month 200X Use menu "View - Header & Footer" for Presentation title - Siglum - Reference Large Jig Verification Project LVMC 06 Geraint W Jones Engineering Group Leader Metrology Airbus UK

© AIRBUS UK LTD. All rights reserved. Confidential and proprietary document. month 200XUse menu "View - Header & Footer" for Presentation title - Siglum - ReferencePage 2 Background

© AIRBUS UK LTD. All rights reserved. Confidential and proprietary document. month 200XUse menu "View - Header & Footer" for Presentation title - Siglum - ReferencePage 3 Stage 01 Jig The main geometrical features to be controlled during the periodic jig verification process are hinge lines for all the movables I.e. Spoilers and ailerons. On an A380 periodical verification of the assembly tooling approximately 150 points are measured today

© AIRBUS UK LTD. All rights reserved. Confidential and proprietary document. month 200XUse menu "View - Header & Footer" for Presentation title - Siglum - ReferencePage 4 Recertification Prepare tool Measure tool Features In spec? Return tool to production Rework End JIG HEALTH CHECK JIG PERIODIC RECERTIFICATION PROCESS No Yes

© AIRBUS UK LTD. All rights reserved. Confidential and proprietary document. month 200XUse menu "View - Header & Footer" for Presentation title - Siglum - ReferencePage 5 Project The project aims to understand and improve the process capability of the Jig Health Measurement process of a candidate Wing Assembly jig. BENEFITS Perceived benefits of the project include: Less rework due to measurement variation Improved accuracy and repeatability of the measurement process Improved product performance Data base of capability for future design of wings and tooling KEY FACTORS AFFECTING MEASUREMENT PERFORMANCE The measurement instrument The environment The measured features The measured object PROJECT AIMS

© AIRBUS UK LTD. All rights reserved. Confidential and proprietary document. month 200XUse menu "View - Header & Footer" for Presentation title - Siglum - ReferencePage 6 Instruments and Software Axyz Software Spatial Analyzer Laser Tracker Measurement System & Software Φ=Horizontal angle θ=Vertical angle r=Distance

© AIRBUS UK LTD. All rights reserved. Confidential and proprietary document. month 200XUse menu "View - Header & Footer" for Presentation title - Siglum - ReferencePage 7 Final report Data processing Measurement Health Check Process Existing Health Check Measurement Process Measure ERS points Measure jig geometry points (OTP) Execute the bundle adjustment Least squares best fit and scale to nominal jig OTP’s OTP point qualification Generate hidden points

© AIRBUS UK LTD. All rights reserved. Confidential and proprietary document. month 200XUse menu "View - Header & Footer" for Presentation title - Siglum - ReferencePage 8 Measurement Phase ERS- Enhanced Reference System Network of points permanently attached to the tool Attached in positions on substantial structure where they can be seen from convenient positions of the measurement system Can be used to orient the network of instruments and/or allow local positioning with respect to some defined coordinate system

© AIRBUS UK LTD. All rights reserved. Confidential and proprietary document. month 200XUse menu "View - Header & Footer" for Presentation title - Siglum - ReferencePage 9 Measurement phase Typical Optical Tooling Points (OTP) VIEW A TYPICAL TRACK FLAG VIEW A B VIEW A

© AIRBUS UK LTD. All rights reserved. Confidential and proprietary document. month 200XUse menu "View - Header & Footer" for Presentation title - Siglum - ReferencePage 10 Measurement phase Instrument Positions and Measurements Position0 ERS points Measured OTP’s Position1 Position2

© AIRBUS UK LTD. All rights reserved. Confidential and proprietary document. month 200XUse menu "View - Header & Footer" for Presentation title - Siglum - ReferencePage 11 Data processing Bundle Adjustment An algorithm which consists of an optimisation routine. The transformation of each instrument is determined which minimises the observational errors of the system Minimized Pointing Error

© AIRBUS UK LTD. All rights reserved. Confidential and proprietary document. month 200XUse menu "View - Header & Footer" for Presentation title - Siglum - ReferencePage 12 Data processing Generate hidden points Required OTP Calculated Hidden Point

