1. Computer Aided Design, Manufacturing & Measurement Integration August 13-17 2001 Coordinate Measurement System Committee Albuquerque, New Mexico Richey-McIvor-Sandwith Computer Aided Design Manufacturing & Measurement Integration Copyright © 2001 The Boeing Company Michael Richey & Robb McIvor, BoeingScott Sandwith, New River Kinematics

2. Computer Aided Design, Manufacturing & Measurement Integration August 13-17 2001 Coordinate Measurement System Committee Albuquerque, New Mexico Richey-McIvor-Sandwith CAD Geometry Data management Local Area/Zone X-form from Part Attributes Key Characteristics – FD&T Tolerances Factory demonstration Major Assembly directly from CAD Multiple Real-time Hybrid Measurement Systems Integrated Dynamic Graphical Interface Applications Determinate Assembly Multiple Measurement Interfaces Bulkhead Assembly Simulation Summary - Questions

3. Computer Aided Design, Manufacturing & Measurement Integration August 13-17 2001 Coordinate Measurement System Committee Albuquerque, New Mexico Richey-McIvor-Sandwith Design Produce Measurement/ Analysis Reporting I n f o r m a t i o n b a c k i n t o D e s i g n 3D Cad Model Authority Process Scope

4. Computer Aided Design, Manufacturing & Measurement Integration August 13-17 2001 Coordinate Measurement System Committee Albuquerque, New Mexico Richey-McIvor-Sandwith 2D Drawing Authority 2D Drawing Interpretation Digital Product Line Today 3D Design 3D Model Release Tool Oriented Detail Assembly 2D drawing Assembly Inspection 3D Measurement Equipment MFG Engineering NC Programming Manufacturing Quality Assurance Tooling Product Integrated Digital Product Line 3D Model Assembly Inspection 3d Model Oriented Detail Assembly And Authority

5. Computer Aided Design, Manufacturing & Measurement Integration August 13-17 2001 Coordinate Measurement System Committee Albuquerque, New Mexico Richey-McIvor-Sandwith Wing Spar Test Program Aug 2000

6. Computer Aided Design, Manufacturing & Measurement Integration August 13-17 2001 Coordinate Measurement System Committee Albuquerque, New Mexico Richey-McIvor-Sandwith Overview of 3D Measurement Pilot Create 3D CAD Models of components, sub-assemblies and major components CATIA Model with Embedded Tolerancing Local Area/Zone X-form from Part Attributes Key Characteristics FD&T Tolerances Measurement Systems

7. Computer Aided Design, Manufacturing & Measurement Integration August 13-17 2001 Coordinate Measurement System Committee Albuquerque, New Mexico Richey-McIvor-Sandwith Functional Dimensioning and Tolerancing (FDT)

8. Computer Aided Design, Manufacturing & Measurement Integration August 13-17 2001 Coordinate Measurement System Committee Albuquerque, New Mexico Richey-McIvor-Sandwith Data Transfer between CAD system and metrology system STEP (Standard for the Exchange of Product) International Standard ISO 10303 AP203, AP219, and XML-Express Boeing Standard for Data Exchange (Lifecycle) IGES (International Graphics Exchange Specification). The format used for this project was STEP

9. Computer Aided Design, Manufacturing & Measurement Integration August 13-17 2001 Coordinate Measurement System Committee Albuquerque, New Mexico Richey-McIvor-Sandwith Measurements System Integration Challenges Boeing uses different types of CAMS for tool construction and maintenance which are controlled by 2D drawings. Operators are not trained to operate all of the different measurement systems. Operating software and data analysis varies significantly between systems, even for like kind technologies. Measurements System Integration Solution A key to the success of this project was software which provided a common instrument interface, simultaneous and synchronsis data acquisition from different measurement instruments.

10. Computer Aided Design, Manufacturing & Measurement Integration August 13-17 2001 Coordinate Measurement System Committee Albuquerque, New Mexico Richey-McIvor-Sandwith Common Measurement Systems Interface

11. Computer Aided Design, Manufacturing & Measurement Integration August 13-17 2001 Coordinate Measurement System Committee Albuquerque, New Mexico Richey-McIvor-Sandwith Measurement and Assembly Dynamic real time graphical interface shows the measured location of the part against the CAD model. Easy to make adjustments with confidence. Distributed Computing Capable (real-time multi-task measurement and analysis across multiple computers) Synchronous Measurement between Instruments (Master-Slave or Synchronous Polled Modes) TCP/IP interfaces to instruments to enable distributed processing Supports remote process control and monitoring.

