wingbox A380 II.Former Mean of Measurement III.Tests of feasibility and comparisons with other systems IV.Measurement and Automation V.Additional features

Measurement and automation 1.Targets 2.Preparation of the measurement 3.Taking pictures 4.Automation with V-StarsCom 5.Results

Measurement - Targets Two kinds of targets used : for free holes for holes with tooling struts free holes tooling strut

Measurement - Targets TSOR with 3 Balls : balls

Measurement - Targets Target for free holes: Tree balls mounted on spring  Auto-centres the target  Holds the target in the hole without constraint

Measurement - Targets Target for holes with tooling strut : 3 balls to centre and maintain the target

Measurement - Targets The target is aligned to the centre of the hole mounted on the bar pin Base of the target against the surface

Measurement - Targets Target for holes with tooling strut : Feature Target is used to construct a point with the same offset than the TSOR

Measurement - Targets Coded targets : for Feature Target for Automation (Driver file is used) Right label Strut’s length automatically computed

Measurement - Preparation The measurement is done in 2 steps : Wingbox Front Part (66 lengths) Wingbox Rear Part (77 lengths) TSOR targets can be inserted in any free holes. Targets installed on tool struts have a specific position.

Measurement - Preparation Each target is used in Front Part and Rear Part of the Wingbox.

Measurement - Preparation Scale Bar :

Measurement - Pictures Wingbox front part ready to be measured :

Measurement Procedure Stations

Measurement Procedure Stations

Measurement - Pictures Measurement : 48 pictures Remove the memory card from the camera and insert it in the PC. Open “V- StarsCom” (automation software of V-STARS)

Measurement – V-StarsCom

Measurement – Excel File Result in Excel file

Measurement – Excel File Results of Front Part are filled in the Excel file. The Excel file will be completed automatically with the measurement data of the Rear Part. After results validation, the Struts can be manufactured.

Synopsis I.Struts in Wingbox A380 II.Former Mean of Measurement III.Tests of feasibility and comparisons with other systems IV.Measure and Automation V.Additional features

Additional Features Measurement of the Reference Plane :

Additional Features Check the “ΔY” value for each Strut // with the Reference Plane within 2mm Point on Upper Panel Point on Lower Panel

Additional Features A new Excel file will be automatically created with “ΔY” coordinates :

One operator measurement DISINSTALLING THE TARGETS = 30min TREATMENT with V-StarsCom = 10min TAKING PICTURES = 10min INSTALLING THE TARGETS = 30min for each part Front and Rear

Users and Supplier  Airbus Nantes France System Information Dept. Manager: Patrick GUERIN Metrologist Expert: Thierry PAVAGEAU FAL Wing Box Manager: Antoine BAUD  Engineering Supplier (G.M.S. France) Manager : Nabil ROMMAN