Aircraft Familiarization for Manufacturing and Qualitysnocamp.s3.amazonaws.com/.../uploads/files/fam_002.pdf767 The Boeing 767 family includes three ... Aft of the flight deck door

Aircraft Familiarization for Manufacturing and Quality

Copyright © 2012 Boeing. All rights reserved.

Airplane Development & History


Can you name these planes?

707

Out of Production

Out of Production

717

727

Out of Production

In Production

737

747

In Production

Out of Production

757

767

In Production

In Production

777


Boeing Airplanes – 707 Out of Production

707 First flight December 20, 1957 vs DC-8 Douglas Company. Special ID – stinger on vertical fin, 4 engines. KC-135 is tanker version. Also used as AWACS. AWACS

Where it all began!

Dash 80


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Boeing Airplanes – 727, 757 Out of Production 727 First flight February 9, 1963. Trio engines in whale tail empennage. Manufactured in Renton. Could get in and out of Mexico City. High altitude and short runways. 757 First flight February 19, 1982. Thinner than the sister 767. The 757 was a single aisle airplane.


Boeing Airplanes – Business Jets, 737 In Production

Boeing Business Jets Boeing Business Jets are a customized business configuration of any of our airplanes.

737 The square airplane – as long as it is wide. Twin engines mounted on the wings. First flight April 9, 1967. Produced in Renton. Competition was DC-9. Built Quickly


http://www.boeing.com/commercial/bbj/index.html�

http://www.boeing.com/commercial/737family/background.html�

Boeing Airplanes – 747, 767 In Production

747 Queen of the Skies! First flight February 9,1969. The -100 version was passenger only, the -300 version extended the upper deck. On the -400 composites played a large role. Distinction is the upper deck and 4 wing engines. Manufactured and assembled in Everett, WA

767 The Boeing 767 family includes three passenger models -- the 767-200ER, 767-300ER and 767-400ER -- and a freighter, which is based on the 767-200ER fuselage. The 767 has been converted into a Tanker for military purposes. Passengers are never more than one seat from the aisle. AWACS

Air Force One

http://www.boeing.com/companyoffices/gallery/streamingmedia/767_AWACS.html�

http://www.boeing.com/defense-space/military/af1/index.html�

Boeing Airplanes – In Production 777 First 100% digitally designed airplane. Launched in 1990, the first flight took place on June 12, 1994. Largest of all the twin engine jets. Distinguishing item is the oversized engines. Potential Folding Wing introduced, but never certified. (a 737 fuselage could fit inside its engine cowling!)

787 First composite fuselage commercial airliner. 50% of the 787 is made of composite materials. Scheduled to begin flight tests in 2008. The Power-plant Strut will take both Rolls Royce and GE Engines.

Boeing Airplanes – In Production

747-8 The Boeing 747-8 Intercontinental and 747-8 Freighter are the new high-capacity 747s that offer airlines the lowest operating costs and best economics of any large passenger or freighter airplane. Wide use of composite material.

747 Comparison: Then and Now


1.What was Boeings’ first commercial jet airplane?

2.What is the newest Boeing commercial airplane?

3.The first Boeing twin engine jet aircraft certified for Extended Twin Operations (ETOPS)?

4.The first Boeing jet to be certified for 0/0 visibility take off / landing? Why 0/0 visibility Take-off & landing?

5.Which jet is made of 50% composite materials (by Weight). Why use lighter materials?

Discussion


Airplane Familiarization Airplane Familiarization ActivityActivity

Name the following Name the following commercial airplane models:commercial airplane models:

Airplane Activity


Aircraft Mockup, Past and Present A scaled model to verify the shape

and form would fly in the wind tunnel. Critical to find out early if the air foil (surface) was functional.

Class I Mockup = Made from Wood. Entire Structure was created for fit-up and interference purposes.

Class II Mockup = Made from Metal, Styrofoam, and Plywood to ensure no fit-up and interference of assembly and installation processes.

Class III Mockup = Used the Class II Mockup, but add Tubing and Wire bundles to verify clearances and fit.

What aircraft was built using digital CATIA data sets and no Mockup?

