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WIMO Report Summary

Project ID: 286745
Funded under: FP7-JTI
Country: Germany

Periodic Report Summary 3 - WIMO (Outer Wing Metrology)

Project Context and Objectives:
Within the FP7 context of the European Union‘s CleanSky programme, carried out as BLADE (Breakthrough Laminar Aircraft Demonstrator in Europe) under management of Airbus, a technology is being developed to build airplane wings for passenger planes that allows a natural laminar flow under cruise conditions. This will help reduce fuel consumption and emissions caused by air travel. Numerous technological challenges must be overcome to build wings that will comply with the necessary tight tolerances for profile waviness and roughness, and the precision manufacturing and assembly must necessarily be accompanied by high precision metrology on scales from meters to sub-millimeters.
We have built a customized and highly accurate fringe-projection stereo measurement system that complies with the specifications. In this third periodic we report the progress made towards the objectives as set out in the description of work.
There were five main objectives for this period:
− Improvement and further development of the stereo camera system and the integration of the laser tracker as the global reference coordinate system. This includes improvement of calibration algorithms, operational software and algorithms to minimize errors for the laser-tracker data embedding.
− Improvement and further development of data evaluation procedures for establishing form and waviness errors, including how to set the cut planes and what direction vector to use for comparisons. The software development had to meet all Airbus requirements.
− Recording and evaluation of wing cover tooling shape data on-site at Saab (Linköping).
− Monitoring of the assembly process at Aernnova on-site in Berantevilla for both wings
− Data evaluation for the assembly process deviations as basis for the evaluation of the set manufacturing tolerances.

The technical content of the WiMo Project has not changed. Delays against the original DoW caused by manufacturing delays have been accounted for by a project extension until the end of 2016; however, further production delays have occurred and it is now envisaged by Airbus that the effort may not be finished by that date.

Project Results:
WP 1 is dedicated to the management of the project. Within this task several meetings with all relevant partners of the BLADE project were held to establish personal and efficient contacts, to clarify the requirements further, and to organize the measurement campaigns. In addition, regular WebEX conferences have been held for updates and progress monitoring.

WP 2: The stereo camera fringe-projection system has to undergo a permanently improvement, inspection with respect to the accuracy of the measurement procedure, maintenance, control of function and calibration parameters. Consequently, the corresponding work package 2 has the long runtime from month 1 to 69 (end of WiMo project). The fringe-projection system is especially developed for the tasks in the BLADE project and therefore is today an outstanding measuring tool. The abilities of the system cover all requirements to work very robust and reliable in the industrial environments. The system proved during period 3 its long term stability and also transportability. (see attachment for photographs on-site measurement at Aernnova in Berantevilla.

WP8, 10: Procedures for Data Evaluation / Automated Data Evaluation / Data Evaluation for Assembly Process Deviations
One main point in the WiMo project is the software development of a tool to analyse and evaluate the so called waviness of the wing surface. The waviness is defined with the Airbus “Reference 101105_SFWA_Pres_WP21_PPhillips_v3_final”, Author Paul Phillips (BLADE WP2 Leader, Sep 2014) and approved by Dan Dodd (Head of Aero Design, Sep 2014) and Heinz Hansen (Top LDA-Leader, Oct 2014). The waviness is the criterion for the verification of the surface smoothness according to the tolerances. The tolerances are also defined in this reference. The task of WP 8 and 10 was the development of a software-tool which detects the waviness of a specified wing profile, analyses and evaluates the waviness exact according to the rules defined in the mentioned Airbus reference. The tool was successfully developed and tested and can be used to determine the waviness for every profile cut.

WP14: Data Evaluation for Assembly Process Deviations
The procedure of WP 14 passes following work steps:
a) measuring the wing surface (BIAS/VEW),
b) data preparation (BIAS/VEW) step 1 (cleaning, orientation, stitching),
c) data preparation (BIAS/VEW) step 2 (connection of nominal and real data),
d) data preparation (BIAS/VEW) step 3 (visualisation of deviation between nominal and real data)
e) data evaluation for assembly process deviation (Airbus/BIAS/VEW/Aernnova)
f) waviness analysis according to defined profile cuts (results from e)) (BIAS)
g) transfer of waviness data to Airbus for final evaluation (BIAS)
This procedure is the basis in the BLADE project to investigate the laminar flow wing realization during production and flight phases and will be executed on-site, at BIAS, with an Airbus ordered WebEx-Meeting.
WP11: Tool Measurement Saab, Linköping
The Saab tool was measured in Linköping and evaluated concerning waviness and bumps. More details in the attachment.

WP12: Tool / Wing Measurement GKN, Bristol
Tool and Wing of GKN was measured in Bristol. Additionally the wing was measured after its arrival at Aernnova in Berantevilla 2015. The comparison delivers the same surface distribution from the tool and on the wing as well.

WP16: Outer Wing Assembly, Vitoria
The first measurements after the wings arrival in Berantevilla took place in 11.2015 – 12.2015. This concerned mainly the GKN wing. The measurement campaign started very successfully. It could be proved that the developed fringe-projection system is able to deliver reliable measurement values under these harsh conditions. The deviation between nominal and real data can be calculated with an accuracy high enough to evaluate the waviness within the given tolerances. The deviation will be visualized as coloured images for the whole wing.
First result for the GKN wing: In the area around the leading edge are some locations out of the tolerance. This is caused because the nose was not completely fixed during the measurement campaign. The results from the upcoming measurements in February 2016 should confirm this assumption. Mostly all other parts from the wing are within the tolerance except at the fixing points in the jig (dark blue upper side). The missing areas in the results (horizontal “stripes”) are caused by covering of the profile assys of the jig. At these areas no measurement is applicable.

Potential Impact:
The objective of this project is to develop and establish a sustainable strategy for measuring the quality of the surface of a wing which will be used as a natural laminar flow (NLF) wing. This includes the development of a new integrated measurement system as well as new procedures for the characterization of the surface with fast and automated algorithms.
As a result of this project European aircraft industry will be strengthened due to the capability of manufacturing a NLF aircraft. In addition the developed measurement system can be used in other areas where a high surface quality is mandatory like in inspection of forming tools in automotive industry.
The performed research and development during this project is a crucial contribution to an overall strategy for a reliable manufacturing solution of NLF components. Therefore, it is embedded in the BLADE project with all involved partners.

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