PRODUCT STRUCTURE RELATION BASED CONFORMITY INSPECTION FOR CIVIL AIRCRAFT

Transcription

1 PRODUCT STRUCTURE RELATION BASED CONFORMITY INSPECTION FOR CIVIL AIRCRAFT 1 YU ZHENG, 2 YANRONG NI, 3 JUNTONG XI, 4 LINGYUN PAN, 5 MIN LU, 1 Lecturer, Computer Integrated Manufacturng Insttute, School of Mechancal Engneerng, Shangha Jao Tong Unversty, , Shangha, Chna 2 Assoc. Prof., Computer Integrated Manufacturng Insttute, School of Mechancal Engneerng, Shangha Jao Tong Unversty, , Shangha, Chna 3 Prof., Computer Integrated Manufacturng Insttute, School of Mechancal Engneerng, Shangha Jao Tong Unversty, , Shangha, Chna 4,5 Commercal Arcraft Corporaton of Chna, Ltd., Shangha Arcraft Manufacturng Co., Ltd.(SAMC), ,Shangha, Chna E-mal: 1 yuzheng@sjtu.edu.cn, 2 nyr@sjtu.edu.cn, 3 jtx@sjtu.edu.cn, 4 lm@comac.cc, 5 ply@comac.cc ABSTRACT Cvl arcraft s a knd of complcated product wth the tremendous product data and ntrcate data evoluton process. Data consstency management n the product lfecycle s an extremely sgnfcant problem especally for the cvl arcraft product. Product data consstency management for cvl arcraft s not only requred by the arworthness certfcaton on product conformty nspecton, also related to the success of the new product development. On the product data consstency management, there are many researches whch focus and dscuss on the structure of BOM data, BOM data mantenance method, but few study on the technque of mult-bom data consstency nspecton method. In ths paper, the arcraft product BOM layer and structure are analyzed n the "arframer-supplers" development model, operatons and changes durng the BOM transton and reconstructon from engneerng BOM to manufacturng BOM are llustrated. The dfferences between engneerng BOM and manufacturng BOM whch are generated durng the BOM transton are classfed nto normal nconsstences and erroneous nconsstences. For the erroneous nconsstences nspecton, a product structure relaton based conformty nspecton method s proposed. The correspondng algorthm s clarfed, and ts workflow s descrbed n detal. The cvl arcraft conformty nspecton system s developed. The method and system are appled n practcal product data management of ARJ and verfed effcently. Keywords: Product Data Management, Data Conformty Inspecton, BOM, Conformty Inspecton Algorthm 1. INTRODUCTION The desgn and manufacturng of cvl arcraft product s a long-cycle and hgh rsk system engneerng. Developng a new type of arcraft from desgn to producton generally takes at least 24 months [1]-[3]. The frst arcraft of ARJ took about 80 months from the development project begnnng to the start of producton. Wth the cooperaton between enterprses n depth, the desgn and manufacturng data wll be produced and reconsttuted n dfferent collaboraton unts. The consstency of product data n the lfecycle s a serous problem especally to the complex arcraft products. At the same tme, cvl arcraft as a specal product, ts safety requrement s very hgh. Manufacturer must obtan the arworthness certfcaton before delverng the product to the customer. The arworthness certfcaton process nvolves the product data conformty nspecton. Therefor the effectve consstency nspecton method and the correspondng tools to support arcraft product data consstency management are crtcal. 2. SUMMARY OF RELATED WORK The BOM data s the most basc, unversal and common means of product data. The researches of product data consstency management are mostly based on BOM structural data [4], [5]. There are much more research works on the data consstency mantenance method and tools for the mult-bom, but fewer study works on the conformty nspecton method and tools for product data. The dscussons of data consstency nspecton algorthm are mostly 120

