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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
