1. 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

2. 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

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

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 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.

7. 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

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.
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.

11. 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

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

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
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

15. 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.

16. 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

17. 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.

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 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

20. QUESTIONS?

21. Thank you!