© AIRBUS UK LTD. All rights reserved. Confidential and proprietary document. month 200XUse menu "View - Header & Footer" for Presentation title - Siglum - ReferencePage 13 Data processing Best fit and Scale to nominal Jig OTP’s Trackers bundled, not best-fit Trackers bundled and best-fit Measured OTP’s Jig Nom OTP’s Unused Jig Nom OTP’s

© AIRBUS UK LTD. All rights reserved. Confidential and proprietary document. month 200XUse menu "View - Header & Footer" for Presentation title - Siglum - ReferencePage 14 Data processing Best-Fit and scale to nominal jig OTP’s Least squares routine that minimises the sum of the squares Scale: account for temperature effects on jig

© AIRBUS UK LTD. All rights reserved. Confidential and proprietary document. month 200XUse menu "View - Header & Footer" for Presentation title - Siglum - ReferencePage 15 Final report OTP Qualification = Jig Health Check

© AIRBUS UK LTD. All rights reserved. Confidential and proprietary document. month 200XUse menu "View - Header & Footer" for Presentation title - Siglum - ReferencePage 16 What can be done better? Improvement opportunities Scale Factor not included  Apply scale to the instruments during network adjustment, not points in the best-fit Assess Measurement Uncertainty  “error footprint” not applied  Least squares treats all points with equal weight Laser Tracker “error footprint”

© AIRBUS UK LTD. All rights reserved. Confidential and proprietary document. month 200XUse menu "View - Header & Footer" for Presentation title - Siglum - ReferencePage 17 What can be done better? Improvement opportunities The effect on measurement performance due to laser tracker instrument placement and ERS proximity is unknown. If we knew these effects we could optimise and standardise the measurement procedure If we could express the measurement process capability it could result in:- - Better informed decisions regarding rework - Better designs for future tools - More appropriate specifications for setting and periodic checks - Save time and money!!

© AIRBUS UK LTD. All rights reserved. Confidential and proprietary document. month 200XUse menu "View - Header & Footer" for Presentation title - Siglum - ReferencePage 18 What can be done better? Evidence of ERS and subsequent OTP point variation upon recertification Excessive rework on seemingly stable tooling monuments ERS best fit results degradation No standard method for valuation of ERS involving how many instruments required, best practice for instrument placement and minimum points required for tie-in Use of DVT (hidden point) tooling can have detrimental effect on measurement performance, need a case to back this up Additional evidence to back up case for improvement

© AIRBUS UK LTD. All rights reserved. Confidential and proprietary document. month 200XUse menu "View - Header & Footer" for Presentation title - Siglum - ReferencePage 19 Measurement Uncertainty - U D A parameter that is associated with the result of a measurement, that characterises the dispersion of values that could reasonably be attributed to the measurand (VIM 1993, 3.9) An uncertainty is not an error, which is defined as the difference between the result of a measurement and the true value If a measurement error is known, a correction can be applied to achieve a more accurate result. The remaining uncertainty (from that component) is the uncertainty in the correction Arriving at a measurement uncertainty for a typically Large Scale measurement process such as this Airbus example involving multiple instrument locations was hitherto very difficult and Impractical.This is now possible!

© AIRBUS UK LTD. All rights reserved. Confidential and proprietary document. month 200XUse menu "View - Header & Footer" for Presentation title - Siglum - ReferencePage 20 Measurement uncertainty How can we understand the effects of instrument uncertainty, placement and the measurement procedure for Large Jig Verification? New River Kinematics Unified Spatial Metrology Network (USMN) - Element of the Spatial Analyser software - Combines measurement systems - Allows for scaling at the bundle adjustment stage - Effectively uses the instrument “error footprint” to assess measurement performance - Simulation tools to optimize job layout

© AIRBUS UK LTD. All rights reserved. Confidential and proprietary document. month 200XUse menu "View - Header & Footer" for Presentation title - Siglum - ReferencePage 21 Uncertainty Analysis Example Combining measurement systems  2 Laser Trackers Pos0 Pos1 Common Targets

© AIRBUS UK LTD. All rights reserved. Confidential and proprietary document. month 200XUse menu "View - Header & Footer" for Presentation title - Siglum - ReferencePage 22 Uncertainty Analysis Example Network Solution: USMN Combining measurement systems  2 Laser Trackers –Optimize the instrument locations –Apply scale and instrument “error footprint” –Generate a weighted composite coordinate group –Generate a valid Uncertainty statement and Uncertainty fields for each composite point.

