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3D Scanning Methods & Equipment for 3D Scanning Methods & Equipment for Reverse Engineering Airplane OMLsReverse Engineering Airplane OMLs
Michael RaphaelMichael RaphaelPresident & Chief EngineerPresident & Chief Engineer
www.directdimensions.commraphael@dirdim.commraphael@dirdim.com
410-998-0880410-998-0880
There are many reasons why firms need to model the exterior contour of existing aircraft OMLs (Outer Mold Lines). Most aircraft flying today were not designed in a modern 3D CAD program. Even with a current 3D digital design, the actual as-built contour deviates from the intended shape, at least at some level.
Direct Dimensions has used a wide variety of 3D measurement equipment and
software for nearly 15 years to accurately capture and model these shapes for many different applications and purposes. This presentation will focus on the evolution of 3D scanning equipment and software through many examples with emphasis on practical application, costs, schedules, deliverables, etc.
Having real world customers that demand higher quality and lower price over time
for this application, Direct Dimensions has continually searched for the best tools and methods for performing these projects. This experience and perspective will be freely shared with the audience in order to develop an appreciation for the selection of such tools for these projects.
3D Scanning Methods & Equipment for 3D Scanning Methods & Equipment for Reverse Engineering Airplane OMLsReverse Engineering Airplane OMLs
AbstractAbstract
rapid solutions to 3D problems...rapid solutions to 3D problems...Direct Dimensions, Inc.Direct Dimensions, Inc.
• Leading Experts in Close-Range 3D Imaging• Widest Toolset for Portable 3D Metrology• Specialists in Manufacturing Problems• Reverse Engineering to CAD Models
• Raw Data into Surfaces & Solids• Engineering for “Design Intent”
• Complex 3D Inspection and FAI’s• Thousands of Successful Projects• 14+ years of Experience, Staff over 20• One-Stop-Shop for Expert 3D Scanning
Technical Expertise AreasTechnical Expertise Areas
Military/AerospaceMilitary/Aerospace AutomotiveAutomotive IndustrialIndustrial
Consumer ProductsConsumer Products MedicalMedical Art/ArchitectureArt/Architecture
1000’s of Projects for 100’s of Customers1000’s of Projects for 100’s of Customers
Direct Dimensions, Inc.Direct Dimensions, Inc.
Products and CapabilitiesProducts and Capabilities
Hardware• Portable CMMs & Laser Line Scanners • Various Model 3D Scanning Cameras• Mid & Long-Range Spherical Scanners• DCC CMMs w/Laser Line Scanner• Photogrammetry & Camera Tools• Haptic Freeform Modeling Tools
Software• PolyWorks • Geomagic• RapidForm• Pointools• Imageware• SolidWorks• 3D Studio Max• Mechanical Desktop• ProEngineer• Verisurf• 3D Doctor• Rhino3D
Direct Dimensions, Inc.Direct Dimensions, Inc.
Embraer EMB-120 Turbo PropEmbraer EMB-120 Turbo PropProject OverviewProject Overview
January 9, 1997 – Comair Flight 3272, an Embraer EMB-120 Brasilia, crashes near Ida, Michigan during a snowstorm. All 29 on board die.
The NTSB determined that the probable cause was inadequate icing operation standards while in flight, specifically inadequate minimum airspeeds for icing conditions.
Led to a loss of control when the airplane accumulated a thin, rough accretion of ice on its lifting surfaces.
A contributing factor was the decision of the crew to operate in icing conditions while near the lower end of the while the flaps were retracted.
DDI contracted by engineering investigation team supporting the legal case.
Deliverable: OML CAD model of same model airplane for icing CFD analysis.
Embraer EMB-120 Turbo PropEmbraer EMB-120 Turbo PropProject OverviewProject Overview
Dimensions: Wing span 19.8m/65ft, length 20.0m/66ft, height 6.4m/21ft Tools: Two 8-ft FaroArms, AnthroCAM software, tripods, Imageware Personnel: 2 engineers Location: Mena, AK Date: Summer 1998 On-Site Time: 4 days including travel Modeling Time: 4 weeks Description: Because of a prior legal requirement, two engineers with two
FaroArms measured virtually the entire OML contour. The FaroArms were leap-frogged thru over 40 positions in 3 days. The ultimate wireframe model was believed to be accurate to within less than .25” overall.
Embraer EMB-120 Turbo PropEmbraer EMB-120 Turbo PropProject OverviewProject Overview
Embraer EMB-120 Turbo PropEmbraer EMB-120 Turbo PropProject OverviewProject Overview
Embraer EMB-120 Embraer EMB-120 Turbo PropTurbo PropProject OverviewProject Overview
Aircraft Hulks for Flight SimulatorsAircraft Hulks for Flight SimulatorsProject OverviewProject Overview
Multiple platforms: fixed wing, rotary wing, ground vehicles, etc. Numerous customers: US Navy/Army/Air Force; commercial
firms including J.F. Taylor, Lockheed Martin, CAE, etc. Purpose: To capture the OML contours and some interior
geometry for use in manufacturing designs for accurate flight simulator units.