747 Interiors Mock Up


Job Role and Description

Role Description Design Engineering (DE) Designs the parts, creates the drawings

Project Engineering (PE) Design Engineering Manufacturing Engineering (ME)

Designs and determines build plan decisions – Make or buy decisions…

Industrial Engineering (IE) Innovation of manufacturing processes

Development of schedules, bar charts, flow times, and control codes.

Evaluation of time standards, time frames for processes.


Job Role and Description (Continued) Role Description MRB / Liaison Engineering Identify non-conforming material,

parts, and/or assemblies, and then disposition the noted non-conformity (s) as required ensuring the original design intent has either been maintained or exceeded.

Program Planning and Control (PP&C)

Integrated scheduling

Manufacturing The “Incredibles.” They do the impossible. Build A/C from Drawings, Documents, and Specifications.

Quality Inspect Critical Processes


1.Who is responsible for the drawings?

2.Make or buy decisions?

3.Who is responsible for when and where

to load Joins?

Discussion


• Seven million parts are used make the 747.

• All parts are identified with a part number. Engineering Designed Part Numbers

Part Standards

Vendor Part Numbers

• Engineering Drawings list the Specifications and Documents required for Critical Operations.

• Three levels of engineering drawings Detail

Assembly

Installation

• Production Illustrations

How Parts and Assemblies are Identified


Detail Drawing


Assembly Drawing


14January, 2007

PreplanningAssembly Sequence: Factory

747-400 Major Control Points

Process begins at the upper left and flows to the

lower right.

CC 130 Stub Wing Join

CC 581 Vertical TailInstallation

CC 304 41-42 Systems Installation

CC 520 Horizontal Tail Join

CC 948 Landing Gear R&H

CC 1

21 F

inal A

ssy

Instl

, Fun

ct’l T

est

CC 105 Preflight Systems Testing

CC 132 Engine Hang

CC 303 46-48 Systems Installation

747 Wing Control Codes


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Sections Section Description 41 Flight deck and

electronics bay

42 Aft of the flight deck door for passenger and cargo area prior to wings. (747)

43 Aft of the flight deck door for passenger and cargo area prior to wings. (777)

44 Passenger section where wings join to body.

45 Cargo level – center fuel tank, landing gear, un-pressurized area.

Plane Sections

Red Sections are Pressurized


Sections Section Description 46 Aft of wings, cargo and

passenger area. 47 Prior to empennage (tail

section) but aft of 46 section (777)

48 Empennage (tail section) aft of pressure dome.

Vertical Stabilizer

72 section (777) 86 section (747) Vertical Fin where rudder is mounted. Provides steering left and right.

Horizontal Stabilizer

82 Section

Wings Teens: 12, 13, 14, etc. Landing Gear 60s section Wing Box Structure for rigidity of

wing join area.

Plane Sections


777 Sections


Planes have the ability to fly at altitudes where they encounter very little air resistance. This allows them to increase fuel efficiency as well as fly over the weather (less turbulence). Because the air is “thinner” the plane needs to have pressurized compartments to maintain a certain level of air pressure/density, temperature and moisture. The pressurized sections of the plane include the following: Section 41, 42, 43, 44, 46, 47

Cargo portion of section 45

Forward of the rear pressure dome.

Pressurized Areas within our Airplanes


1. The flight deck is in what major body section?

2. Why are body sections pressurized?

3. Wing sections begin with what number?

Discussion


Plane Parts Part Description Radome A nonmetallic fairing, usually

located in the nose section, that covers the radar antenna.

Fuselage Main portion of the airplane where passengers and/or cargo resides

Fairings Aerodynamically designed structure to allow air to flow more efficiently. Fairings reduce Drag significantly.


http://www.boeing.com/companyoffices/aboutus/community/fof_intro.html�

1. Winglet 2. Low Speed Aileron 3. High Speed Aileron 4. Flap track fairing 5. Krüger flaps 6. Slats 7. Three slotted inner

flaps 8. Three slotted outer

flaps 9. Spoilers 10.Spoilers-Air brakes

Wing


Plane Parts Part Description Slats A movable airfoil section attached

to the leading edge of each wing, which when lowered provide the airplane with greater lift at lower speeds.

Strut An extension designed to brace loads, e.g., pylons which support the engine.


Plane Parts

Part Description

Aileron A movable section of the trailing edge of each wing which operate together to provide longitudinal (roll) axis.

