measureupH e x a g o n M e t r o l o g y P o r t a B l e C M M n e w s l e t t e r 0 3 / 2 0 0 8

roMer arm at Dassault aviation Pages 4 − 5

„First class and very reliable“: Customers on Hexagon MetrologyPages 6 − 7

Cognitens: scanning technology for aircraft assembly Pages 8 − 9

Integration and automation for measuringlarge-size partsPages 12 − 13

special:

aerospace Industry

Case study:roMer arm at Dassault aviation & leica tracker at Bae systemsPages 4 − 5

„First class and very reliable“: Customers on Hexagon MetrologyPages 6 − 7

Cognitens: scanning technology for aircraft assemblyPages 8 − 9

Case study: nasa - Perfecting the last Hubble rendezvousPages 10 − 11

technical article:Integration and automatision for measuring large-size parts & Case study: Integrated measuring system at sneCMa Pages 12 − 13

Case study airbus st. eloi & Precision Centers in europePage 14

shows october – December 2008 Content

Lakber and Sakana use Laser Tracker system with new marker probeLakber is a company specialized in foundry and milling of big parts like hubs or big mechanic components, especially for the eolic energy industry. The parts will be inspected with the new Leica AT-901 and the Leica T-Probe. The foundry of parts takes place at Sakana. There, the parts are inspected and marked using the Leica T-Probe and the newly developed marker probe. .

BAE SYSTEMS order two new Leica Absolute TrackersBAE SYSTEMS order two new Leica Absolute trackers AT901-B for use on the 2nd Eurofighter laser alignment facility. BAE confirm with this new order its confidence and satisfaction of Leica Trackers to perform all automated measurements tasks linked with MAA (measurement automated assembly). The Leica Absolute Tracker integrates future-oriented technologies providing the basis for several new metrology features and products being developed by Leica Geosystems. One such advance is the Absolute Interferometer or «AIFM» in the Absolute Tracker, extremely accurate, reliable and productive

Müggenburg now use 2 Leica Geosystems Laser TrackersThis German service company works closely with Airbus and Hamburg University. Müggenburg focuses on providing and developing automated solutions for aerospace manufacturing processes.

newsticker

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editorial

METALEX 2008November 20-23, 2008Bangkok, Thailandwww.metalex.co.th

AEROMART TOULOUSE 2008December 3-4, 2008Toulouse, Francewww.aeromart.tm.fr

EUROMOLD 2008December 3-6, 2008Frankfurt, Germanywww.euromold.com

Dear Readers,

The autumn edition of measureup is aiming high. This edition focuses on the aerospace sector, one of the most important fields of application for portable CMMs from Hexagon Metrology.

This industry sets sky-high requirements for its measuring equipment – and Hexagon Metrology delivers intelligent and reliable systems. The French aerospace group Dassault Aviation has been using ROMER arms since the end of the 1980s to test tools and retrofits – an important task at a key stage in production. Measurement solutions from Hexagon Metrology can be found at many EADS production sites: Laser Trackers from Leica Geosystems have played a part in the Airbus success story, including at the Bremen, Toulouse and St. Eloi factories. And CogniTens, the optical 3D metrology system specialist within Hexagon Metrology, provides the aircraft manufacturing industry with know-how in the fields of prototype development and reverse engineering.

Return your seat backs to the upright position and fly with us through the exciting world of aerospace. We hope you enjoy reading this issue!

Best regards,

Your measureup Editorial Team

P.S: A new generation of measureup is already taxiing for take-off. Keep your eyes peeled for issue 4/08!

EuroBLECH 2008October 21-25, 2008Hannover, Germanywww.euroblech.de

TCT 2008October 21-22, 2008Coventry, United Kingdomwww.tctmagazine.com

JIMTOF 2008October 30 - November 4, 2008Tokio, Japanwww.jimtof.org

MIDEST 2008November 4-7, 2008Paris, Francewww.midest.com

Large Volume Metrology ConferenceNovember 6-7, 2008Liverpool, United Kingdomwww.lvmc.org.uk

AIRTECNovember 11-14, 2008Frankfurt, Germanywww.airtec.aero

PRODEX 08November 18-22, 2008Basel, Switzerlandwww.prodex.ch

KIMEX 2008November 19-22, 2008Changwon, South Koreawww.kimex.org/en

„I used to be afraid of flying. But thanks to airplanes, not any more!“

4 measureup measureup 5

simplifying the correction process. The results are very indicative and leave no room for false interpretation. For example, in the past it was fairly difficult to inspect the correct position of interior paneling alignment. Nowadays, reference points are inspected, a data report is created, and it is immediately clear where the errors lie. This new process allows Dassault to drastically cut inspection times, increasing productivity.

