Portable Large Shape Inspection System Project Presentation

NCMS/CTMA ConferenceApril 19, 2005

Overview

• WR-ALC Introduction• Reconfigurable Press• Fabrication Tools• Urgent Need / Solution• Project Team• Project Tasks• Wrap-up

Presenter: Clayton HoltWR-ALC Project Manager

WR-ALC Introduction

Warner Robins Air Logistics Center.

Worldwide management and engineering responsibility for repair, modification, and overhaul of:

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

Reconfigurable Press

Film Clip

Stretch Forming Process

Film Clip

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

Urgent Need

• WR-ALC needs a very high performance surface scanner:

– To support re-configurable press operations

– To certify its 700 fabrication tools annually

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

AFI Animation

Film Clip

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

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

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

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

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

Wrap-up

• Questions?

Clayton Holt, WR-ALCclay.holt@robins.af.mil(478) 222-4721

Scott Ackerson, DPIscott.ackerson@dphotonics.com484.888.2379