Forum for Science, Industry and Business

Sponsored by:     3M 
Search our Site:

 

Automatic Completeness Check: Optical Measurement Technologies Detect the Smallest of Errors

05.05.2014

Thousands of parts, bolts and rivets are mounted on everything from aircraft fuselage shells to turbines. Until now, workers have inspected the correctness of an assembly manually – a tedious job during which errors can be overseen easily. Researchers at the Fraunhofer IFF have developed an automatic inspection system that will take over this job in the future. They will be presenting it at the 2014 Automatica in Munich.

Airliners like the Airbus A380 are custom made and thus hardly different from other capital goods like custom machines or plants. Each airline attaches importance to custom interiors and has its planes modified for its specific needs.


An inspection robot checking the completeness of an aircraft fuselage shell.

Fraunhofer IFF

While one airline wants as many rows of seats as possible accommodated, another places emphasis on comfort and allows passengers somewhat more legroom. The situation is similar for monitors, luggage compartments and ventilation systems for instance. All of these requests entail custom manufacturing with thousands of small parts that always have to be positioned and mounted anew.

This makes assembly and subsequent quality assurance very difficult. Workers get the specifications from paper documents and compare each part with them manually. The number of parts inspected for an aircraft like the A380 is huge. Up to 40,000 rivets hold each of the twenty aircraft fuselage shells together. The correctness of each of the up to 2,500 attached parts has to be checked. Error detection is time-consuming and subsequent correction is sometimes extremely expensive.

Robot Compares Components with CAD Data

In the future, workers will receive support when they are checking for errors. An automatic inspection system reliably detects errors during assembly. Researchers at the Fraunhofer IFF were contracted to develop it by Premium AEROTEC GmbH, a developer and manufacturer of structures and production systems for aircraft. The technology has been field tested in pilot systems that independently inspect every mounted part and joint on aircraft fuselage shells.

The system consists of a robotic arm with a specially developed sensor head attached. Equipped with image sensors and 3D sensors, the head automatically scans every relevant inspected feature - between 1000 and 5000 - on fuselage shells. From any position, it generates absolutely reliable, high resolution measured data on the state of assembly of the real mounted parts.

The system extracts the data it needs from the 3D CAD data on the fuselage shells. These specify the desired result and also contain all of the coordinates of the inspection points. At the same time, the system uses these data to generate virtual measured data of the inspected features - in the form of synthetic images and 3D point clouds. Every joint and every single mounted part is represented exactly in them.

During an inspection, the system overlays the real measured data with the virtual specifications, factoring in image area and camera angle automatically. When both sets of measured data match, i.e. the mapped parts have been mounted correctly, the system marks the parts virtually with green for correct. If it detects discrepancies, they are marked in red. Uncertainties are marked in yellow. Workers can view different evaluations in an inspection report, used interactively much like an app. The system delivers not only photographs to users but also coordinates of components so that inspected parts can be easily located again.

Faster and More Reliable Than Manual Inspection

The digital inspection system is not only more reliable but also significantly faster than manual inspection: The pictures are taken in approximately five seconds; evaluations for each position are performed in another five. Instead of eight to twelve hours, it only takes about three hours to inspect the fit of every part. The system also inspects all sorts of sizes, effortlessly analyzing volumes of up to 11 m x 7 m x 3 m very precisely and with high resolution.

It not only detects errors but also helps eliminate them in the long term. Errors have been proven to occur in some places with greater frequency. Where and why, though? To find out, the detected errors are fed into a database that analyzes whether they simply occur once or recur. This information can then be forwarded to assembly technicians with appropriate instructions.

Fraunhofer researchers will be presenting the systems technology at Automatica in Munich from June 3 to 6, 2014.

Weitere Informationen:

http://www.iff.fraunhofer.de/en/press/press-releases/2014/automatic-completeness...
http://www.iff.fraunhofer.de/en/business-units/measurement-testing-technology/op...