The variety of possible applications for the Romer articulated arm and the department’s expertise have allowed Dassault to broaden the arm’s use well beyond the Merignac location. Mr. Blasquez has recently been to Little Rock, Arkansas facility, where he used the articulated arm to inspect and adjust complex tooling systems that were apparently out of spec. On the same trip, he also visited a military base where he used the arm to reverse-engineer a complex part that was later replicated and installed without the need to polish the part to assure a good fit. All this was done while substantially reducing costs.

“With our articulated arm, we always stay within the prescribed tolerances. Reverse engineering is performed with expedience, is effective and accurate,” boasts Mr. Blasquez and concludes: “Unfortunately, too few people are aware of this tool’s existence. The utilization of our Romer arm is sure to increase in the future.”

Contacts

external partner. Toward the late eighties our Argenteuil subsidiary had already purchased their first Romer articulated arm, and we used to borrow it from them on a per-need basis. Finally, in 1992 we took delivery of our first Romer articulated arm. It was incorporated directly into the tube bending process, and has been in daily use ever since – for more than 15 years. The second Romer articulated arm was delivered to the department in 2004, quickly becoming our most critical measurement instrument.”

The articulated arm is in frequent use at Dassault. The staff is particularly keen on the G-Scan scanner, which can collect thousands of points per second with extremely high accuracies. The same applies to the G-tube software with its accessories for tube measurement. “Romer covers 100 percent of our metrology needs,” explains Blasquez, continuing: “The service department also deserves high praise because the personnel is knowledgeable and there is always someone to take our call and answer our questions.” Dassault has constructed a custom-made cart for transporting the arm to various physical locations within the premises, including aircraft interiors and exteriors. In addition, the company has constructed its own arm extension which allows them to conduct aircraft interior inspections in one step. Yet another arm elevation system is in the works, which will let them get the elongated arm above the aircraft to reach even more points in one go. To get the measurements of the aircraft underside, the articulated arm has to be mounted upside down, but the quality of the collected data is unaffected.

Part inspections occur daily within the department. With the production start of the Rafale and the 7FX version of the Falcon aircraft, new production challenges arose. Dassault has launched a new integrated digitalized network to tackle those two operations. Falcon F7X has established a new standard in terms of product life cycle management standards. The digitized data is frequently exchanged within the production facility, assigning the inspection process with the Romer arm tremendous importance, both for tooling and part inspection. The finished aircraft needs to comply with the CAD values. Assembly issues are quickly resolved with the articulated arm because the inspection can be done right there on the shop floor,

Rafale, Falcon, Mirage 2000, Super Etendard, Alfajet: Over the years, the company has earned its righteous place as one of the top-ranking aerospace manufacturers in the world. Dassault boasts the largest number of different aircraft designs of any company in the industry.

Dassault‘s computer-aided design and manufacturing department, located at the facility at the Bordeaux airport in Merignac, designs and inspects tooling conception, tooling control and retrofitting.This department, under the guidance of Jacky Blasquez, is part of the production department, and is crucially involved in all Dassault‘s projects.

“At the beginning, most work was done by hand, later migrating to CADAM and CATIA software for surfacing and tubing drawing. The metrology equipment was rather basic then: theodolites, plummets and rulers. For 3D measurements we had to rely on an

leading aircraft manufacturer loyal articulated arm user for more than 15 years

Case studies

Full version of this case study available upon request using the feedback form in the back.

For further information, please contact your closest Hexagon Metrology Precision Center (see list on page 14). www.dassault-aviation.comwww.bae-systems.comwww.portable-cmm.com

Bae systems: entrusting leica geosystems laser trackersBAE Systems is a global company engaged in the development, delivery and support of advanced defence and aerospace systems in the air, on land and at sea.

