In Work Package 1, the datum flow chains in the RA-IADP wing were studied, and the relationships between tolerances and Assembly Key Characteristics were modelled using a statistical approach. This allowed an uncertainty budget to be calculated.
In work package 2, the assembly of reduced-size wingbox was simulated in 3DCS Computer Aided Tolerancing software, to calculate the variation in key characteristics. This used expected manufacturing tolerances, but will in future use the expected uncertainties of the measurement system to simulate the assembly using a part-to-part assembly method. A 3DCS model was validated against a mathematical approach using homogeneous transformations.
In work package 3, the requirements of the VADIS cell were refined with the Topic Manager, and potential solutions proposed and decided upon. This included various metrology systems capable of measuring features on the wingskins, and various options for measuring cell layout. Measurement tests were completed on representative samples provided by the Topic Manager to ensure suitability of the measurement system and associated software for the specific use case.
In work package 4, the uncertainty of the measuring system was further investigated, including its ability to measure the required features and interface zones. The scanning paths and measurement extraction parameters were studies and optimised. The position of the ribs was optimised to minimise the amount of shim material remaining at the upper skin IML interface. The measurement data was used to construct a reverse engineered “digital twin” of the scanned components, and project the relevant features into the models of mating components to allow CNC machining and thus enable part-to-part assembly.
In work package 5, the conceptual design presented at the preliminary design review was turned into a detailed design for acceptance at the critical design review. Methods of holding the wingskins in their nominal positions were developed. To ensure the jigs can be used with future variation in wing design, methods of resetting the jigs to cope with different product configurations were also established.
In work package 6, the jigs were manufactured and assembled. Sub-assemblies and sub-systems were tested to ensure their performance met the requirements of the project. The jigs were shipped to the University of Nottingham's Centre for Aerospace Manufacturing, where development work could continue with real components.
In work package 7, refinement of the VADIS processes is underway. Representative aerospace components have been mounted in the VADIS jigs and scanned using state-of-the-art metrology equipment. Measurement data was processed by custom VADIS programs to transferrable datasets, which are then used by a VADIS digital twin creation script to automate modification of the CATIA models. The models can be used to check the quality of the wing panels, and for manufacturing mating components for subsequent one-way assembly.
In work package 8, the mid-scale wingbox parts, VADIS jigs and measurement equipment was shipped to the Topic Manager in Pomigliano D'Arco under Article 250 Temporary Admission import rules. The jig was installed and commissioned by the VADIS consortium, and the VADIS measurement update processes were demonstrated.
In work package 9, the VADIS processes were developed for the full-scale RA-IADP wingbox demonstrator. Although parts were not available, projects were provided to the topic manager for controlling the measurement process, and a "nominal" measurement dataset was used to demonstrate that VADIS processes could be used to update the CATIA models according to the Topic Managers requirements, including position optimisation of the ribs to minimise shim.
In work package 10, the project management was controlled through the use of risk registers and dissemination and exploitation plans.
