Robotic geometric and volumetric inspection of high value and large scale aircraft wings

Carmelo Mineo, Charles Norman MacLeod, Riliang Su, David Lines, Santi Davi', Bruce Cowan, Stephen Pierce, Scott Paton, Gavin Munro, Coreen McCubbin, David Watson, William Kerr

Research output: Contribution to conferencePaper

Abstract

Increased demands in performance and production rates require a radical new approach to the design and manufacturing of aircraft wings. Performance of modern robotic manipulators has enabled research and development of fast automated non-destructive testing (NDT) systems for complex geometries. This paper presents recent outcomes of work aimed at removing the bottleneck due to data acquisition rates, to fully exploit the scanning speed of modern 6-DoF manipulators. The geometric assessment of the parts is carried out with a robotised dynamic laser scanner encoded through an absolute laser tracker. This method allows scanning speeds up to 330mm/s at 1mm pitch. State of the art ultrasonic instrumentation has been integrated into a large robot cell to enable fast data acquisition, high scan resolutions and accurate positional encoding. A fibre optic connection between the ultrasonic instrument and the server computer enables data transfer rates up to 1.6 GB/s. The robotic inspection system presented herein is currently being tested for industrial exploitation. The adopted system integration strategies allow traditional ultrasonic phased array scanning as well as full matrix capture (FMC) and other novel scanning approaches (e.g. multi-Tx phased array). Scan results, relative to a 1.2m x 3m carbon fibre sample, are presented. The system shows a reference scanning rate of 25.3m2/hour with an 8Tx/8Rx PA approach and an ultrasonically reachable scanning rate over 100m2/hour with the novel techniques.
LanguageEnglish
Number of pages5
Publication statusPublished - 20 Jun 2019
Event2019 IEEE International Workshop on Metrology for AeroSpace - Turin, Italy
Duration: 19 Jun 201921 Jun 2019

Conference

Conference2019 IEEE International Workshop on Metrology for AeroSpace
CountryItaly
CityTurin
Period19/06/1921/06/19

Fingerprint

Robotics
Inspection
Scanning
Ultrasonics
Manipulators
Data acquisition
Data transfer rates
Lasers
Optical resolving power
Nondestructive examination
Fiber optics
Carbon fibers
Servers
Robots
Geometry

Keywords

  • robotic NDT
  • phased array
  • laser scanning
  • CFRP

Cite this

Mineo, C., MacLeod, C. N., Su, R., Lines, D., Davi', S., Cowan, B., ... Kerr, W. (2019). Robotic geometric and volumetric inspection of high value and large scale aircraft wings. Paper presented at 2019 IEEE International Workshop on Metrology for AeroSpace, Turin, Italy.
Mineo, Carmelo ; MacLeod, Charles Norman ; Su, Riliang ; Lines, David ; Davi', Santi ; Cowan, Bruce ; Pierce, Stephen ; Paton, Scott ; Munro, Gavin ; McCubbin, Coreen ; Watson, David ; Kerr, William. / Robotic geometric and volumetric inspection of high value and large scale aircraft wings. Paper presented at 2019 IEEE International Workshop on Metrology for AeroSpace, Turin, Italy.5 p.
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title = "Robotic geometric and volumetric inspection of high value and large scale aircraft wings",
abstract = "Increased demands in performance and production rates require a radical new approach to the design and manufacturing of aircraft wings. Performance of modern robotic manipulators has enabled research and development of fast automated non-destructive testing (NDT) systems for complex geometries. This paper presents recent outcomes of work aimed at removing the bottleneck due to data acquisition rates, to fully exploit the scanning speed of modern 6-DoF manipulators. The geometric assessment of the parts is carried out with a robotised dynamic laser scanner encoded through an absolute laser tracker. This method allows scanning speeds up to 330mm/s at 1mm pitch. State of the art ultrasonic instrumentation has been integrated into a large robot cell to enable fast data acquisition, high scan resolutions and accurate positional encoding. A fibre optic connection between the ultrasonic instrument and the server computer enables data transfer rates up to 1.6 GB/s. The robotic inspection system presented herein is currently being tested for industrial exploitation. The adopted system integration strategies allow traditional ultrasonic phased array scanning as well as full matrix capture (FMC) and other novel scanning approaches (e.g. multi-Tx phased array). Scan results, relative to a 1.2m x 3m carbon fibre sample, are presented. The system shows a reference scanning rate of 25.3m2/hour with an 8Tx/8Rx PA approach and an ultrasonically reachable scanning rate over 100m2/hour with the novel techniques.",
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author = "Carmelo Mineo and MacLeod, {Charles Norman} and Riliang Su and David Lines and Santi Davi' and Bruce Cowan and Stephen Pierce and Scott Paton and Gavin Munro and Coreen McCubbin and David Watson and William Kerr",
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Mineo, C, MacLeod, CN, Su, R, Lines, D, Davi', S, Cowan, B, Pierce, S, Paton, S, Munro, G, McCubbin, C, Watson, D & Kerr, W 2019, 'Robotic geometric and volumetric inspection of high value and large scale aircraft wings' Paper presented at 2019 IEEE International Workshop on Metrology for AeroSpace, Turin, Italy, 19/06/19 - 21/06/19, .