2 descrbed n somorphsm problem based on the graph theory and matrx theory. The product s decomposed nto many small parts, and then data consstency nspecton s carred out wth each small part. These methods are usable for products smply n structure. But to the complex products, the scale of the cvl arcraft product matrx s too large to calculate, and t s very tme-consumng [6]-[10]. Based on the above contents, the rest of paper s organzed as follow. In Secton 3 we analyse the product data structure, the changes made durng the transton from engneerng BOM to manufacturng BOM and the dfference and nconsstency problem n the product data evoluton. And relaton based data consstency nspecton method and correspondng algorthm are presented n Secton 4. The system tools and ts applcaton n practce are explored n the Secton 5. We conclude our paper and suggest some possble future drecton n Secton ANALYSIS OF TRANSITION FROM ENGINEERING BOM TO MANUFACTURING BOM 3.1 EBOM, M-BOM, SPSBOM and SBOM The manufacture of cvl arcraft usually takes the "arframer-supplers" busness model. In the development of a new type craft, there wll be many supplers who have close cooperaton wth fnal assembly plant to provde arcraft subassembly parts. Each partcpant wll buld ts BOM for ts producton based on the desgn requrements. The followng wll gve the defnton and descrpton of all the BOM type. (1)EBOM EBOM s generated late n the desgn stage. It s formed accordng to the work of engneerng desgner n accordance wth the customer orders and the product functonal requrement [11]-[13]. The typcal EBOM of arcraft are descrbed n the Fgure1. In the product lfecycle, EBOM s followng BOM s nput data, and t wll be converted to the manufacturng BOM. And the product consstency nspecton s based on t. (2) Arframer s manufacturng BOM (M-BOM) EBOM reflect the product desgn structure, M- BOM n ths paper refers to the arframer s manufacturng BOM. It generate from the EBOM after the transton by the process engneer n consderaton of manufacturablty and assemblablty [14]-[18]. The typcal M-BOM of arcraft are descrbed n the Fgure1. Top layer of the M-BOM s the work staton and poston staton dvded from the arcraft s general assembly process, the mddle layer ncludes the assembly outlne and ts process assembly parts, engneerng assembly parts and the subassembly parts provded by the supplers. The scattered parts provded by the supples n the workpece package are also lsted n the M-BOM. The bottom layer ncludes the components and the parts. (3) Suppler product standard BOM (SPSBOM) SPSBOM s set up by the arframer whch s the product BOM requrement collecton of the subassembles provded by the supplers. It has man three layers, the top layer s the product type and the supplers, the mddle layer s the product packages by the supplers, and the bottom layer ncludes the component parts and scattered parts. (4)Suppler BOM (SBOM) SBOM s defned as the subassembles BOM structure whch wll be fnally delvered by the supplers. It records the product data nformaton durng the manufacturng perod n the supplers plants and the nformaton n t should be accordant wth real physcal subassembly product. It s provded by the supples and accompany wth the product delvery. The M-BOM s the man arframer s basc BOM whch s transformed from EBOM. SPSBOM s establshed by the man arframer accordng to the EBOM and M-BOM as the product delvery standards of supplers subassembles. And SBOM s the materal nformaton of the eventual physcal subassembly product. Therefore the relatons between BOMs mentoned above are complcated whch s showed n the Fgure BOM Reconstructon Operaton and Dfference Analyss In the product desgn process, the engneerng BOM s formed accordng to the functon and subject. The top-down methodology s usually adopted to set up the product engneerng BOM and fnsh the detal desgn. But on the contrary, the manufacturng BOM s formed accordng to the 121

3 Fgure.1 EBOM, M-BOM, SPSBOM And SBOM Of Arcraft manufacturng and assembly process. The Convenence of manufacturng and assemble s consdered as the paramount factor durng the constructon of the manufacturng BOM. So the structure of engneerng BOM and manufacturng BOM are defntely dfferent. But these dfferences does not mean the data nconformty errors. In the followng, the changes of product structure durng the BOM transton and reconstructon are llustrated and dvded nto several forms. (1) Eengneerng parts transform to the process parts by the postonal shft of sub-part For the convenence of fabrcaton and assembly, Part G s moved to the Part I and J together to form a new process components durng the BOM transton as showed n fgure 2 Case 1. Part G n ths case s moved from one branch to another branch, and ther parent components form new process components. (2) Engneerng component dsappear by the postonal shft of ts sub-parts In fgure 2 case 2, parts n a branch of the engneerng BOM are replaced n other branches for the assembly durng the transton wth the form of a new process components, and the orgnal parent 122

4 engneerng components wll no longer appear n the manufacturng BOM. (3) Scattered engneerng parts collected together to form new process components In fgure 2 case 3, scattered engneerng parts n a branch of the engneerng BOM, are collected together to form a new process components n the manufacturng BOM, and the engneerng parent node also convert nto process components. Fgure 2. The Deformaton Of The BOM Structure In Transton Process (Case 1) Fgure 2. The Deformaton Of The BOM Structure In Transton Process (Case 2) 123