12. Computer Aided Design, Manufacturing & Measurement Integration August 13-17 2001 Coordinate Measurement System Committee Albuquerque, New Mexico Richey-McIvor-Sandwith Project Specifics Using a 3D CAD model; build components onto a wing spar web in tolerance with minimal tooling and CAMS equipment CAMS equipment consisted of two different manufacturers laser trackers and a PCMM “Tooling” consisted of movable steel stanchions and wooden wedges

13. Computer Aided Design, Manufacturing & Measurement Integration August 13-17 2001 Coordinate Measurement System Committee Albuquerque, New Mexico Richey-McIvor-Sandwith Registration/Transformation Example: The tracker on the “wet” (i.e., fuel) side of the spar web measured reference holes on the spar and was best-fit transform to the spars coordinate frame. The tracker on the “dry” side of the web was oriented to the spar’s model by best fitting measurements of web, chord, and ribs features to the spar’s CAD model on the shop floor. The PCMM measurements of reference features on the spar were used to transform it into the spar system. The PCMM could of just as easily transformed into the coordinate system established by the tracker on the “wet” side.

14. Computer Aided Design, Manufacturing & Measurement Integration August 13-17 2001 Coordinate Measurement System Committee Albuquerque, New Mexico Richey-McIvor-Sandwith

15. Computer Aided Design, Manufacturing & Measurement Integration August 13-17 2001 Coordinate Measurement System Committee Albuquerque, New Mexico Richey-McIvor-Sandwith After establishing the appropriate coordinate systems, the “dry” side tracker set a stiffener while the PCMM simultaneously set a hinge line assembly.

16. Computer Aided Design, Manufacturing & Measurement Integration August 13-17 2001 Coordinate Measurement System Committee Albuquerque, New Mexico Richey-McIvor-Sandwith Determinate Assembly Application Design & Tool Reduction Potential reduction and elimination of families of tools and their maintenance.Potential reduction and elimination of families of tools and their maintenance. Multiple airplane models using one holding fixture and 3D data sets from secured wireless server. (Rate adjustable)Multiple airplane models using one holding fixture and 3D data sets from secured wireless server. (Rate adjustable) Produce multiple airplane models, end to end within the same docking tool station.Produce multiple airplane models, end to end within the same docking tool station. Benefits Reduction in Tool designs, build, and maintenance cost. Short design to build time. Eliminate 2D release process. Less factory floor space. Rate sensitive production process.

17. Computer Aided Design, Manufacturing & Measurement Integration August 13-17 2001 Coordinate Measurement System Committee Albuquerque, New Mexico Richey-McIvor-Sandwith Philosophy Change  Many Production Assemblies produced in one Tool... 777 5 less tools 767 5 less tools 747 5 less tools Cad Model Transition From Many Tools for One Production Assembly to…

18. Computer Aided Design, Manufacturing & Measurement Integration August 13-17 2001 Coordinate Measurement System Committee Albuquerque, New Mexico Richey-McIvor-Sandwith Aft Pressure Bulkhead Assembly Simulation

19. Computer Aided Design, Manufacturing & Measurement Integration August 13-17 2001 Coordinate Measurement System Committee Albuquerque, New Mexico Richey-McIvor-Sandwith CAD -> Design By-pass the 2D drawing release process Smart DA Tool applications and wireless real-time location of CAD data to factory Use of full production part assembly tolerances “embedded CAD attributes” Compress Design to Build cycle times CAMS -> Produce & Measure Anywhere Perform Tool Routines with the tool in the loaded condition for sustaining programs Fleet Support and filed maintenance Wireless data between the DB and factory floor Rate adjustable Determinate Assembly Smart Tool docking stations Integrate "Key Characteristics" from the production part, into the & build plans CAD -> Analysis Common web enabled database for Internal/External Supplier Provide database foundation for reduction in product variability and work repetition Statistical Process Control, focus on unstable features to drive out root cause Information, Utilized by all organizations 24/7 Summary

20. Computer Aided Design, Manufacturing & Measurement Integration August 13-17 2001 Coordinate Measurement System Committee Albuquerque, New Mexico Richey-McIvor-Sandwith References: Boeing Team Members: Michael Richey, CATIA LEAD Instructor Rob McIvor 777 Tool Construction New River Kinematics Team Members: Scott Sandwith