When laser tracking was first introduced at BAE Systems, the laser tracker’s ability to measure and inspect with repeatable, accurate measurements, and a user-friendly software interface yielded savings in both time and money. These concrete savings were pivotal in winning the metrology staff over. After all, they were dealing with brand-new technology with few precedents. However, over the years BAE Systems grew to be one of Leica Geosystems most valuable customers, using more than twenty laser trackers from all successive product generations within their Samlesbury Site assembly facilities.

Nigel Gore, Business and Process Development Manager, has some final thoughts about the new Absolute Tracker: «It sports a plethora of innovative features that help it rise above anything else available on the market. The Quick Release feature is great. The users know how easy it is to mount and dismount the laser tracker from the stand, and are therefore less likely to show reluctance in moving the equipment around, thus speeding up measurements. We also have great automated reporting tools. In addition, the Absolute Tracker takes a mere five minutes from the moment it is powered up to the time it can start measuring within spec. And it stays within spec through out the day, which is the best indicator for the solid design both inside and out. All in all, our tooling department greatly benefits from these new features, doing its part to keep us ahead of the competition.»

measureup 7

testimonials

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The broad palette of products and services from Hexagon Metrology offers the right solution for every measurement task. More than just a promise – as many satisfied customers can confirm

With a clearly graduated product portfolio Hexagon Metrology can objectively assess and cover the measurement requirements in any industrial sector. Our guiding principle applies: Anyone can sell measuring equipment – but we prefer to offer a lasting solution. Our specialists are there to support you in making the best decision on specific production and verification requirements. Hexagon Metrology service and technical support are still available many years after the purchase of a system. Our regional Precision Centers are always standing by to provide the answers to your questions (see page 14).

„First class and very reliable“:Customers on Hexagon Metrology

“Leica Geosystems Laser Tracker is perfect for the measurement of aircraft components. The systems are robust and extremely accurate even when measuring large objects. And if the going gets tough from long periods of continuous use then we can rely on the service from Hexagon Metrology.”

Erwin Hoffmann, Metrology Manager, Airbus Bremen

“I have had the pleasure of being able to work with Hexagon Metrology products and staff for many years now, and have found all aspects of the company first class and very reliable.

Brian Dash, Senior Tooling Engineer GKN AEROSPACE SERVICES ,Yeovvil

“Marshall Aerospace purchased our Leica Geosystems Laser Tracker 12 months ago, having had noprevious experience of this type of equipment. Our Laser Tracker meets all our needs regarding its capability and accuracy. The training given and the on and offsite assistance provided during our initial learning curve has allowed us to achieve an on time quality product to our customers.”

Steve Rudd, Aircraft Manager, Marshall Aerospace, Cambridge

“The ROMER service department deserves high praise because the personnel is knowledgeable and there is always someone to take our call and answer our questions.“

Jacky Blasquez, Dassault Aviation

“In this business, the risk of failure is simply too high to leave anything to chance. With Leica Geosystems, there are no open questions.”

Graham Tudor, Tooling Operations Manager, Airbus Broughton

“With the new range of products from Leica Geosystems we have just purchased, we can offer our customers new solutions to their production needs, minimizing production times and costs and offering new possibilities that until today were just dreams.”

Iván García, general coordinator, ATEC MEDICIONES INDUSTRIALES Madrid (Grupo TAM), with many years of experience using Leica Geosystems Laser Tracker

With sheet metal parts, it was possible to trim down skins in case deviations were discovered from the prescribed dimensions. This option is not available when working with composite parts, so making sure that a part corresponds to the CAD design within very tight tolerances becomes paramount. CogniTens is able to provide scans of very large surface areas in record times, immediately graphically displaying any deviations and producing automated reports – all of which is crucial in fulfilling strict certification guidelines.

these structures, the positions of the holes need to be inspected, something that was not the case with aircraft made solely of sheetmetal.