René Maresch | Fraunhofer-Institut
Further information:
http://www.iff.fraunhofer.de/en

Further reports about: Airbus Automatic CAD CAD data Error IFF Optical clouds compartments documents errors planes structures synthetic

More articles from Trade Fair News:

nachricht COMPAMED 2016 connected medical devices and people
23.11.2016 | IVAM Fachverband für Mikrotechnik

nachricht Successfully transferring Industrie 4.0 into reality
21.11.2016 | Deutsches Forschungszentrum für Künstliche Intelligenz GmbH, DFKI

All articles from Trade Fair News >>>

The most recent press releases about innovation >>>

Die letzten 5 Focus-News des innovations-reports im Überblick:

Im Focus: Novel silicon etching technique crafts 3-D gradient refractive index micro-optics

A multi-institutional research collaboration has created a novel approach for fabricating three-dimensional micro-optics through the shape-defined formation of porous silicon (PSi), with broad impacts in integrated optoelectronics, imaging, and photovoltaics.

Working with colleagues at Stanford and The Dow Chemical Company, researchers at the University of Illinois at Urbana-Champaign fabricated 3-D birefringent...

Im Focus: Quantum Particles Form Droplets

In experiments with magnetic atoms conducted at extremely low temperatures, scientists have demonstrated a unique phase of matter: The atoms form a new type of quantum liquid or quantum droplet state. These so called quantum droplets may preserve their form in absence of external confinement because of quantum effects. The joint team of experimental physicists from Innsbruck and theoretical physicists from Hannover report on their findings in the journal Physical Review X.

“Our Quantum droplets are in the gas phase but they still drop like a rock,” explains experimental physicist Francesca Ferlaino when talking about the...

Im Focus: MADMAX: Max Planck Institute for Physics takes up axion research

The Max Planck Institute for Physics (MPP) is opening up a new research field. A workshop from November 21 - 22, 2016 will mark the start of activities for an innovative axion experiment. Axions are still only purely hypothetical particles. Their detection could solve two fundamental problems in particle physics: What dark matter consists of and why it has not yet been possible to directly observe a CP violation for the strong interaction.

The “MADMAX” project is the MPP’s commitment to axion research. Axions are so far only a theoretical prediction and are difficult to detect: on the one hand,...

Im Focus: Molecules change shape when wet

Broadband rotational spectroscopy unravels structural reshaping of isolated molecules in the gas phase to accommodate water

In two recent publications in the Journal of Chemical Physics and in the Journal of Physical Chemistry Letters, researchers around Melanie Schnell from the Max...

Im Focus: Fraunhofer ISE Develops Highly Compact, High Frequency DC/DC Converter for Aviation

The efficiency of power electronic systems is not solely dependent on electrical efficiency but also on weight, for example, in mobile systems. When the weight of relevant components and devices in airplanes, for instance, is reduced, fuel savings can be achieved and correspondingly greenhouse gas emissions decreased. New materials and components based on gallium nitride (GaN) can help to reduce weight and increase the efficiency. With these new materials, power electronic switches can be operated at higher switching frequency, resulting in higher power density and lower material costs.

Researchers at the Fraunhofer Institute for Solar Energy Systems ISE together with partners have investigated how these materials can be used to make power...

All Focus news of the innovation-report >>>

Anzeige

Anzeige

Event News

ICTM Conference 2017: Production technology for turbomachine manufacturing of the future

16.11.2016 | Event News

Innovation Day Laser Technology – Laser Additive Manufacturing

01.11.2016 | Event News

#IC2S2: When Social Science meets Computer Science - GESIS will host the IC2S2 conference 2017

14.10.2016 | Event News

 
Latest News

UTSA study describes new minimally invasive device to treat cancer and other illnesses

02.12.2016 | Medical Engineering

Plasma-zapping process could yield trans fat-free soybean oil product

02.12.2016 | Agricultural and Forestry Science

What do Netflix, Google and planetary systems have in common?

02.12.2016 | Physics and Astronomy

VideoLinks
B2B-VideoLinks
More VideoLinks >>>