Presented at the THIC Meeting WestCoast Silverdale Hotel

Silverdale, WA 98383-9191 USAon October 9, 2001

Future Needs and Capabilities for Data Acquisition

747: Queen of the Sky Goes Digital

James D. (Jim) GreenBoeing Commercial Airplanes

Principal Engineer, 747 Spatial Integration

Presentation Objectives

• Share Information on 747 Spatial Integration

• Illuminate the Mountain of CATIA V4 Boeing Design

• Look at the Future of Boeing Spatial Integration

The 747 Product

The 747 Family

Longer-Range 747-400

747 Trivia

Parts

A 747-400 has six million parts, half of which are fasteners. A 747-400 has 171 miles (274 km) of wiring and 5 miles (8 km) of tubing. A 747-400 consists of 147,000 pounds (66,150 kg) of high-strength aluminum. The 747-400 has 16 main landing-gear tires and two nose landing-gear tires. The 747-400 tail height is 63 feet 8 inches (19.4 m), equivalent to a six-story building.

Wings

One 747-400 wing weighs 28,000 pounds (12,700 kg), 10 times the weight of the first Boeing airplane, the 1916 B&W. One 747-400 wing measures 5,600 square feet (524.9 m2), an area large enough to hold 45 medium-sized automobiles. Four World War I vintage JN4-D "Jenny" airplanes could be lined up on each of the Boeing 747 wings. How much weight does an additional 6-foot (1.8 m) wingtip extension and winglet add to the 747-400 wing? None! A weight savings of approximately 5,000 pounds (2,270 kg) was achieved in the wing by using new aluminum alloys, which offset the weight increase of the wingtip extension and winglet.

More Trivia...

Engineering and Testing

• Seventy-five thousand engineering drawings were used to produce the first 747. • The first 747 completed more than 15,000 hours of wind-tunnel testing. • The original 747 flight test program, which led to the airplane's certification for commercial service in

December 1969, used five airplanes, lasted 10 months and required more than 1,500 hours of flying.

Flight

• The 747 fleet has logged 20 billion statute miles (32 billion km) -- enough to make 42,000 trips to the moon and back.

• The 747 fleet has flown 2.2 billion people -- the equivalent of nearly 40 percent of the world's population. • The 747-400 range is approximately 8,400 statute miles (13,515 km), an increase of nearly 2,300 statute

miles (3,700 km) more than the first 747. • A 747-400 typically takes off at 180 mph (290 km/h), cruises at 565 mph (910 km/h) and lands at 160 mph

(260 km/h). • For a typical international flight, one 747 operator uses no fewer than 5.5 tons of food supplies and more

than 50,000 in-flight service items.

…and More…

Engines

• Engine thrust has grown from 43,500 pounds (19,730 kg) per engine on the early 747s to 62,100 pounds (27,490 kg) on the current model.

• The diameter of the 747 engine cowling is 8 feet 6 inches (2.6 m). • Engine noise from today's 747-400 is half of what it was on the original 747s delivered in 1970.

Fuel

• The 747-400 can carry more than 57,000 gallons of fuel (215,745 L), making it possible to fly extremely long routes, such as San Francisco to Sydney, Australia.

• A 747-400 that flies 3,500 statute miles (5,630 km) and carries 126,000 pounds (56,700 kg) of fuel will consume an average of five gallons (19 L) per mile.

• The 747-400 carries 3,300 gallons (12,490 L) of fuel in the horizontal (tail) stabilizer, allowing it tofly an additional 400 miles.

• The 747-400 is up to 13 percent more fuel efficient than its predecessor, the 747-300, depending on the engine.

…and More!

Interior

• At 31,285 cubic feet (876 m3), the 747-400 has the largest passenger interior volume of any commercial airliner, which is equivalent to more than three houses each measuring 1,500 square feet (135 m2).

• The 747-400 has a redesigned "flexible" cabin interior that not only improves passenger conveniences and appeal, but allows airlines to rearrange seats and class configuration overnight (in eight hours).

• They also permit 48-hour conversion times for changes in galley and lavatory locations. • Airline cargo handlers use the 747-400's lower-lobe cargo handling system to load or unload more than 65,000

pounds (30,000 kg) of cargo -- the equivalent of 625 pieces of luggage combined with 20 tons of revenue freight -- in less than 15 minutes.

• The Wright brothers' first flight at Kitty Hawk, N.C., could have been performed within the 150-foot (45 m) economy section of a 747-400.

• There are 365 lights, gauges and switches in the 747-400 flight deck, reduced from 971 on earlier 747 models.

The History of Boeing Digital Pre-Assembly

...