Dates: late 90’s and into 2005 Tools: Conventional FaroArms, AnthroCam software On-Site Time: Typical hulk in 1 day, 2-persons Modeling Time: less than 1 week
Aircraft Hulks for Flight SimulatorsAircraft Hulks for Flight SimulatorsProject OverviewProject Overview
Aircraft Hulks for Flight SimulatorsAircraft Hulks for Flight SimulatorsProject OverviewProject Overview
Aircraft Hulks for Flight SimulatorsAircraft Hulks for Flight SimulatorsProject OverviewProject Overview
Aircraft Hulks for Flight SimulatorsAircraft Hulks for Flight SimulatorsProject OverviewProject Overview
Aircraft Hulks for Flight SimulatorsAircraft Hulks for Flight SimulatorsProject OverviewProject Overview
Aircraft Hulks for Flight SimulatorsAircraft Hulks for Flight SimulatorsProject OverviewProject Overview
In early 2001, Northrop Grumman Flight Test Group in Baltimore, MD installs a large side-mounted fiberglass radome on BAC 1-11.
During flight test, disturbed airflow causes in-flight engine stall Critical military radar development program is grounded pending fix. DDI contracted by NG to create accurate OML model for CFD.
BAC 1-11 Radar Test PlaneBAC 1-11 Radar Test PlaneProject OverviewProject Overview
Dimensions: Wing span 27m/88ft, length 28.5m/93ft, height 7.5m/25ft Tools: API Laser Tracker with man lift Personnel: 2 engineers with assistants Location: Northrop Grumman Flight Test Group - Baltimore, MD Date: Summer 2001 On-Site Time: 6 working days Modeling Time: 4 weeks
BAC 1-11 Radar Test PlaneBAC 1-11 Radar Test PlaneProject OverviewProject Overview
BAC 1-11 Radar Test PlaneBAC 1-11 Radar Test PlaneProject OverviewProject Overview
BAC 1-11 Radar Test PlaneBAC 1-11 Radar Test PlaneProject OverviewProject Overview
BAC 1-11 Radar Test PlaneBAC 1-11 Radar Test PlaneProject OverviewProject Overview
Sabreliner Test PlaneSabreliner Test PlaneProject OverviewProject Overview
Dimensions: Wing span 13.5m/45ft, length 14m/47ft, height 5m/16ft Tools: FARO LS Laser Scanner Personnel: 2 technicians Location: Northrop Grumman Flight Test Group - Baltimore, MD Date: Fall 2006 On-Site Time: 1 evening Modeling Time: 2 weeks
Sabreliner Test PlaneSabreliner Test PlaneProject OverviewProject Overview
Sabreliner Test PlaneSabreliner Test PlaneProject OverviewProject Overview
Sabreliner Test PlaneSabreliner Test PlaneProject OverviewProject Overview
Sabreliner Test PlaneSabreliner Test PlaneProject OverviewProject Overview
NASA F15 & F16 Test Planes NASA F15 & F16 Test Planes Project OverviewProject Overview
Dimensions: Wing span 27m/88ft, length 28.5m/93ft, height 7.5m/25ft Tools: FARO LS Laser Scanner Personnel: 2 technicians Location: NASA – Dryden Flight Research Center at Edwards AFB, Calif.
Date: Summer 2006 On-Site Time: 5 working days for both including travel Modeling Time: 4 weeks each plane
NASA F15 Test Plane NASA F15 Test Plane Project OverviewProject Overview
NASA F15 Test Plane NASA F15 Test Plane Project OverviewProject Overview
NASA F15 Test Plane NASA F15 Test Plane Project OverviewProject Overview
NASA F16 Test Plane NASA F16 Test Plane Project OverviewProject Overview
NASA F16 Test Plane NASA F16 Test Plane Project OverviewProject Overview
NASA F16 Test Plane NASA F16 Test Plane Project OverviewProject Overview
NASA Gulfstream II NASA Gulfstream II Project OverviewProject Overview
NASA Gulfstream II NASA Gulfstream II Project OverviewProject Overview
NASA Gulfstream II NASA Gulfstream II Project OverviewProject Overview
Michael RaphaelMichael RaphaelPresident & Chief EngineerPresident & Chief Engineer
www.directdimensions.comwww.directdimensions.commraphael@dirdim.commraphael@dirdim.com
410-998-0880410-998-0880
Thank You!Thank You!Questions?Questions?
3D Scanning Methods & Equipment for 3D Scanning Methods & Equipment for Reverse Engineering Airplane OMLsReverse Engineering Airplane OMLs
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