portable large shape inspection system project presentation ncms/ctma conference april 19, 2005
TRANSCRIPT
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Portable Large Shape Inspection System Project Presentation
NCMS/CTMA ConferenceApril 19, 2005
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Overview
• WR-ALC Introduction• Reconfigurable Press• Fabrication Tools• Urgent Need / Solution• Project Team• Project Tasks• Wrap-up
Presenter: Clayton HoltWR-ALC Project Manager
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WR-ALC Introduction
Warner Robins Air Logistics Center.
Worldwide management and engineering responsibility for repair, modification, and overhaul of:
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WR-ALC Operations• 14000+ people…20+ percent are contractors
– Engineers, Contracting, Logistics, Acquisition, Support
• Product support for almost 3400 aircraft– U-2, F-15, C-130, JSTARS, C-5, C-141, C-17,
SOF/CSAR, CH-53
• Large F-15 and C-130 international programs– RSAF, Japan, Israel, Poland, Romania, many
more
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Reconfigurable Press
Film Clip
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Stretch Forming Process
Film Clip
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700 Fabrication Tools• WR-ALC recently became ISO-9000 certified• 700 fabrication tools like those shown here
must now be re-certified annually …
Stretch Form Die
Metal Bonding Tool
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Urgent Need
• WR-ALC needs a very high performance surface scanner:
– To support re-configurable press operations
– To certify its 700 fabrication tools annually
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Search for Solution
• AFI-based scanners• Prototype tested
extensively by WR-ALC in 2003 and met key specifications.
• Had two key limitations:– Was not portable– Needed special dark
room
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AFI Animation
Film Clip
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Accordion Fringe Interferometry
• Invented at MIT around 2000.• Based on two very simple principles:
– Interference of light passing through two pin holes to
generate a bright, accurate fringe pattern– Triangulation with digital camera
Fiber or laser diode
Collimatinglens
Grating
Objectivelens
Pin Holes
Interference fringes
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What’s the “big deal”?
• Dense point clouds Non-contact, dense point clouds are the universal way to make 3D measurements.
• High performance/cost AFI lends itself to production of high performance, simple, low cost systems.
A “disruptive” technology?
Accordion Fringe Interferometry
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Project Team
• End user: WR-ALC• Program manager: Bill Waddell, NCMS/CTMA• Industrial partners and other participants:
– US Navy (Naval Foundry and Propeller Center)– Dimensional Photonics International (DPI)– Manufacturing Resources, Inc. (MRI)– GFM/AGFM Corporation
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Key Project Tasks
• Task 1: Develop Detailed Requirements
• Task 2: Engage Software Vendor
• Task 3: Develop AFI 5000 Subsystem
• Task 4: Develop AFI 5000P System
• Task 5: Develop Press Support Frame
• Task 6: Deliver and Test the AFI 5000P
• Task 7: Application Demonstrations
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Key Developments
• Sensors: Laser projector + digital camera– reduce size, increase stability & accuracy
New AFI 5000 projector
Prototype projector
• Software components– Basic software development
kit (SDK) development– Application software
• Crossbar– Needed for portability– Bar shown is > 100 X
better
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Wrap-up
• Questions?
Clayton Holt, [email protected](478) 222-4721
Scott Ackerson, [email protected]