CMSC 2005
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
CMSC 2005
Composite Solutions
Applied Throughout the 787
Other
Fiberglass 5%
10%
Carbon laminate
Carbon sandwich
Titanium
15%
Fiberglass
Aluminum
Aluminum/steel/titanium pylons
Aluminum
20%
Composites
50%
CMSC 2005
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]).
CMSC 2005
Completed Test Barrel
CMSC 2005
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)
a. Inspect Tools for Quality Assurance
b. Use As-Built data to optimally assemble the tool
c. 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
CMSC 2005
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)
CMSC 2005
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
PowerPoint
Catia
Catia
Excel
Spatial
Analyzer
MEASURED
DATA
ANALYZED
RESULTS
REPORTED
Excel
These processes
may take several
weeks because
they are mostly
manual input
CMSC 2005
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.
CMSC 2005
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).
CMSC 2005
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.
New Method Flow
CMSC 2005
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
PowerPoint
Spatial
Analyzer
Spatial
Analyzer
CHECK
TOOL
GENERATE
REPORTS
Spatial
Analyzer
Spatial
Analyzer
CMSC 2005
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
CMSC 2005
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
CMSC 2005
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
CMSC 2005
Measurement Plan
Automation
 Automated Drive File Creation – Feature Based
CMSC 2005
MP Process Components
 Templates
 CAD Model
 Instruments
 Measurement plan
 Initialize (load template)
 Enhancements
 Data Collection
 Registration/Fit to
Features
 Feature Extraction
 Query/Analysis
 Process Checks
 Reporting
 Data Export
 Step (AP203,214)
 Documents:
Word,Excel,AVI,HTM
L
 User feed back
 Pass Fail
 Graphics
 Tabular
 Save & Archive
 Operator interface
 Inputs (User info)
 Run
 Output
CMSC 2005
Completed Barrel with (3)
LR200 Scanners Setup
#1
#3
#2
CMSC 2005
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
CMSC 2005
Acknowledgments
Scott Sandwith
New River Kinematics
Technical support
Craig Neidig
Boeing Commercial Airplanes
787 Tool Engineering
File Creation
M.J. Fjellestad
Boeing Commercial Airplanes
777 Program
Editing
David B. Holm
Karl W. Kunst
Boeing Management
CMSC 2005
QUESTIONS?
CMSC 2005
Thank you!