Flaps On trailing edge of wing– A hinged section of the trailing edge of each wing which, when lowered or extended, provides the airplane with greater lift at lower speeds. And gives primary control around the airplane longitudinal (roll) axis. Flap Display

Spoilers A hinged panel on the upper surface of each wing which can be raised individually or together as speed brakes to reduce the airspeed. When the flaps are down, the spoilers lower (droop) to help with the high lift system. Spoiler Pairs


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Plane Parts Part Description Empennage The tail feathers of the Aircraft. The

Empennage controls both yaw and pitch axis. Empennage

Stabilizer or Horizontal Stabilizer

A tail surface which gives the long term control around the lateral (pitch) axis.

Elevator The elevator surface panels are a hinged portion of the trailing edge on each side of the horizontal stabilizer that provide primary control around the lateral axis (pitch).

Vertical Fin or Vertical Stabilizer

Generally, the vertical tail surface of an airplane which provides directional stability.

Rudder The hinged trailing edge of the vertical stabilizer - provides the primary control around the airplane vertical axis (yaw).


Aircraft Frame and Stringer

Shear Tie

Brackets are used to attach secondary structure or removable parts to structural components.

Stringer clips are used to attach the stringers to the circumferential frames.

Shear ties are used to attach the circumferential frame to the skin of the airplane.


Stringers & Stringer Clip

Frames

Shear Ties Copyright © 2012 Boeing. All rights reserved.

Frame Splice

Shear tie

A Frame Splice is used to structurally fasten two sections of a frame together. The frames are something made in sections to provide for ease of installation or to promote structural reliability and longevity.


Truss

Web

A Web ties two structural components together. It acts as a brace between two separate parts and has the effect of making the parts act as one structural unit.

A Truss behaves in a similar manner as a web. It is used in place of a web when an open design is required for access or weight considerations are important.


Joggle

A joggle is a manufactured bend in a part to allow it to overlap other adjoining parts. This helps promote better fit between parts and eliminates the need for spacers and shims.


777 Forward Cargo – EE Rack, Floorbeams, Stanchions, Standoffs


Floorbeam & Stiffener


Shim

Intercostal & Gusset


Airplane Systems

Airplane Systems System Description Mechanical / Hydraulics Actuators, gears, makes the airplane work mechanically.

Environmental Control System Air, Water, heating and cooling, pressurization.

Cabin Systems & Seats Passenger Service Units (PSU), Seat back Video, telephones, OEU (oxygen equipment units) lights, air, attendant call buttons, music, etc.

Electrical / Electronic Everything is operated with electricity. There are many miles of wiring within an airplane.

Computer Operations of all the systems.


Airplane Systems

Airplane Systems System Description Navigation / Avionics This is a large group of airplane systems. There are Flight

Management, Onboard Maintenance, Displays, Flight Management Performance, AIMS (Automatic Information Management System) Recording, Communications, Air Data, Radio Navigation, etc.

Entertainment Seat back videos, in flight entertainment.

Safety Oxygen, fire, seat belts, etc.

Emergency Escape slides, fire detection and suppression.

Flight control Flight deck operations.


Aircraft Terms and Symbols

Reference Lines •Water Line •Station Line •Buttocks Line Terms •Forward •Aft •Outboard •Inboard


Plane Cross Section

Section Description

Butt Line (Buttocks)

LBL or RBL (787 +/- designator) Is the left to right measure. Measurements start with zero at the center of the airplane.

Passenger Floor

Mid ship level. Cargo below. “200”

Waterline The water line is a horizontal reference location from below the ground to the top of an airplane – similar to the waterline on a boat or ship. Note: The most commonly known waterline is 200.

Cargo Floor Cargo floor below waterline. Station Number

This diagram shows one “slice” of the station line, cross section of front to back. Are measurements from the front of an airplane aft to the plane’s tail.

NOTE: All drawing reference lines and planes are expressed in inches and shown in a decimal form.

Passenger Floor

Cargo Floor

Looking from tail to nose from inside+ Designator

Right Butt Line- DesignatorLeft Butt Line

Waterline

0001

03 02

05

07 08

06

1009




Wing Reference Lines and Planes





777 Stringer Rear View


Questions?