5 Fgure 2. The Deformaton Of The BOM Structure In Transton Process (Case 3) (4) Numerous engneerng parts splt n the manufacturng BOM Prevously descrbed are all about the result of the structure changes durng the movement and the re-combnaton of the part objects. The followng wll take nto account the splttng of the number of parts. In the fgure 2 Case4 of Fgure 1, Part H has 10 quanttes n the branch D. In the transton for the requrements of assembly, fve Part H are kept n the orgnal D branch, the other fve Part H are moved nto the branch E next to D. The number of H s splt n ths process, whle the formaton of the new process components D 'and E '. And the more complex one s showed n the Case5 of Fgure 2. In ths case, the Part H appears a pluralty of postons n the engneerng BOM. Durng the transton and reconstructon process, Part H s assgned to dfferent process component branches. And n such crcumstances t s dffcult to determne the one-toone relatonshp of Part H n manufacturng BOM and engneerng BOM. (5) The merge of the part quantty to form a new process components In the Fgure2's Case 6, Part H whch has numerous quanttes appear at multple locaton, and they are collected together n the manufacturng BOM to form a new parent process component. Fgure 2. The Deformaton Of The BOM Structure In Transton Process (Case 4) 124

6 Fgure 2. The Deformaton Of The BOM Structure In Transton Process (Case 5) 3.3 Inconformty Analyss Fgure 2. The Deformaton Of The BOM Structure In Transton Process (Case 6) The structure of engneerng BOM s generally organzed accordng to the product functon, however manufacturng BOM s formed consderng manufacturng process, manufacturablty and assemblablty. The changes made durng the reconstructon from engneerng BOM to manufacturng BOM have been llustrated n above. These dfferences caused by the parts actvtes of movement, quantty splt and merge are normal nconsstency whch are manly due to separaton of desgn and manufacture. And the data nconformty n the product data management, whch s erroneous nconsstency such as the structure dfference, nconsstent of part quantty and verson and should be found by the data nspecton n the arcraft confguraton management, s caused by the man-made or systemmade nconsstency of product nformaton durng 125 the BOM transton or engneerng change propagaton. Therefore, the nconformty nspecton method must completely dentfy the erroneous nconsstency and normal nconsstency, and take the erroneous nconsstency as the fnal result. On the base of data structure and dfferences analyss, n the followng a relaton based conformty nspecton method s proposed accordng to the practcal requrements. 4. PRODUCT STRUCTURE RELATION BASED CONFORMITY INSPECTION METHOD 4.1 Algorthm Product BOM structure s a complex tree. The smallest unts whch are the tree composed of are branches. Therefore, the tree structure comparson can base on the smallest branch. For EBOM structure, the smallest branch unt ncludes the

7 parent node, chld node and the correspondng relaton (lnk relaton) of them. The dfference between engneerng BOM and manufacturng BOM would be found through the comparson of lnk relaton n engneerng BOM to the attrbute relaton n manufacturng BOM, showed n Fgure 3. Fgure 3. Schematc Of Product Structure Relaton Based Method (1) The scope of conformaton nspecton For the cvl arcraft whch adopts the arframersupplers busness model, ts product data conformty nspecton has two levels, as showed n Fgure 4. The frst level s the comparson of the engneerng BOM wth the whole arcraft manufacturng BOM, whch means the consstency nspecton of EBOM versus the collecton of M- BOM and SPSBOM n ths paper, at the same tme t should be ensured about the data consstency of scattered parts n M-BOM and SPSBOM. The second level s to ensure the consstency of the SPSBOM and SBOM to keep the conformty of suppler subassembly requrement and fnal delvered physcal product. The conformty on the product confguraton management must make sure the BOM data consstency of the two levels mentoned above. Although the scope of comparson and the form of the product data structure dfferent n the two levels are dfferent, but the core data comparson method s the same, and the specfc algorthm wll be descrbed n detal below. (2) The mathematcal expresson of the algorthm The man dea of the product structure relaton based conformty nspecton algorthm takes the branch, chld part and ts parent engneerng assembly, as the dentfer to search the correspondng attrbute relaton n the manufacturng BOM and compare the nformaton on the part quanttes and verson. The mathematcal defnton of entre algorthm s n the followng. 1) Defnton of BOM data Frst the BOM data should be defned. The manufacturng BOM are smlar to the engneerng BOM n the data structure, so are the defnton. e : A node of the engneerng BOM, n practce t s a part or a component wth the part number e. name, verson number e. verson, quanttes wth herarchy e. quantty, and ts engneerng parent node e. efather. Fgure 4. Scope Of The Conformty Inspecton m : A node of the engneerng BOM, n practce t s a part or a component wth the part number m. name, verson number m. verson, quanttes wth herarchy m. quantty, and ts engneerng parent node m. efather. E: the data set of engneerng BOM can be defned as E = { e1, e2, e3 e } (1) M: the data set of manufacturng BOM can be defned as 126

