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Computer Aided Design, Manufacturing

& Measurement Integration

Computer Aided Design Manufacturing


& Measurement Integration

Copyright 2001 The Boeing Company

Michael Richey & Robb McIvor, Boeing

August 13-17 2001

Scott Sandwith, New River Kinematics

Richey-McIvor-Sandwith

Coordinate Measurement System Committee


Albuquerque, New Mexico

Computer Aided Design, Manufacturing


& Measurement Integration

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
August 13-17 2001

Richey-McIvor-Sandwith

Coordinate Measurement System Committee


Albuquerque, New Mexico

Computer Aided Design, Manufacturing


& Measurement Integration
Process Scope

Produce
Design

Measurement/
Analysis
Reporting

3D Cad Model Authority

Information back into Design


August 13-17 2001

Richey-McIvor-Sandwith

Coordinate Measurement System Committee


Albuquerque, New Mexico

Computer Aided Design, Manufacturing


& Measurement Integration
Digital Product
Line Today
Integrated
Digital
Product Line

MFG Engineering
NC Programming

2D Drawing
Authority
2D Drawing
Interpretation

Manufacturing
Quality Assurance

Tooling

3D Design
Tool
Oriented
3d
Model
Oriented
Detail
DetailAssembly
Assembly

3D Model Release
And Authority
August 13-17 2001

2D
Assembly
3Ddrawing
Model Assembly
Inspection

Richey-McIvor-Sandwith

3D Measurement
Equipment

P ro d u c t
Product

Coordinate Measurement System Committee


Albuquerque, New Mexico

Computer Aided Design, Manufacturing


& Measurement Integration

Wing Spar
Test Program
Aug 2000

August 13-17 2001

Richey-McIvor-Sandwith

Coordinate Measurement System Committee


Albuquerque, New Mexico

Computer Aided Design, Manufacturing


& Measurement Integration

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
August 13-17 2001

Richey-McIvor-Sandwith

Coordinate Measurement System Committee


Albuquerque, New Mexico

Computer Aided Design, Manufacturing


& Measurement Integration

Functional Dimensioning and Tolerancing (FDT)

August 13-17 2001

Richey-McIvor-Sandwith

Coordinate Measurement System Committee


Albuquerque, New Mexico

Computer Aided Design, Manufacturing


& Measurement Integration

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
August 13-17 2001

Richey-McIvor-Sandwith

Coordinate Measurement System Committee


Albuquerque, New Mexico

Computer Aided Design, Manufacturing


& Measurement Integration

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.
August 13-17 2001

Richey-McIvor-Sandwith

Coordinate Measurement System Committee


Albuquerque, New Mexico

Computer Aided Design, Manufacturing


& Measurement Integration

Common Measurement Systems Interface

August 13-17 2001

Richey-McIvor-Sandwith

Coordinate Measurement System Committee


Albuquerque, New Mexico

Computer Aided Design, Manufacturing


& Measurement Integration

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.
August 13-17 2001

Richey-McIvor-Sandwith

Coordinate Measurement System Committee


Albuquerque, New Mexico

Computer Aided Design, Manufacturing


& Measurement Integration

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

August 13-17 2001

Richey-McIvor-Sandwith

Coordinate Measurement System Committee


Albuquerque, New Mexico

Computer Aided Design, Manufacturing


& Measurement Integration

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
spars model by best fitting measurements of web, chord, and
ribs features to the spars 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.
August 13-17 2001

Richey-McIvor-Sandwith

Coordinate Measurement System Committee


Albuquerque, New Mexico

Computer Aided Design, Manufacturing


& Measurement Integration

August 13-17 2001

Richey-McIvor-Sandwith

Coordinate Measurement System Committee


Albuquerque, New Mexico

Computer Aided Design, Manufacturing


& Measurement Integration

After establishing the appropriate coordinate systems, the dry


side tracker set a stiffener while the PCMM simultaneously set a
hinge line assembly.

August 13-17 2001

Richey-McIvor-Sandwith

Coordinate Measurement System Committee


Albuquerque, New Mexico

Computer Aided Design, Manufacturing


& Measurement Integration

Determinate Assembly Application


Design & Tool Reduction

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)

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.

August 13-17 2001

Richey-McIvor-Sandwith

Coordinate Measurement System Committee


Albuquerque, New Mexico

Computer Aided Design, Manufacturing


& Measurement Integration

Aft Pressure Bulkhead Assembly Simulation

August 13-17 2001

Richey-McIvor-Sandwith

Coordinate Measurement System Committee


Albuquerque, New Mexico

Computer Aided Design, Manufacturing


& Measurement Integration

Summary
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
Coordinate Measurement System Committee

August 13-17 2001

Richey-McIvor-Sandwith

Albuquerque, New Mexico

Computer Aided Design, Manufacturing


& Measurement Integration

References:
Boeing Team Members:
Michael Richey, CATIA LEAD Instructor
Rob McIvor 777 Tool Construction
New River Kinematics Team Members:
Scott Sandwith
August 13-17 2001

Richey-McIvor-Sandwith

Coordinate Measurement System Committee


Albuquerque, New Mexico