© AIRBUS UK LTD. All rights reserved. Confidential and proprietary document. month 200XUse menu "View - Header & Footer" for Presentation title - Siglum - ReferencePage 23 Uncertainty Analysis Example Network Solution: USMN Pos0 2 Laser Trackers After Combination Pos1 Composite pt r3, and uncertainty field

© AIRBUS UK LTD. All rights reserved. Confidential and proprietary document. month 200XUse menu "View - Header & Footer" for Presentation title - Siglum - ReferencePage 24 Uncertainty Analysis Example Network Solution: USMN Pos0 Pos1 Common Targets Add a 3 rd tracker to the measurement chain Pos2

© AIRBUS UK LTD. All rights reserved. Confidential and proprietary document. month 200XUse menu "View - Header & Footer" for Presentation title - Siglum - ReferencePage 25 Uncertainty Analysis Example Network Solution: USMN Uncertainty propagation: open loop survey Pos0 Pos1 Pos2 Fixed Reference

© AIRBUS UK LTD. All rights reserved. Confidential and proprietary document. month 200XUse menu "View - Header & Footer" for Presentation title - Siglum - ReferencePage 26 Uncertainty Analysis Example Application: A330/340 Stage 01 Assy Jig Network Solution: USMN

© AIRBUS UK LTD. All rights reserved. Confidential and proprietary document. month 200XUse menu "View - Header & Footer" for Presentation title - Siglum - ReferencePage 27 Uncertainty Analysis Example Application: A330/340 Stage 01 Assy Jig Network Solution: USMN OTP’s ERS points

© AIRBUS UK LTD. All rights reserved. Confidential and proprietary document. month 200XUse menu "View - Header & Footer" for Presentation title - Siglum - ReferencePage 28 Uncertainty Analysis Example Application: A330/340 Stage 01 Assy Jig Add a 4 th laser tracker to the network! Network Solution: USMN Down 50% Down 39% Down 54% Down 56% Down 64% Down 66% OTP’s ERS points

© AIRBUS UK LTD. All rights reserved. Confidential and proprietary document. month 200XUse menu "View - Header & Footer" for Presentation title - Siglum - ReferencePage 29 Additional USMN and SA benefits Pre and post tool design simulations to optimise the network Produce uncertainty statements which effectively define the jig build and verification process capability index (CPK) Effective use of the uncertainty statements to challenge legacy tolerances or define the new standard for new programs Instrument angular measurement capability can be assessed and monitored Standardise and automate data gathering and reporting through use of SA measurement plans (MP)

© AIRBUS UK LTD. All rights reserved. Confidential and proprietary document. month 200XUse menu "View - Header & Footer" for Presentation title - Siglum - ReferencePage 30 Best practice statements Process so far has yielded: Pre plan/optimise job using simulation tools Consider U for measurement tolerances Minimise hidden point projection length Minimise target distance from the laser tracker Measure multiple observations on each point Try to employ good intersection geometry Always try to close the survey loop Overlap targets between positions by 80% - 100%

© AIRBUS UK LTD. All rights reserved. Confidential and proprietary document. month 200XUse menu "View - Header & Footer" for Presentation title - Siglum - ReferencePage 31 Questions??

© AIRBUS UK LTD. All rights reserved. Confidential and proprietary document. month 200XUse menu "View - Header & Footer" for Presentation title - Siglum - ReferencePage 32 © AIRBUS UK LTD. All rights reserved. Confidential and proprietary document. This document and all information contained herein is the sole property of AIRBUS UK LTD. No intellectual property rights are granted by the delivery of this document or the disclosure of its content. This document shall not be reproduced or disclosed to a third party without the express written consent of AIRBUS UK LTD. This document and its content shall not be used for any purpose other than that for which it is supplied. The statements made herein do not constitute an offer. They are based on the mentioned assumptions and are expressed in good faith. Where the supporting grounds for these statements are not shown, AIRBUS UK LTD will be pleased to explain the basis thereof. AIRBUS, its logo, A300, A310, A318, A319, A320, A321, A330, A340, A350, A380, A400M are registered trademarks.