V-STARS AUTOMATED MEASUREMENT Measurement and Record of Connecting Rods Lengths (Struts) in the A380...

V-STARSAUTOMATED MEASUREMENT

Measurement and Record of Connecting Rods Lengths

(Struts) in the A380 Wing Box TR21

AIRBUS Nantes France

Speaker : N. ROMMAN

Synopsis

I. Struts in Wingbox A380

II. Former Mean of Measurement

III. Tests of feasibility and comparisons with other systems

IV. Measurement and Automation

V. Additional features

Synopsis

I. Struts in Wingbox A380

II. Former Mean of Measurement

III. Tests of feasibility and comparisons with other systems

IV. Measurement and Automation

V. Additional features

WingBox A380

During assembly:

Volume and Maintain of Wingbox

Tooling Struts

WingBox A380

Tooling Struts :

Front Part

WingBox A380

Tooling Struts :

Rear Part

WingBox A380

Measurement of Connecting Rods Lengths :

Manufacture Carbon Struts

143 Struts :

• 66 Front Part

• 77 Rear Part

WingBox A380

Measurement of Connecting Rods Lengths :

//19.042 à 22.217 H9

Lengths between 1050mm and 2350mm

Synopsis

I. Struts in Wingbox A380

II. Former Mean of Measurement

III. Tests of feasibility and comparisons with other systems

IV. Measurement and Automation

V. Additional features

Former Measurement

« Caliper » :

Former Measurement

Former Process (4 separate areas):

1. Remove the floor in the Measurement area

2. Remove the Tooling Struts in the Measurement area

3. Calibrate the caliper with a Reference Bar

Former Measurement

4. Mesurement of Connecting Rods Lengths

5. Fill manually the results sheet

6. Re-install the Tooling Struts

7. Restart the same process for the 3 other areas

8. Fill all the results in an Excel file

Former Measurement

Drawbacks :

• Need to remove the floor

• Need to divide the Measurement into 4 parts

• Need to remove and install again all the Tooling Struts

• Lead time: 8 hours for 2 operators

• Caliper : heavy, bulky, difficult to handle

Former Measurement

Drawbacks :

• Need to calibrate the caliper

• Risk of errors in the positioning of the caliper

• Risk of errors when the operator reads or writes the values

• Risk of errors when filling the Excel file

Synopsis

I. Struts in Wingbox A380

II. Former Mean of Measurement

III. Tests of feasibility and comparisons with other systems

IV. Measure and Automation

V. Additional features

Tests and Comparisons

•Measurement of WingBox’ Front Part

•Adhesive targets to simulate all the struts position

Tests and Comparisons

•14 accurate targets for a comparison between the four measurement systems :

V-STARS S8/ INCA3

V-STARS E4X/ NIKON D2X

Laser Tracker LEICA (LTD500)

Caliper in service

Tests and Comparisons

V-STARS Measurement :

Tests and Comparisons

Comparison:

Values in millimeters

Tests and Comparisons

Results :

•Feasibility of the measurement with V-STARS shown (~ 50 pictures)

•Rapidity and simplicity to set up the targets and to achieve the measurement

Tests and Comparisons

System chosen by AIRBUS Nantes:

V-STARS E4X System / NIKON D2X

Synopsis

I. Struts in Wingbox A380

II. Former Mean of Measurement

III. Tests of feasibility and comparisons with other systems

IV. Measurement and Automation

V. Additional features

Measurement and automation

1. Targets

2. Preparation of the measurement

3. Taking pictures

4. Automation with V-StarsCom

5. Results

Measurement - Targets

Two kinds of targets used :

• for free holes

• for holes with tooling struts

free holes

tooling strut

Measurement - Targets

TSOR with 3 Balls :

balls

Measurement - Targets

Target for free holes:

Tree balls mounted on spring

Auto-centres the target

Holds the target in the hole without constraint

Measurement - Targets

Target for holes with tooling strut :

3 balls to centre and maintain the target

Measurement - Targets

• The target is aligned to the centre of the hole mounted on the bar pin

• Base of the target against the surface

Measurement - Targets

Target for holes with tooling strut :

Feature Target is used to construct a point with the same offset than the TSOR

Measurement - Targets

Coded targets :

• for Feature Target• for Automation (Driver file is used)

Right label

Strut’s length automatically computed

Measurement - Preparation

The measurement is done in 2 steps :

• Wingbox Front Part (66 lengths)

• Wingbox Rear Part (77 lengths)

TSOR targets can be inserted in any free holes.

Targets installed on tool struts have a specific position.

Measurement - Preparation

Each target is used in Front Part and Rear Part of the Wingbox.

Measurement - Preparation

Scale Bar :

Measurement - PicturesWingbox front part ready to be

measured :

Measurement Procedure

Stations

Measurement Procedure

Stations

Measurement - Pictures

Measurement : 48 pictures

Remove the memory card from the camera and insert it in the PC.

Open “V-StarsCom” (automation software of V-STARS)

Measurement – V-StarsCom

Measurement – V-StarsCom

Measurement – V-StarsCom

Measurement – Excel File

Result inExcel file

Measurement – Excel File

Results of Front Part are filled in the Excel file.

The Excel file will be completed automatically with the measurement data of the Rear Part.

After results validation, the Struts can be manufactured.

Synopsis

I. Struts in Wingbox A380

II. Former Mean of Measurement

III. Tests of feasibility and comparisons with other systems

IV. Measure and Automation

V. Additional features

Additional Features

Measurement of the Reference Plane :

Additional Features

Check the “ΔY” value for each Strut

// with the Reference Plane within 2mm

Point on Upper Panel

Point on Lower Panel

Additional Features

A new Excel file will be automatically created with “ΔY” coordinates :

One operator measurement

for each part Front and Rear

Users and Supplier

Airbus Nantes France• System Information Dept. Manager: Patrick GUERIN

• Metrologist Expert: Thierry PAVAGEAU

• FAL Wing Box Manager: Antoine BAUD

Engineering Supplier (G.M.S. France)• Manager : Nabil ROMMAN