In addition, minor imperfections in the aerodynamics of complete aircraft resulting from deviations from the ideal positions of where wings are mounted on the fuselage were in practice dealt with corrective steering maneuvers in-flight. Nowadays, in the era of sky-rocketing fuel prices, such methods are absolutely cost-prohibitive. Even the most minute improvements in the aerodynamics translate into huge reductions in fuel consumption over the entire lifetime of an aircraft.

With CogniTens’ innovative scanning technology, both sheet metal and composite parts can be scanned in a fraction of time needed by comparable solutions whose limiting factors include either too narrow a scanning path or the inability to cope with surfaces with a varying degree of shininess. Being able to perform native scans of carbon composites without prepping the part substantially cuts down on inspection times and streamlines processes.

8 measureup

new innovative products in highest quality standards and beat their competitors by making it available in the sooner. In addition, the competitive structure of the global industry pressures manufacturers to reduce costs, develop products on a global basis while meeting local requirements and maintaining a common standard for quality across their global operations.

With the increased acceptance of composite materials in the production of mainstream passenger aircraft, a need has emerged to inspect large swathes of wings or to conduct full wing or body scans. Such composite aircraft sport a lot of structures in which sheet metal is mounted to composite parts, with large numbers of bolts. To pre-certify

With its unique white-light scanning solutions, CogniTens focuses on the needs of both automotive and aerospace sectors, serving many different types of companies involved in bringing a new product to the market: from OEM suppliers to some of the biggest names in the automotive and aerospace industries. In addition, more and more medium-sized companies in the general precision industry have begun to realize the myriad advantages brought on by relying on the CogniTens product line.The automotive and the aerospace industries are being affected by several key trends. Consumers around the world have more alternatives to choose from than ever before. This variety alone is pushing OEMs, their suppliers and collaborators to offer

Innovative scanning technology reduces inspection time and costsCognitens develops white light scanner solutions that can examine very large surface areas very quickly for deviations from a CaD model. the automobile industry has long since recognized the advantages of this system and works with it to great success. the know-how of this high-tech company is also ideally suitable for aerospace industry metrology.

Know-how

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Case study

The laser tracker works in tandem with a Leica T-Probe, a wireless 6DoF tracking device for automated applications. The wireless probe has a point rate output of 1,000 points per second, a measurement volume of up to 30m (98ft), and an ultra-wide acceptance angle: pitch ±45°, yaw ±45°, roll 360°. The probe has a single retro-reflector so the laser tracker can track its position, and the 10 LEDs residing on its surface are registered by the tracker‘s T-Cam camera to track its orientation in space.. Insensitive to environmental light, the device delivers a 2 sigma length measurement accuracy of 60 microns in a measurement volume of 15m (49ft).

The Leica T-Probe was mounted securely to the soft capture mechanism, and was used to measure dynamic 3D motion data (x,y,z, pitch, roll, and yaw) as the robot moved the attachment fixture randomly in space. During the test cycles, precision data captured by the device would be used to validate measurements simultaneously gathered by each of the 3 sensor systems. The T-Probe is normally hand-held. But due to numerous adaptations for machine tracking applications, Leica Geosystems introduced a variation of the product in 2007 called the T-Mac, which is designed for mounted applications such as this NASA project. Presiding over the laser tracker operations was Brent Barbee of Emergent Space Technologies, Inc. Brent was tasked with learning the nuances of two software programs - Spatial Analyzer (New River Kinematics) and a specialized software program developed for the laser tracker at the NASA Marshall Space Center. This custom software was written to interface with the Leica tracker to give continuous time stamped measurements of the of the T-Probe‘s orientation in space. Acquiring motion data is only one of many measurement tasks that leverages the mobility and accuracy of a laser tracker. These portable CMMs, Leica Theodolites, and the Leica T-Scan, a non-contact hand scanner, are utilized daily by a very experienced team of technicians for a wide range of metrology applications from general inspection of 3D coordinates to component alignment, to space craft integration and complex assembly operations.

