CMSC2001R3 Avi

Computer Aided Design, Manufacturing
& Measurement Integration
Computer Aided Design Manufacturing

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

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


Process Scope
Produce
Design
Measurement/
Analysis
Reporting
3D Cad Model Authority
Information back into Design

August 13-17 2001


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
3D Measurement
Equipment
P ro d u c t
Product


Wing Spar
Test Program
Aug 2000
August 13-17 2001


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


Functional Dimensioning and Tolerancing (FDT)
August 13-17 2001


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


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


Common Measurement Systems Interface
August 13-17 2001


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


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


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


August 13-17 2001


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


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


Aft Pressure Bulkhead Assembly Simulation
August 13-17 2001


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
August 13-17 2001

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


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Computer Aided Design, Manufacturing

& Measurement Integration

Computer Aided Design Manufacturing

Copyright 2001 The Boeing Company

Michael Richey & Robb McIvor, Boeing

August 13-17 2001

Scott Sandwith, New River Kinematics

Coordinate Measurement System Committee

Computer Aided Design, Manufacturing

Coordinate Measurement System Committee

Computer Aided Design, Manufacturing

3D Cad Model Authority

Information back into Design

Coordinate Measurement System Committee

Computer Aided Design, Manufacturing

Coordinate Measurement System Committee

Computer Aided Design, Manufacturing

August 13-17 2001

Coordinate Measurement System Committee

Computer Aided Design, Manufacturing

Overview of 3D Measurement Pilot

Coordinate Measurement System Committee

Computer Aided Design, Manufacturing

Functional Dimensioning and Tolerancing (FDT)

August 13-17 2001

Coordinate Measurement System Committee

Computer Aided Design, Manufacturing

Data Transfer between CAD system and metrology

Coordinate Measurement System Committee

Computer Aided Design, Manufacturing

Measurements System Integration Challenges

Measurements System Integration Solution

Coordinate Measurement System Committee

Computer Aided Design, Manufacturing

Common Measurement Systems Interface

August 13-17 2001

Coordinate Measurement System Committee

Computer Aided Design, Manufacturing

Measurement and Assembly

Coordinate Measurement System Committee

Computer Aided Design, Manufacturing

August 13-17 2001

Coordinate Measurement System Committee

Computer Aided Design, Manufacturing

Coordinate Measurement System Committee

Computer Aided Design, Manufacturing

August 13-17 2001

Coordinate Measurement System Committee

Computer Aided Design, Manufacturing

After establishing the appropriate coordinate systems, the dry

August 13-17 2001

Coordinate Measurement System Committee

Computer Aided Design, Manufacturing

Determinate Assembly Application

Potential reduction and elimination of families of tools and their maintenance.

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

Coordinate Measurement System Committee

Computer Aided Design, Manufacturing