8 M { m, m, m m } (2) = ) Merge records by dentfer and draw the compare result Before the conformty nspecton, the data of engneerng and manufacturng BOM should be merged accordng to the dentfer chld node and parent node separately. Take engneerng BOM data for example: eid. dentfer = { e. name, e. efather } (3). = n eid quantty e. quantty (4) = 1 eid. = n verson e. = 1 verson (5) where eid. quantty s the total quanttes of parts n engneerng BOM whch have the same dentfer, eid. verson s the collecton of the parts verson whch have the same dentfer, n s appearng tmes of e. name n the engneerng BOM, and after t draw the new record set E ' and the respectvely record eid. The same merge operaton accordng to mid. dentfer s done to the data set of manufacturng BOM, draw the correspondng ' record set M, and the respectvely record mid. The product data dfference set D s the symmetrc dfference between E ' ' and M. ' ' D = E M (6) between eid. dentfer, eid. verson, eid. quantty and mid dentfer, mid. verson, mid. quantty wth. operaton of symmetrc dfference Stage3: dfference type judgment and the workflow ends. 5. APPLICATION SYSTEM AND ITS VERIFICATION Based on the above analyss and algorthm, we have developed an applcaton software for the cvl arcraft conformty nspecton on product confguraton management. The system and the algorthm s developed by the Java language and database Oracle. The followng dagrams of fgure 6, 7, 8 are the demonstraton about the database table structure and software page. 4.2 Workflow of Inspecton Method The nspecton algorthm ncludes forward and reverse comparson between product engneerng data and manufacturng data. The workflow of the nspecton method s descrbed n the followng, and t can be dvded nto three stages (as shown n Fgure 5): Stage 1: data mport and pre-processng. Import the engneerng BOM and manufacturng BOM data, pre-process these data ncludng calculatng the part quanttes accordng to the herarchy, mergng the data records wth dentfer, unfyng the part verson, judgng the part type and flterng process parts by the rule. Then store all the processed data nto the database. Stage2: dfferences computaton. Draw the ' dfferences result set D accordng to the comparson respectvely Fgure 6. Database Table Structure Of Cvl Arcraft Conformty Inspecton System 127

9 Fgure 7. Homepage Of Cvl Arcraft Conformty Inspecton System The research method of ths paper was appled by the Shangha Arcraft Manufacturng Co.Ltd. n ts product confguraton management for arcraft ARJ The followng n fgure 8 demonstrates the developed conformty nspecton system and applcaton results. Fgure 8. Applcaton Of The Conformty Inspecton System 6. CONCLUSION Cvl arcraft as a specal product, has tremendous amount of data and complex product 128 data evoluton process, and t also has hgh product securty requrements. Durng the development of the arcraft, the manufacturer has to make the conformty nspecton between desgn and manufacturng for the product data management requrements to obtan the arworthness certfcaton. On the background of ARJ s development, ths paper analyss the product data structure dfferences n mult-bom and ts causes. Then the data structure relaton based nspecton method s proposed, and the algorthm of the method s defned wth set theory. The workflow of the method s descrbed n detal. Fnally the system tool s developed and appled n the ARJ s product management. The applcaton result shows that the method and ts tool can effectvely help the enterprse to fnd the nconsstency of the product data, and provdes the support to the cvl arcraft conformty nspecton. In ths paper the algorthm s not very perfect for recognzng the normal nconsstency, the ntellgent algorthm based on the rules and knowledge wll be n mportant aspect of study. ACKNOWLEDGMENTS: Ths research s supported by the Shangha Key lab of Advanced Manufacturng Envronment, and the Scence and Technology Commsson of Shangha Muncpalty under grant 10dz and 11dz

10 Fgure 5. The Workflow Of The Product Structure Relaton Based Inspecton Method 129

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