747 Digital Opportunity

Mockup Elimination Longer Range 747-400

New Interior Cabin Equipment Standardization

Progress on 747 Digital Pre-Assembly

747 Accurate Fuselage Assembly Geometry

747-400ER Additional Fuel Cell

Potable Water Tanks Relocated Aft

747 New Interior

747-400ER Halon Bottles

The DPA Process

Goals of Digital Pre-Assembly

• Reduce Change, Error, and Rework caused by

– Part Interferences

– System Separation Infractions

– Produce-ability Issues

– Maintainability Issues

Process Change

Is Now...

Digital Mockup

CATIA Design

Concurrent Process

Integration Before Build

Was...

• Physical Mockup

• Mylar Design

• Sequential Process

• Integration by Rework

Digital Pre-Assembly (DPA) Process

CompleteSpatial

IntegrationReleaseModels

Producibility analyzed

Maintainability analyzed

Fully integrated design

Safety, stress, customer requirements

Old FocusNew Focus

DefineWork

Statement

ShareInitialDesign Evolve the Design

All Parts represented

Reference models in place

Interfaces are negotiated

System separation achieved Interferences resolved

Design Evolution Example

Spatial Integration VolumesSpatial Integration Volumes

Upper Deck & Forward Cabin Crown & Aft Passenger Cabin

Lower Lobe & Un-pressurized

Interior Design ReviewsInterior Design Reviews

CATIA V4 Format

Update drawingUpdate drawingDuplic

ate

Duplic

ate

Duplicate

Duplicate

Update drawingUpdate drawing

InstallationModel

Update drawingUpdate drawing

AssemblyModel

DetailModel

Conversion Modeling

• Def: 3D Models where part is still defined on mylar.

• Models used as reference in Digital Pre-Assembly process.

• Difficult to balance the need with the cost.

• Support accurate interface definition for new design only.

• Boeing offloads conversion modeling to CATIA shops.

• Conversion models must be maintained with minor change or upgraded to sole-authority product definition with major change.

Interesting 747 DPA Trivia

• 98,800 CATIA V4 models at released status

• 18,000 models used for DPA process (installations)

• 4,800 models for one customer

• 80,100 solids for one customer

• 180,000 interferences detected each month

Manufacturing Simulation

Fuel Cell Installation

• Manufacturing Engineering Organization

• ME participates in design integration to provide produce-ability input at each stage of the design

• Simulations used to prove out high risk installations & major assembly changes

• Would like to expand simulations, but current tools and data are not integrated with Engineering design tools. Final Body Join

Digital Maintainability

• Reliability, Maintainability, and Testability Organization

• New opportunities with digital product definition

• Provide design checklist with Boeing requirements and objectives

• Work with designers to provide an airline mechanic’s viewpoint

• Ensure designers provide enough space for mechanics and tools to complete a maintenance task

• Consider removal times, removal paths and failure rates of maintenance significant items.

Cargo Fire Protection - Halon Bottle Access

• Problem• New fuel tanks caused difficult access to the bottles

• Halon bottles weigh approximately 67 pounds

• Requires cumbersome position for installation/maintenance

• Solution• Relocate halon bottles to aft cargo compartment

• Provide a step to ease installation and removal

• Provide a tool for installation and removal

• Adjust handles and attaching hardware

• Change location of distribution lines

A Peek at Our Future

FunctionalFunctionalModelingModeling

SpatialSpatialModelingModeling

BuildBuildModelingModeling

SupportSupportModelingModeling

VirtualVirtualProductProductModelModel

Vision

777747 737NG767757

Methodology: Process Maturity MatrixDigital

Enterprise

DigitalProduct

Definition

DigitalProcess

Definition

DigitalResourceDefinition

ParallelPPR

Development

SimulationBasedDesign

DigitalPre-Assembly

Designin

Context

RelationalDesign

SpecificationBasedDesign

DiversityDrivenDesign

ProductLife Cycle

Optimization

3D BasedDesign

CollaborationManagement

InterfaceManagement

Designfor

Variability

Design toTarget

Maintainability,Reliability, ...

DigitalService &

MaintenanceManagement

PartBasedDesign

Data SetManagement

Configuration & Commonality

Management

Life CycleManagement As Planned

Life CycleManagement

As Built

Life CycleManagement

As Maintained

AssemblyBased Design

DocumentManagement

DesignChange

Management

IPTChange

Management

ProgramChange

Management

Supply/DesignChain

Integration

CustomerRelationshipManagement

FileManagement

FileVault

ProgramVault

DistributedProgram

Vault

ExtendedProgram

Vault

- businessHub

V5 Process & Tool Validation Process

747 FreighterNose Cargo Door

Proc

ess

Tool

s

Key Issues for Moving into V5

• Developing and Deploying the Underlying Tools ---CATIA, ENOVIA, DELMIA, & Boeing Infrastructure

• Developing the Processes that Employ those Tools

• Maturing the Processes that move the processes and tools to production ready

• Training the users and supporting them with a cost effective infrastructure

• Migration and conversion of CATIA V4 data into the V5 environment in a usable format

747 “Majesty” Video