computer aided design, manufacturing & measurement integration

Computer Aided Design, Manufacturing & Measurement Integration

August 13-17 2001Coordinate Measurement System Committee

Albuquerque, New MexicoRichey-McIvor-Sandwith

Computer Aided Design Manufacturing& Measurement Integration

Copyright © 2001 The Boeing Company

Michael Richey & Robb McIvor, Boeing Scott Sandwith, New River Kinematics




•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




Design

Produce Measurement/Analysis

Reporting

Information back into Design

3D Cad Model Authority

Process Scope




2D Drawing Authority

2D Drawing Interpretation

Digital Product Line Today

3D Design

3D Model ReleaseProduct

Tool Oriented Detail Assembly

2D drawing Assembly Inspection

3D Measurement Equipment

MFG Engineering

NC ProgrammingManufacturingQuality Assurance

Tooling

Product

Integrated Digital Product Line

3D Model Assembly Inspection

3d Model Oriented Detail Assembly

And Authority




Wing Spar Test Program

Aug 2000




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




Functional Dimensioning and Tolerancing (FDT)




•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




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.




Common Measurement Systems Interface




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.




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




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.




After establishing the appropriate coordinate systems, the “dry” side tracker set a stiffener while the PCMM simultaneously set a hinge line assembly.




Determinate Assembly ApplicationDesign & 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.




Aft Pressure Bulkhead Assembly Simulation




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 plansCAD -> 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




References:Boeing Team Members:Michael Richey, CATIA LEAD InstructorRob McIvor 777 Tool ConstructionNew River Kinematics Team Members:Scott Sandwith

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