Airbus practices for maintainability and human simulation - EDKMT1 - Ref. PR0500004 - Issue 1

7th and 8th January 2005

Airbus practices formaintainability and human simulations

Movie Workshop 7th and 8th January 2005, LAAS-CNRS.

Presented by

Christophe Le RoyProject leader in research on tools and devices for DMU exploitation

7th and 8th January 2005 Airbus practices for maintainability and human simulation - EDKMT1 - Ref. PR0500004 - Issue 1 Page 2© A

IRB

US

S.A

.S.

All

right

s re

serv

ed.

Con

fiden

tial a

nd p

ropr

ieta

ry d

ocum

ent.

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.

7th and 8th January 2005 Airbus practices for maintainability and human simulation - EDKMT1 - Ref. PR0500004 - Issue 1 Page 3© A

IRB

US

S.A

.S.

All

right

s re

serv

ed.

Con

fiden

tial a

nd p

ropr

ieta

ry d

ocum

ent.

Airbus | The organization.

20% 80%

AIRBUSFRANCE

AIRBUSDEUTSCHLAND

AIRBUSESPAÑA

AIRBUSUK

GIE transformed into Airbus Integrated Company since July 11, 2001Adding value through integration.

E u r o p e a n A e r o n a u t i c D e f e n c e a n d S p a c e C o m p a n yE u r o p e a n A e r o n a u t i c D e f e n c e a n d S p a c e C o m p a n y

7th and 8th January 2005 Airbus practices for maintainability and human simulation - EDKMT1 - Ref. PR0500004 - Issue 1 Page 4© A

IRB

US

S.A

.S.

All

right

s re

serv

ed.

Con

fiden

tial a

nd p

ropr

ieta

ry d

ocum

ent.

Airbus | Production and engineering sites.

* Approximate figures July 2004

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

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

St NazaireSt Nazaire

ToulouseToulouse

BroughtonBroughton

NantesNantes

FiltonFilton

MadridMadrid

MéaulteMéaulte

IllescasIllescas

Puerto RealPuerto Real

LaupheimLaupheim

StadeStade

HamburgHamburgBremenBremen

VarelVarelBuxtehudeBuxtehudeNordenhamNordenham

50,000 people sharing on 16 competences centers.

Production sitesMajor engineering sites

7th and 8th January 2005 Airbus practices for maintainability and human simulation - EDKMT1 - Ref. PR0500004 - Issue 1 Page 5© A

IRB

US

S.A

.S.

All

right

s re

serv

ed.

Con

fiden

tial a

nd p

ropr

ieta

ry d

ocum

ent.

Airbus | Production system.

AIRBUS-France

AIRBUS-Deutschland

AIRBUS-UK

Belairbus

AIRBUS-España

Production sharing by the Centres of Competence.Production sharing by the Centres of Competence.

7th and 8th January 2005 Airbus practices for maintainability and human simulation - EDKMT1 - Ref. PR0500004 - Issue 1 Page 6© A

IRB

US

S.A

.S.

All

right

s re

serv

ed.

Con

fiden

tial a

nd p

ropr

ieta

ry d

ocum

ent.

Airbus | ACE : AIRBUS Concurrent Engineering

To develop a new aircraft program, all functions must join their skills and efforts…

ACE is a key integration project and enabler for the new aircraft.Strong impact on tools, processes and methods.

MISSION:Providing Airbus with a competitive advantage by establishing integrated and efficient processesprocesses, methodsmethods and toolstools along the whole product life cycle.

SCOPE:Integrate data and information related to the Airbus development process in the trans-national organizationtrans-national organization. Major focus on new aircraft programs.

7th and 8th January 2005 Airbus practices for maintainability and human simulation - EDKMT1 - Ref. PR0500004 - Issue 1 Page 7© A

IRB

US

S.A

.S.

All

right

s re

serv

ed.

Con

fiden

tial a

nd p

ropr

ieta

ry d

ocum

ent.

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.

7th and 8th January 2005 Airbus practices for maintainability and human simulation - EDKMT1 - Ref. PR0500004 - Issue 1 Page 8© A

IRB

US

S.A

.S.

All

right

s re

serv

ed.

Con

fiden

tial a

nd p

ropr

ieta

ry d

ocum

ent.

Digital Mock-Up applications.

Feasibility Concept Definition Development Series

M3 M5 M7 M13

Numerical Command

Tooling Master Geometry

Assembly Instructions

Tooling Principles

Tooling Space Allocation

Tooling Frontier Models

Manufacturing Plan

Ind

ust

rial

izat

ion

Ind

ust

rial

izat

ion

Supportability Analysis

Supportability Discrepancies

Support Specification

Support Objectives

Su

pp

ort

Su

pp

ort

Master Geometry

Frontier Models

Definition Model

Space Allocation

Stress Design Reference Base

Design Principles

Definition Dossier

Air

craf

tA

ircr

aft

Systems Architecture

PartsParts

ToolsTools

FactoryFactory

7th and 8th January 2005 Airbus practices for maintainability and human simulation - EDKMT1 - Ref. PR0500004 - Issue 1 Page 9© A

IRB

US

S.A

.S.

All

right

s re

serv

ed.

