CMSC 2024

 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. 

Various portable laser scanners are used at multiple sites throughout Lockheed Martin Aeronautics. In October 2022, our production and quality teams noticed variation between scan results which was large enough that it could lead to material misidentification as conforming or nonconforming.  The team worked together to investigate the repeatability of the system, came to understand system limits, and deployed improvements which increased capability on most parts.

This presentation will review how a Measurement System Analysis revealed that certain part characteristics can challenge portable laser scanners, as well as what adaptations yielded positive results.

©2024 Lockheed Martin Corporation. All Rights Reserved

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. As the main requirement for this important task, all the parts and components need to be accurately modeled. Due to the large variety of the parts and assembly items collected from the various suppliers, accurate 3D modeling for many of these items were missing. The Original Equipment Manufacturers (OEM) in automotive industries typically collect the required information and 3D models over the years and decades through their organic development. However, this was not the case in project arrow design and fabrication. Therefore, a comprehensive reverse engineering project was conducted at Advanced Digital Design, Manufacturing, and Metrology (AD2M Labs), Ontario Tech university to complete this task. Digital metrology using various optical and tactile sensors were conducted by the team to digitize over 50 parts and assemblies. The objective has been to interactively revise the overall packaging of the vehicle for an optimum functionality and fit of the designed components.

Working within a very tight timeframe, the team innovatively developed a consistent and efficient procedure to reconstruct surfaces and model the parts and assemblies in high level of accuracy and at the minimum cost. The team structured and implemented a systematic reverse engineering process to complete this task, which allows deconstructing individual components of complex assemblies, piece by piece, to collect and revise the engineering knowledge in their original design and re-model them for the purpose of Arrow project. The developed innovative process named as 5Cs includes five stages of Combining, Cleaning, Converging, Coordinate Alignment, and Condensing. This paper principles of the developed procedure and presents the employed methodologies behind this development. The procedure successfully implemented in reverse engineering of all the digitalized parts and assemblies used in project arrow and the highly satisfactory results have been achieved. Following the successful completion of the project, the 5Cs procedure have been used to model in several other reverse engineering projects with satisfactory results. This procedure can be well adopted by many other industrial sectors when there is a need to reconstruct surface and solid models from actual parts and assemblies.

Ahmad Barari*
The University of Ontario Institute of Technology
Oshawa, Ontario, Canada
Ahmad.Barari@ ontariotechu.ca

Dylan Bender
The University of Ontario Institute of Technology
Oshawa, Ontario, Canada
Dylan.Bender@ontariotechu.ca

The Edge Coating Verification (ECV) process has been transformational to F-35 production and quality in Fort Worth and throughout the world. The team integrated 3D scanning automation to verify the application of F-35 component edge coatings, driving down variation and ensuring adherence to engineering and performance requirements (process known as seam validation). The Edge Coating Verification process was originally developed in 2017 for F-35 Component Final Finishes to mitigate downstream seam validation issues in assembly. In 2023, the team completed integration of two automated industrial robotic scanning cells in Fort Worth to further increase scope/efficiency and support F-35 rate requirements.

An intuitive user interface guides an operator through the proper steps to setup panels within the cell. Optical projectors, in-cell displays, and cameras are integrated in the work cells to errorproof the process and enhance operator repeatability. The panels are fixtured in the work cell with Lockheed Martin developed vacuum cup standoffs that are compatible with 107 unique panels across the three F-35 variants. The standoffs quickly secure and elevate the part, allowing the systems to scan both the outer and inner planes of all edges.

The scanning robot cell is a commercial off-the-shelf system. After the operator sets up the panel in the system, an industrial robot manipulates a 3D laser scanner to automatically collect surface data along a pre-programmed path. All data needed to generate a report is collected within minutes, compared to the legacy manual process that took 2-3 times longer per panel. Complex and robust metrology analysis algorithms automatically compare scan data of coating conditions once scanning is complete. Easily interpretable reports are produced to guide any operator rework and corrective action activities necessary.

Impact
Significantly reduced coating variation to help meet 100% Quality/On-Time Goals.
Reduced downstream scrap, rework, and repair (SRR) hours by identifying any issues prior to panels leaving the coatings facility.

Future
Partner sites, both domestic and international, are leveraging the new “standard” for edge coating verification in support of seam validation. This means supporting sites can avoid development costs and inspect with the same tools to the same standard across the program, both during initial manufacturing all the way through depot maintenance teams.
Most recently, an additional Aeronautics site is implementing a similar solution based on the success of the integrated Fort Worth systems. Future expansion of this automated metrology solution is very strong with the support of the suppliers and Operations Technology team.

© 2024 Lockheed Martin Corporation. All Rights Reserved.