Henry Sampler, a veteran in the Optics, Test and Alignment department, explains how non-contact scanning adds a new dimension to their metrology toolset, „We have been in critical situations where we need to get close to flight hardware and there are contamination issues. We don‘t want people actually touching things, and the non-contact scanning was really the answer to this issue. A good example is the James Webb Space Telescope where there are cryogenic mirrors and other instruments that affect the focus of the telescope. When it comes to optics, non-contact scanning gives us the ability to gather data about a position or a component very accurately without touching or contaminating sensitive areas.“With laser tracking technology providing a „reality check“, NASA moves space projects forward confidently with dimensional control built into each stage of the program. With the ability to troubleshoot, measure, validate, assemble, and mate parts to very low tolerances with a full six degrees of freedom…the sky is nowhere near the limit for NASA Goddard.

Contacts

Full version of this case study available upon request using the feedback form in the back.

For further information, please contact your closest Hexagon Metrology Precision Center (see list on page 14). www.nasa.govwww.portable-cmm.com

„The soft capture mechanism has retroreflectors and a LIDS adapter on it. LIDS is a low impact docking system. The objective of our work is to make the next rendezvous with the Hubble easier. In the past, our Hubble encounters were made with the Space Shuttle, and Servicing Mission 4 may be the last time we go back to the telescope with Shuttle. We believe a final rendezvous with the Hubble will occur, as NASA safety requirements necessitate that we park it somewhere in the south Pacific Ocean

In anticipation of this event, this week of testing was all about demonstrating our ability to estimate relative position and relative orientation with our suite of sensors to the soft capture mechanism. We mounted the soft capture mockup on the Fanuc robot, which provided a limited 6 DOF motion moving the target around while we are imaging it with engineering prototype relative navigation sensors. The Leica LTD840 was used to provide „truth information“ for the relative positioning and orientation, so we can compare the truth data to the sensor data, and determine how well the sensors performed. We are trying to gain as much expertise as we can with these technologies and the target we will ultimately use for the last Hubble rendezvous.“

Requirements for measurement validation and redundancy of data were also factored into the test program with the use of a high precision Leica Geosystems laser tracking system.

Launched in 1990, the telescope has broadcast over 750,000 celestial images, and has been a major contributor to modern astronomy and space exploration. While a deorbit module project for Hubble has been canceled, the quest for sensor technology and the creation of an attachment fixture has continued full speed ahead. The fixture will be outfitted to the end of the telescope during Servicing Mission 4.

Aligning and mating two moving objects in space is no small task. NASA engineers have proposed a theoretical vehicle-alignment and part-mating methodology designed to connect the Hubble with another spacecraft in very systematic manner. To prove out the concept, a team of experts recently gathered at NASA Goddard for a trial run of their groundwork in sensor technology. On stage were 5 key components: robot, soft capture mechanism (also called an attachment fixture), crew exploration vehicle (CEV), space-certified sensor technology, and a laser tracker with a wireless probe. „„The testing being done is laser imaging of the soft capture mechanism, which will be installed on Hubble during Servicing Mission 4,“ states Bo Naasz, NASA aerospace engineer.

Perfecting the last Hubble rendezvousleica laser tracking Provides “reality Check” in nasa Part-Mate exercise

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Integration and automation of the Measurement of Large Components – Efficiency with solutions from Hexagon Metrology

technical article

To know today what will be asked for tomorrow: the developers of Hexagon Metrology products appreciate the needs of their customers. They are also fully familiar with the special rules of aerospace industry.

The challenge is clear: the increasing size of aircraft requires larger and larger parts. At the same time the demand for standardized production processes – efficiency and higher throughput with higher quality are the cornerstones of a modern manufacturing philosophy. Repetitive testing carried out manually is frequently associated with high staff costs and low reproducibility of results .

Applications engineers from Hexagon Metrology have developed practical solutions to integrate measurements into the production processes. At Airbus in Toulouse for example, the first complete assembly process is based on measurements performed by Leica Geosystems Laser Trackers.

The basic principle is to measure the aircraft directly. The individual elements are placed in relation to one another instead of using frames the reference.Another of our tasks is to find solutions for the assembly in the area of complex intersections – created as a consequence of the oval shape of the A380 and its two decks. In the end it was the idea of assembly with the aid of Leica Geosystems Laser Trackers that convinced those responsible for the A380 program.

