Metrology-Guided Wing Join Automation

Abstract

This article presents the metrology automation Virtual Tooling solution implemented to optimally align aircraft wings at Triumph Aerospace Structures, Red Oak, TX (Triumph). The wing join measurement and alignment process enables the left and right wings of an aircraft to precisely fit to one another to achieve the best possible wing performance characteristics as defined by customers and their aerodynamics requirements. Virtual Tooling enables Triumph to effectively assemble different airplane wing models and minimizes the impact from changes to component configurations that affect assembly cell and processes. The wings are joined in a horizontal (laydown), unconstrained deflected orientation using key feature targets established in individual assembly jigs. The join station at Triumph uses six positioners (three positioners for each wing), which allow each wing section to be adjusted relative to its key features. Operators use the wing join cell’s metrology automation software to sequence two networked laser trackers through the measurement of the key points on critical wing features. The key feature points are optimized, and the resulting transform is used to determine specific sets of incremental six-dimensional moves (e.g., steps) to join the wings. The transform is kinematically broken down into the relative moves for each positioner and sends the specific positioner moves to the tool controller. Each step in the process achieves the required goal positions based on auto