Robotic geometric and volumetric inspection of high value and large scale aircraft wings. / Mineo, Carmelo; MacLeod, Charles Norman; Su, Riliang; Lines, David; Davi', Santi; Cowan, Bruce; Pierce, Stephen; Paton, Scott; Munro, Gavin; McCubbin, Coreen; Watson, David; Kerr, William.

2019. Paper presented at 2019 IEEE International Workshop on Metrology for AeroSpace, Turin, Italy.

Research output: Contribution to conferencePaper

TY - CONF

T1 - Robotic geometric and volumetric inspection of high value and large scale aircraft wings

AU - Mineo, Carmelo

AU - MacLeod, Charles Norman

AU - Su, Riliang

AU - Lines, David

AU - Davi', Santi

AU - Cowan, Bruce

AU - Pierce, Stephen

AU - Paton, Scott

AU - Munro, Gavin

AU - McCubbin, Coreen

AU - Watson, David

AU - Kerr, William

N1 - © 2019 IEEE. Personal use of this material is permitted. Permission from IEEE must be obtained for all other uses, in any current or future media, including reprinting/republishing this material for advertising or promotional purposes, creating new collective works, for resale or redistribution to servers or lists, or reuse of any copyrighted component of this work in other works.

PY - 2019/6/20

Y1 - 2019/6/20

N2 - Increased demands in performance and production rates require a radical new approach to the design and manufacturing of aircraft wings. Performance of modern robotic manipulators has enabled research and development of fast automated non-destructive testing (NDT) systems for complex geometries. This paper presents recent outcomes of work aimed at removing the bottleneck due to data acquisition rates, to fully exploit the scanning speed of modern 6-DoF manipulators. The geometric assessment of the parts is carried out with a robotised dynamic laser scanner encoded through an absolute laser tracker. This method allows scanning speeds up to 330mm/s at 1mm pitch. State of the art ultrasonic instrumentation has been integrated into a large robot cell to enable fast data acquisition, high scan resolutions and accurate positional encoding. A fibre optic connection between the ultrasonic instrument and the server computer enables data transfer rates up to 1.6 GB/s. The robotic inspection system presented herein is currently being tested for industrial exploitation. The adopted system integration strategies allow traditional ultrasonic phased array scanning as well as full matrix capture (FMC) and other novel scanning approaches (e.g. multi-Tx phased array). Scan results, relative to a 1.2m x 3m carbon fibre sample, are presented. The system shows a reference scanning rate of 25.3m2/hour with an 8Tx/8Rx PA approach and an ultrasonically reachable scanning rate over 100m2/hour with the novel techniques.

AB - Increased demands in performance and production rates require a radical new approach to the design and manufacturing of aircraft wings. Performance of modern robotic manipulators has enabled research and development of fast automated non-destructive testing (NDT) systems for complex geometries. This paper presents recent outcomes of work aimed at removing the bottleneck due to data acquisition rates, to fully exploit the scanning speed of modern 6-DoF manipulators. The geometric assessment of the parts is carried out with a robotised dynamic laser scanner encoded through an absolute laser tracker. This method allows scanning speeds up to 330mm/s at 1mm pitch. State of the art ultrasonic instrumentation has been integrated into a large robot cell to enable fast data acquisition, high scan resolutions and accurate positional encoding. A fibre optic connection between the ultrasonic instrument and the server computer enables data transfer rates up to 1.6 GB/s. The robotic inspection system presented herein is currently being tested for industrial exploitation. The adopted system integration strategies allow traditional ultrasonic phased array scanning as well as full matrix capture (FMC) and other novel scanning approaches (e.g. multi-Tx phased array). Scan results, relative to a 1.2m x 3m carbon fibre sample, are presented. The system shows a reference scanning rate of 25.3m2/hour with an 8Tx/8Rx PA approach and an ultrasonically reachable scanning rate over 100m2/hour with the novel techniques.

KW - robotic NDT

KW - phased array

KW - laser scanning

KW - CFRP

UR - http://www.metroaerospace.org/

M3 - Paper

ER -

Mineo C, MacLeod CN, Su R, Lines D, Davi' S, Cowan B et al. Robotic geometric and volumetric inspection of high value and large scale aircraft wings. 2019. Paper presented at 2019 IEEE International Workshop on Metrology for AeroSpace, Turin, Italy.