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Airbus practices for maintainability and human simulations

Movie Workshop 7 th and 8 th January 2005, LAAS-CNRS. Presented by Christophe Le Roy Project leader in research on tools and devices for DMU exploitation. Airbus practices for maintainability and human simulations. Content. Airbus: the organization, the production and engineering sites,

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Airbus practices for maintainability and human simulations

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  1. Movie Workshop 7th and 8th January 2005, LAAS-CNRS. Presented by Christophe Le Roy Project leader in research on tools and devices for DMU exploitation Airbus practices formaintainability and human simulations Airbus practices for maintainability and human simulation - EDKMT1 - Ref. PR0500004 - Issue 1

  2. Content • Airbus: • the organization, • the production and engineering sites, • ACE : Airbus Concurrent Engineering. • Simulation activities: • the use of the Digital Mock-Up, • assembly – disassembly / maintainability / human simulations. • Research activities: • the project SAMIRA. • Conclusions. Airbus practices for maintainability and human simulation - EDKMT1 - Ref. PR0500004 - Issue 1

  3. Airbus |The organization. GIE transformed into Airbus Integrated Company since July 11, 2001 Adding value through integration. 20% 80% AIRBUS FRANCE AIRBUS DEUTSCHLAND AIRBUS ESPAÑA AIRBUS UK Airbus practices for maintainability and human simulation - EDKMT1 - Ref. PR0500004 - Issue 1

  4. Airbus |Production and engineering sites.  50,000 people sharing on 16 competences centers. Production sites Broughton Stade Major engineering sites Nordenham Buxtehude Filton Varel Hamburg Bremen Airbus direct workforce in Europe * Headquarters:  6/7% employees Airbus France:  33 % employees Airbus Germany:  37 % employees Airbus UK:  18 % employees Airbus Spain:  5/6 % employees  50,000 people Méaulte St Nazaire Nantes Laupheim Toulouse Madrid Illescas * Approximate figures July 2004 Puerto Real Airbus practices for maintainability and human simulation - EDKMT1 - Ref. PR0500004 - Issue 1

  5. Airbus | Production system. Production sharing by the Centres of Competence. AIRBUS-France AIRBUS-Deutschland AIRBUS-UK AIRBUS-España Belairbus Airbus practices for maintainability and human simulation - EDKMT1 - Ref. PR0500004 - Issue 1

  6. Airbus | ACE : AIRBUS Concurrent Engineering ACE is a key integration project and enabler for the new aircraft. Strong impact on tools, processes and methods. To develop a new aircraft program, all functions must join their skills and efforts… MISSION: Providing Airbus with a competitive advantage by establishing integrated and efficient processes, methods and tools along the whole product life cycle. SCOPE: Integrate data and information related to the Airbus development process in the trans-national organization. Major focus on new aircraft programs. Airbus practices for maintainability and human simulation - EDKMT1 - Ref. PR0500004 - Issue 1

  7. Digital Mock-Up? What is a Digital Mock-Up? A Digital Mock-Up is a simulation based on numerical and/or digital models that represents partially or globally a product or part of a product (airframe, systems, avionics, …). Why using a Digital Mock-Up? To support the analysis of the product during its different phases (project, feasibility, definition, post EIS). DMU is used to ease design, understanding, validation, modification, information, selling, support & maintenance, ... DMU is used to replace partially or totally the physical mock-up. Airbus practices for maintainability and human simulation - EDKMT1 - Ref. PR0500004 - Issue 1

  8. Digital Mock-Up applications. M3 M5 M7 M13 Feasibility Concept Definition Development Series Systems Architecture Master Geometry Aircraft Design Principles Space Allocation Stress Design Reference Base Industrialization Frontier Models Definition Model Tooling Master Geometry Definition Dossier Tooling Principles Tooling Space Allocation Manufacturing Plan Tooling Frontier Models Support Numerical Command Support Specification Support Objectives Assembly Instructions Supportability Analysis Supportability Discrepancies Parts Tools Factory Airbus practices for maintainability and human simulation - EDKMT1 - Ref. PR0500004 - Issue 1

  9. Simulation activities. • Assembly/disassembly simulation. • Verify if a part or an assembly (set of parts) can be assembled in / disassembled from its environment.  Trajectory simulation performedby a design engineer or/and a maintainability actor. Preliminarysimulation • Maintainability simulation. • Verify if a part or an assembly can be mounted / dismounted by an operator or a manufacturing system (tools, robots, …).  Trajectory, sequence of manipulation,validation by maintainability experts. Staticsimulation • Human simulation / process definition and validation. • Simulate that a part or an assembly can be mounted / dismounted by an operator or a manufacturing system.  Complete human / manufacturing simulationdefined by a maintainability / manufacturing expert. Dynamicsimulation Airbus practices for maintainability and human simulation - EDKMT1 - Ref. PR0500004 - Issue 1

  10. Examples | Human simulation. The manufacturing process & environment is planed, visualized and optimised in one tool. Cost reduction for recurring cost by evaluation of the best process concept • Validate an assembly operation with manikin. Objectives • Validation of news functionalities (Delmia V5). • Check the operations of assembly according to the configuration plane in the post (access and the ergonomics operations). • Check collisions & movements with equipment (tools). Project Benefits • Anticipation of the ergonomic problems for the operator (better comfort to work). • Better hand tooling/Aircraft parts integration (use of check collision). • Lead time reduction & rapid aircraft maturity. • Less effort for documentation (use of 3D mock-up for technical publication). Airbus practices for maintainability and human simulation - EDKMT1 - Ref. PR0500004 - Issue 1

