Technical Papers & Journals

An Efficient Procedure for Reverse Engineering Parts and Assemblies in Vehicle Packaging to Improve Surface Reconstruction Accuracy

Ahmad Barari, Dylan Bender

The Automotive Parts Manufacturers’ Association of Canada launched the first, original, full-build zero-emission concept vehicle named Project Arrow. As an all-Canadian effort, Arrow has been designed, engineered and built by Canadian researchers and manufacturers. This project brought together the best of the best of Canada’s vehicle design, electric-drive, alternative-fuel, connected and autonomous and light-weight technology engineers and Canadian companies to work with university researchers. Ontario Tech partnered in Project Arrow as the lead academic institution to complete the engineering design and the fabrication phase of this national project. Packaging is traditionally the most complex task in vehicle structural design, responsible to accommodate for all the parts and components integrated in the vehicle in minimum space and optimum level of mass distribution, while the interactions between the parts and assemblies are accurately maintained. 

On-machine scanning with contact and non-contact sensors and how it can improve machining with closed loop metrology feedback

Chris Affer, Ray Karadayi

 On-machine probing have been used in most cases with a tactile sensor for simple part setup and reporting. In modern machining operations, gathering fast and precise data has emerged as an important part of producing complex precision products at less cost. The integration of contact and non-contact scanning sensor technologies became a promising avenue for enhancing precision and efficiency. This paper investigates the potential of “on-machine tool scanning” techniques utilizing both contact and non-contact sensors to create metrology data. Furthermore, the implementation of closed-loop metrology feedback enables real-time adjustments, ensuring tighter tolerances and minimizing errors during production hence improving machining process. This presentation explores the principles, capabilities, and practical implications of integrating contact and non-contact sensors into machining operations. Through a thorough examination of case studies, the benefits of this approach in terms of accuracy, speed, and reliability are demonstrated. The findings underscore the transformative potential of on-machine scanning with integrated sensor technologies in advancing the precision and quality of machining processes, paving the way for more efficient and competitive manufacturing practices. 

The Hole Story of the F-35

Matt Maakestad

On the F35 program there are roughly 40,000 fastener holes per aircraft, and on an airframe that pushes the limits of defense aircraft manufacturing presents unique inspection challenges. The Lockheed Martin Operations Technology Metrology team in collaboration with Government Partners have approached these challenges over the years through the development of new technology and methods that enable 3D scanning for difficult bore hole inspections and critical low observable coatings measurement.

HIGH PRECISION METROLOGY IN POWER GENERATION: PHOTOGRAMMETRIC ANALYSIS OF TURBINES AND COMPONENTS

Giuseppe Ganci

 This paper investigates the utilization of photogrammetry for the measurement of two distinct power generation components, situated in New Zealand and the Philippines. Both measurements employed the V-STARS Nikon-based system. 
The application of this technology involved a collaborative effort between a photogrammetric specialist and a turbine plant engineering expert. The outcomes of both studies identified design and construction weaknesses, instigating substantial changes in plant engineering and maintenance strategies, leading to significant improvements in plant availability and reliability. 
The New Zealand project is noteworthy for its comprehensive measurement coverage, encompassing not only the main turbine structure but also the condenser, hotwell pumps, and other crucial structural components of the power generation unit. Spanning approximately 25 x 25 x 25m across four different levels, unified coordinate measurements were repeated under various operational conditions to quantify the changes the entire unit underwent.

Tracking the Tokamak The Holy Grail of Renewable Energy

Jonathan McLaughlin

Bridging the Gap: Addressing Uncertainties in Computer-Aided Metrology and Traditional Metrology

Victoria Knox

Metrology, the science of measurement, plays a crucial role in various industries, ensuring product quality, process control, and compliance with standards. Over the years, traditional metrology techniques have been widely used for measurement and inspection purposes. However, the advent of computer-aided metrology has revolutionized the field, offering numerous advantages over traditional methods. However, uncertainties associated with Computer-Aided Metrology (CAM) measurements continue to pose challenges in achieving accurate and reliable results. This publication aims to bridge the gap between CAM and traditional metrology by addressing uncertainties and proposing strategies to mitigate them.

Photogrammetric calibration of off-the-shelf low-cost cameras – hints, tips and tricks

Stuart Robson

Photogrammetry using off the shelf low-cost camera systems is being applied to a wide variety of industrial activities where the emphasis is on determining the position, pose and potentially deformation of multiple objects within the field of view of the combined cameras over increasingly large volumes at sub-mm levels of uncertainty. Understanding and calibrating the internal imaging geometry of these camera systems to correct for systematic errors whilst maintaining the freedom to deploy different sensors and lenses with varying angles of view and image magnifications is a key enabler to meeting industrial requirements. This presentation will focus on getting the most from established bundle-adjustment based camera calibration methods. Such methods form a routine part of our low-cost multiple camera photogrammetric system deployment on tasks concerned with tracking robots, tools and objects under both laboratory and industrial situations.

Efficient Dry-Run Commissioning of Robots with Large-Volume Metrology

Alexander Schönberg

 Modern manufacturing trends increase flexibility, increase frequency, and reduce the time to commissioning. Highly flexible virtual planning forms the basis for real production processes that must deal with machine, part, and process deviations. From FFT's point of view as a system integrator, there will be economic benefits if measurement technology is used not only for end-of-line control but also for other tasks in plant engineering via dual use or only temporarily during ramp-up. With the Nikon Metrology MV331-HS and the FFT-VisionVIEW software solution developed in-house, FFT equips body-in-white and battery cell lines with traceable automated measurement functions to ensure quality close to and integrated in the production flow. The latest version of the sensor technology used, the Nikon APDIS and the API Dynamic 9D LADAR, are highly flexible sensors for fully automatic optical probing that can be used in stationary and mobile applications or on robots. 

Importance of Holding Fixtures in Aerospace Metrology

Francesco Savelli

In the realm of aerospace metrology, precise measurement is paramount for ensuring the safety, efficiency, and performance of aircraft components. Holding fixtures play a crucial role in achieving accurate measurements by securely holding the workpiece in place during inspection and testing processes. This abstract elucidates the significance of holding fixtures in aerospace metrology.

The paper will outline few case studies of inspection of complex geometry hardware, touch two critical points :
Firstly, holding fixtures provide stability and repeatability, minimizing variations in measurement results. By securely clamping or supporting the workpiece, they mitigate the risk of dimensional distortions caused by external forces, such as vibrations or gravitational effects. This stability is indispensable for achieving consistent and reliable measurements, essential for meeting stringent aerospace industry standards.

Advancements in Portable Metrology for Defense Aircraft Manufacturing

Chris Barrow

More than a decade ago, I gave my first brief at CMSC on the current state of 3D portable metrology and potential use cases that would benefit defense aircraft manufacturing. Evaluations of many of the state-of-the-art systems at the time were performed to determine what might be best suited to accomplish common tasks like detail part validation, hole inspection, seam validation, and coating thickness measurement. Since that time, these technologies have grown into a critical piece of Lockheed Martin’s digital transformation and I have been fortunate to ride that wave to a Technical Fellowship.
This presentation will review my previous study, the deployed applications that followed for F35 and other defense aircraft, lessons learned over the past ten years, and where I see 3D portable metrology being used in the future as those technologies and our aircraft platforms continue to evolve.