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Portable Large Shape Inspection System Project Presentation NCMS/CTMA Conference April 19, 2005

Portable Large Shape Inspection System Project Presentation NCMS/CTMA Conference April 19, 2005. Overview. WR-ALC Introduction Reconfigurable Press Fabrication Tools Urgent Need / Solution Project Team Project Tasks Wrap-up. Presenter: Clayton Holt WR-ALC Project Manager.

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Portable Large Shape Inspection System Project Presentation NCMS/CTMA Conference April 19, 2005

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  1. Portable Large Shape Inspection System Project PresentationNCMS/CTMA ConferenceApril 19, 2005

  2. Overview • WR-ALC Introduction • Reconfigurable Press • Fabrication Tools • Urgent Need / Solution • Project Team • Project Tasks • Wrap-up Presenter: Clayton Holt WR-ALC Project Manager

  3. WR-ALC Introduction Warner Robins Air Logistics Center. Worldwide management and engineering responsibility for repair, modification, and overhaul of:

  4. 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

  5. Reconfigurable Press Film Clip

  6. Stretch Forming Process Film Clip

  7. 700 Fabrication Tools • WR-ALC recently became ISO-9000 certified • 700 fabrication tools like those shown here must now be re-certified annually … Metal Bonding Tool Stretch Form Die

  8. Urgent Need • WR-ALC needs a very high performance surface scanner: • To support re-configurable press operations • To certify its 700 fabrication tools annually

  9. 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

  10. AFI Animation Film Clip

  11. Interference fringes Objective lens Collimating lens Fiber or laser diode Grating Pin Holes 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

  12. Accordion Fringe Interferometry • 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?

  13. 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

  14. 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

  15. Key Developments • Sensors: Laser projector + digital camera • reduce size, increase stability & accuracy • Software components • Basic software development kit (SDK) development • Application software Prototype projector New AFI 5000 projector • Crossbar • Needed for portability • Bar shown is > 100 X better

  16. Wrap-up • Questions? Clayton Holt, WR-ALC clay.holt@robins.af.mil (478) 222-4721 Scott Ackerson, DPI scott.ackerson@dphotonics.com 484.888.2379

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