  11. Examples | Process Definition & Validation. Validation of the assembly of a big structure. Jigs and human assembly processes are validated for a subassembly. The manufacturing engineer is supported by doing the process optimisation. Planning safety and quality is increased. Objectives • Software validation (Delmia V5). • Validate the process of assembly and unassembly. • Check collisions & movements with equipment (Jigs & Tools). Project Benefits • Clashes at section movement discovered and alternative proposed. • Reduction of tool cost (more than 10 major problems discovered). • On dock safety regulations approved. • First time right achieved (planned). • Better associativity between data (very useful in case of modification). Airbus practices for maintainability and human simulation - EDKMT1 - Ref. PR0500004 - Issue 1

  12. Simulation activities | Today status. • DMU status for geometrical engineering design and for manufacturing process. • Until 1998, all our previous aircraft programs have been fully developed by using the physical mock-up. • The A340-500/600 and A380 programs have been mainly developed by using the digital mock-up based on the Concurrent Engineering method (engineering simulation, digital factory). • Integration between aircraft engineering and industrialization engineering. • How to improve the today status? • Do more simulations? • Improve integration in our business processes and methods? • Improve tools : accuracy, rapidity,automation? Airbus practices for maintainability and human simulation - EDKMT1 - Ref. PR0500004 - Issue 1

  13. Research activity on simulation (1/4). Simulationexpert Request forsimulation support No Yes Automatedprocess Interactiveprocess • Simulation issue. • Engineering. • Manufacturing. • Support. • … Simulationsupport • Resolution. Find the compromise between: • resources, • time, • methods, • processes, • competencies, • ... • Solution. Airbus practices for maintainability and human simulation - EDKMT1 - Ref. PR0500004 - Issue 1

  14. Research activity on simulation (2/4).Interactive simulation process. • January 2004 : new research activity with 6D force feedback : SAMIRA II. • January 2004 : operational deployment of SAMIRA I based on a SpaceBall / SpaceMouse. • SAMIRA – SimulAtion de Maintenance Interactive avec Retour hAptique / Intuitive manipulation using force feedback (EADS CCR). • History in brief. • 1998 - 2001 : PhD thesis on interaction and force feedback (EADS CCR).  Great interest for Airbus ! • June 2001 : GO for a first prototype with 3D force feed-back. • April 2002 : first demonstration SAMIRA v1.0. • September 2002 : in-situ tests and validation (v1.1). • 2003 : general improvements.  Force feedback in 3D : poor, not useful.  Intuitive manipulation with SpaceBall / SpaceMouse : great ! Airbus practices for maintainability and human simulation - EDKMT1 - Ref. PR0500004 - Issue 1

  15. Research activity on simulation (3/4).Interactive simulation process. SAMIRA I short • SAMIRA I functionalities. • Object manipulation out of collision,trajectories out of collision. • Intuitive manipulation. • 6D manipulation (SpaceBall / SpaceMouse / PHANToM). • Interactive limitations of some Degrees of Freedom on request. • Interactive reference frame change. • … • Visual and sound information. • Contact points. • Parts in contact highlighted. • Stereoscopic view. • …  Force feedback in 3D : poor, not useful.  Intuitive manipulation with SpaceBall / SpaceMouse : great ! Airbus practices for maintainability and human simulation - EDKMT1 - Ref. PR0500004 - Issue 1

  16. Research activity on simulation (4/4).Interactive simulation process. SAMIRA II Bourget • SAMIRA II – force feedback in 6D (EADS CCR – DCR/ITP). • SAMIRA II integrates: • Digital Mock-Up. • Interactive 3D visualization (Virtools). • Physics/dynamics (Havok, …). • Collision detection. • Intuitive manipulation 6D(SAMIRA I learning). • Force feedback 6D(Virtuose 6D from Haption). • SAMIRA allows: • Early simulation. • Relevant physical / mechanicalinteraction with the product. • Real intuitive movements. • New metaphor of interaction(touch sense).  Force feedback in 6D : great ! Airbus practices for maintainability and human simulation - EDKMT1 - Ref. PR0500004 - Issue 1

  17. Conclusion | What optimal solution? • Classical simulation tools are used all along the definition and the development processes based on the Digital Mock-Ups. • Force feedback and simulation of mechanical physics offer a perfect mechanical understanding of the DMU. • Automatic path planning tools have a really great potential. • Kineo Path Planner (Kineo CAM) / LAAS researches. Airbus practices for maintainability and human simulation - EDKMT1 - Ref. PR0500004 - Issue 1

  18. This document and all information contained herein is the sole property of AIRBUS S.A.S. No intellectual property rights are granted by the delivery of this document and the disclosure of its content. This document shall not be reproduced or disclosed to a third party without the express written consent of AIRBUS S.A.S. 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 S.A.S. will be pleased to explain the basis thereof. Airbus practices for maintainability and human simulation - EDKMT1 - Ref. PR0500004 - Issue 1

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