Thierry Fabre, responsible for the assembly based on laser measurements at Airbus in Toulouse, explains: “The problems to be overcome in this work went far beyond simple fabrication. It was necessary to unify the reference systems for all European locations engaged on in production of the aircraft. Each

location had its own ways of working, its own objectives and its own constraints when it came to assembly. In the preparation phase it was therefore critical to ensure that the data from all Airbus production centers were coherent.“

The decision was made to use four Laser Trackers from Leica Geosystems: two for the fuselage and two for the wings. All four are dependent on one another and interlinked by a common reference system. This arrangement guarantees the homogeneity and interchangeability of the Laser Trackers.

As the measurement system is integrated into the aircraft‘s assembly process, which is controlled by the assembly personnel, this contributed from the very beginning directly to project development and the determination of the man/machine interfaces, thus helping to ensure simplicity of operation.

Thierry Fabre is very satisfied with the integration of the Laser Tracker: “Thanks to the powerful and reliable Laser Trackers from Leica Geosystems, the assembly of the aircraft is based on a proven system and the technique can be transferred into other programs. After adoption for the A400 M, the concept can very probably also be used for the A350 program.“

In addition to the successful project in Toulouse, measuring equipment from Hexagon Metrology is also in use in Airbus plants at Nantes, Meaulte, St Nazaire, Bremen, Broughton and Filton.

At the Control 2008 trade fair Leica Geosystems presented a robotized application of the manually guided Laserscanner Leica T-Scan used for the first time as a component of a fully automatic robot system for dimension control. This application allows the whole measuring process to be automated in situations where clients require inspections

to be continuously repeated – even for the checking of large volume parts. The Duo Robot and Leica T-Scan can test a large number of measured objects at high speed with minimum user intervention.

Automation of precise measurement processes is already a reality - and the engineers from Hexagon Metrology are always on the ball: the further development of automation and control systems in production is one of the most important research fields for the largest metrology group in the world – for higher profits from industrial processes.

“Thanks to the capable and dependable Laser Trackers from Leica Geosystems, aircraft assembly based on laser measurements is a technologically mature process and can be carried over to other programs within our organization. After the measurement methods we developed were carried over to the military A400M project, the will most likely be used on the upcoming A350 program as well.“

Thierry Fabre, Airbus Toulouse

laser tracker at sneCMa Propulsion solide: automated large-scale serial inspectionSnecma Propulsion Solide designs, produces and markets rocket engines and composite materials for the defense, aviation and aerospace industries and other related fields.

The installation of the laser tracker was at once both sophisticated and astoundingly simple. Leica Geosystems transferred the implementation of the measurement software and the personal project supervision to a partner software firm. The laser tracker is installed on a lifting stand while the measurement object is mounted on a turning platform, both of which further automate the measurements. Both the lifting/lowering of the stand as well as the platform-turning functions are automated. Software developers integrated additional functionality into the existing Axyz software platform, allowing for complete system automation

“Today, Leica Geosystems is the only manufacturer that can deliver metrology equipment that corresponds to our requirements in both the accuracy and the measurement volume.“

Damien Darriet, SNECMA Propulsion Solide

Contacts

Full version of this case study available upon request using the feedback form in the back.For further information, please contact your closest Hexagon Metrology Precision Center (see list on page 14). www.airbus.comwww.snecma-propulsion-solide.comwww.portable-cmm.com

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super Connie: Have one of the most beautiful aircraft of all times on your desk. receive a model of the Lockheed Super Constellation – for the first 50 respondents only!

airbus st. eloi: time savings from Parallel Installed laser trackers The metrology lab at the St. Eloi pylon unit inspects every single pylon before it is assembled on the planes. 80 pylons are inspected every month. The laser trackers take an overall „snap shot“ of the pylons. These measurements facilitate the final control and, if necessary, any modifications and corrective actions. DThe measurements are updated automatically by re-importing the measurement results database in another database for statistical purposes and, if necessary, corrective actions. A statistical analysis of the measures outside the tolerance values makes it possible to identify the cause of the deviation and to implement the necessary actions..

“We are happy that Hexagon Metrology and Leica Geosystems are able to match the technological evolution of our needs to optimize the control aspect of the process. This is what a real partnership is all about.“

François Richer, Coordinator Airline Customers, Qual,ity Management, Airbus St. Eloi

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