Con

fiden

tial a

nd p

ropr

ieta

ry d

ocum

ent.

Simulation activities.

• Assembly/disassembly simulationAssembly/disassembly simulation.Verify if a part or an assembly (set of parts) can be

assembled in / disassembled from its environment. Trajectory simulation performed

by a design engineer or/and a maintainability actor.Preliminary

simulation

• Maintainability simulationMaintainability 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.

• Human simulationHuman simulation / process definition and validationrocess definition and validation.Simulate that a part or an assembly can be mounted /

dismounted by an operator or a manufacturing system. Complete human / manufacturing simulation

defined by a maintainability / manufacturing expert.Dynamic

simulation

Static

simulation

7th and 8th January 2005 Airbus practices for maintainability and human simulation - EDKMT1 - Ref. PR0500004 - Issue 1 Page 10© A

IRB

US

S.A

.S.

All

right

s re

serv

ed.

Con

fiden

tial a

nd p

ropr

ieta

ry d

ocum

ent.

Examples | Human simulationHuman simulation.

• Validate an assembly operation with manikin.

The manufacturing process & environment is planed, visualized and optimised in one tool. Cost reduction for recurring cost by evaluation of the best process concept

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).

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).

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).

7th and 8th January 2005 Airbus practices for maintainability and human simulation - EDKMT1 - Ref. PR0500004 - Issue 1 Page 11© A

IRB

US

S.A

.S.

All

right

s re

serv

ed.

Con

fiden

tial a

nd p

ropr

ieta

ry d

ocum

ent.

Examples | Process Definition & Validation.

Objectives• Software validation (Delmia V5).

• Validate the process of assembly and unassembly.

• Check collisions & movements with equipment (Jigs & Tools).

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).

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).

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.

• Validation of the assembly of a big structure.

7th and 8th January 2005 Airbus practices for maintainability and human simulation - EDKMT1 - Ref. PR0500004 - Issue 1 Page 12© A

IRB

US

S.A

.S.

All

right

s re

serv

ed.

Con

fiden

tial a

nd p

ropr

ieta

ry d

ocum

ent.

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?

7th and 8th January 2005 Airbus practices for maintainability and human simulation - EDKMT1 - Ref. PR0500004 - Issue 1 Page 13© A

IRB

US

S.A

.S.

All

right

s re

serv

ed.

Con

fiden

tial a

nd p

ropr

ieta

ry d

ocum

ent.

Research activity on simulation (1/4).

• Simulation issue.Engineering.Manufacturing.Support.…

Request forsimulation support

No

Simulationexpert

Yes

Interactiveprocess

Automatedprocess

Simulationsupport

• Resolution.

• Solution.

Find the compromise between: resources, time,methods,processes,competencies, ...

7th and 8th January 2005 Airbus practices for maintainability and human simulation - EDKMT1 - Ref. PR0500004 - Issue 1 Page 14© A

IRB

US

S.A

.S.

All

right

s re

serv

ed.

Con

fiden

tial a

nd p

ropr

ieta

ry d

ocum

ent.

Research activity on simulation (2/4).Interactive simulation process.

• 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).

January 2004 : new research activity with 6D force feedback : SAMIRA II.

January 2004 : operational deployment of SAMIRA I based on a SpaceBall / SpaceMouse.

Great interest for Airbus !

Force feedback in 3D : poor, not useful.

Intuitive manipulation with SpaceBall / SpaceMouse : great !

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.

7th and 8th January 2005 Airbus practices for maintainability and human simulation - EDKMT1 - Ref. PR0500004 - Issue 1 Page 15© A

IRB

US

S.A

.S.

All

right

s re

serv

ed.

Con

fiden

tial a

nd p

ropr

ieta

ry d

ocum

ent.

Research activity on simulation (3/4).Interactive simulation process.

• SAMIRA ISAMIRA 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 !

SAMIRA I shortSAMIRA I short

7th and 8th January 2005 Airbus practices for maintainability and human simulation - EDKMT1 - Ref. PR0500004 - Issue 1 Page 16© A

IRB

US

S.A

.S.

All

right

s re

serv

ed.

Con

fiden

tial a

nd p

ropr

ieta

ry d

ocum

ent.

Research activity on simulation (4/4).Interactive simulation process.

• SAMIRA IISAMIRA 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 !

SAMIRA II BourgetSAMIRA II Bourget

7th and 8th January 2005 Airbus practices for maintainability and human simulation - EDKMT1 - Ref. PR0500004 - Issue 1 Page 17© A

IRB

US

S.A

.S.

All

right

s re

serv

ed.

Con

fiden

tial a

nd p

ropr

ieta

ry d

ocum

ent.

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.

Accuracy EasinessMech.

perceptionRapidity

Classical simulation tools

+ – + –

Interactive simulation with force feedback

+ + + + + +

Automatic simulation process

+ + + – + +

7th and 8th January 2005 Airbus practices for maintainability and human simulation - EDKMT1 - Ref. PR0500004 - Issue 1 Page 18© A

IRB

US

S.A

.S.

All

right

s re

serv

ed.

Con

fiden

tial a

nd p

ropr

ieta

ry d

ocum

ent.

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.