CMSC 2024

Authors:  William. G. Jansma, Joshua S. Downey, Rolando C. Gwekoh, Altaf A. Khan, Keith B. Knight, Animesh Jain, Samuel P. Jarvis, Jeremy Nudell

Argonne National Laboratory, Argonne, Illinois, USA

The Advanced Photon Source (APS) is a synchrotron X-ray facility located at Argonne National Laboratory that has been in operation since 1996. An extensive upgrade to replace the original APS electron storage ring with a state-of-the-art machine was recently completed. The ~1,100-meter circumference storage ring generates X-rays up to 500 times brighter than those created by the original APS. With the new ring completed, focus has shifted to the upgrade and realignment of X-ray beamlines. This presentation will report the progress of the APS Upgrade project and share survey and alignment results for accelerator module assembly and installation, highlighting the metrology methods utilized in building the new storage ring.
* Work supported by U.S. Department of Energy, Office of Sciences, under Contract No. DE-AC02-06CH11357 

 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. 
Not all tasks in automated production require traceable measurements. High investment costs, many features with short cycle times and the lack of certified downtime predictions often require additional sensors. Robot-mounted light section sensors, such as a Keyence LJ-V7080B held by a Fanuc M-900iA, offer the ability to measure many points and can be evaluated by the existing processing pipeline; they can also be extended locally with the option to add traceable measured features. Another advantage of light section sensors is the availability of traceable systems such as the Hexagon AS1 with the AT960, creating a complete sensor palette for FFT-VisionVIEW. 
The integration of the sensors into a functional robot cell to manufacture large train parts with 4 Fanuc M-1000iA robots holding welding guns with 400 kg tools demonstrates the dual usability of the optical sensors. Two of the robots on opposing sides are equipped with Keyence LJ-X8900 sensors, which have the task of flexibly determining the condition of the clamps and the presence of parts to ensure a clean system condition during automatic production. In addition, FFT-VisionVIEW uses the sensors to measure part deviations and provides the information to the online guidance and collision avoidance system to enable advanced welding strategies with optimal geometric results. During commissioning, ramp-up and maintenance, an API Dynamic 9D LADAR is temporarily inserted into the station on a moving stand to support the set-up and check system behavior during the initial commissioning without parts being available yet. Principles of the dry-run phase of setting-in will be shown, and technical details will also be explained in a demonstration set-up to explain the system functionality in more detail. 

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.

©2024 Lockheed Martin Corporation. All Rights Reserved

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.

Secondly, holding fixtures facilitate accessibility and orientation control, enabling efficient inspection of intricate geometries and hard-to-reach areas. They allow technicians to position the workpiece precisely relative to the measurement equipment, ensuring accurate data capture across all critical dimensions. This capability is particularly valuable for complex aerospace components, such as engine parts or airframe structures, which demand meticulous scrutiny for quality assurance.
Technical paper will furthermore outline how holding fixtures aid in streamlining metrology workflows and enhancing productivity. By providing a dedicated setup for measurement tasks, they reduce setup time and minimize the need for manual adjustments, leading to quicker turnaround times and increased throughput. This efficiency gain is invaluable in aerospace manufacturing, where time-to-market and production efficiency are paramount considerations.

Moreover, holding fixtures contribute to cost reduction and waste prevention by minimizing rework and scrap due to measurement inaccuracies. By ensuring that parts are measured accurately the first time, they mitigate the risk of defective components entering the production line, thereby averting costly rejections and delays. This proactive approach to quality control is essential for maintaining competitiveness in the aerospace industry.

Therefore, investment in high-quality holding fixtures is indispensable for aerospace manufacturers striving to uphold the highest standards of precision and quality assurance.

Terrestrial laser scanners (TLSs) are a type of coordinate metrology instrument which collects the three-dimensional coordinates of a scene by measuring the range that a laser beam travels and its orientation (azimuthal and elevation angles). TLSs are subject to a variety of error sources, including those which arise in the ranging, measurement of angles, and interaction of the laser beam with the scanned surface. Documentary standards exist which prescribe tests to expose some of those error sources, including ASTM E2938-15, which addresses errors arising from the ranging unit of a TLS, and ASTM E3125-17, which addresses those from any inherent optical misalignments (leading primarily to angular errors) inside a TLS. While ASTM E2938-15 does allow one to scan different materials, it only captures the impact of the materials’ optical properties in aggregate, along with all other sources’ contribution to ranging errors.

We propose an artifact which interrogates the effects of different materials’ optical scattering behavior on the performance of a TLS. The artifact consists of a planar, media-blasted aluminum plate onto which several, planar materials under test are affixed. The artifact is meant to be modular, so the materials under test can be swapped out easily. Further, the plate holds three to four media-blasted steel spheres from which a unique coordinate system may be established. The artifact is first calibrated on a coordinate measurement machine (CMM). The CMM records a three-dimensional point cloud with sufficient points to fit the radius and center point of each sphere and a plane to the faces of each material and the background plate. The TLS also collects a point cloud of data representing all surfaces on the artifact. From both sets of data, the distance from the approximate center of the surface of each sample to the plane of the background material can be computed and compared. Additionally, the root-mean-square error of each plane fitted to the TLS data is computed. The RMS error and the error in the offset distance can be used as a measure of the ranging uncertainty for that material.

We report on initial testing performed on a grayscale reflectance tile set made from sintered polytetrafluoroethylene. The measured distance from the front of each sample to the background plane shows a strong dependence on the target’s level of reflectance. These preliminary results show that the artifact we propose can be used effectively to examine some errors in TLS measurements. Future measurements must be taken to further examine the impact of range, ranging technology, angle-of-incidence, and additional materials.

Authors:
Braden Czapla, National Institute of Standards and Technology, Mechanical Engineer*
Vincent Lee, National Institute of Standards and Technology, Mechanical Engineer
Bala Muralikrishnan, National Institute of Standards and Technology, Mechanical Engineer
Tam Vo, Naval Surface Warfare Center Corona Division, Senior Electrical Engineer
Matthew Winger, Naval Surface Warfare Center Corona Division, Measurement Scientist
*Primary Author

 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.

In the Philippine project, measuring a seawater pump for the coal fired power plant auxiliaries and condenser cooling presented a unique challenge. The motor assembly is positioned above the main pump, while the main pump and ancillary components are located below sea level. Again, a unified coordinate system for all the key components was required. This project faced the added challenge of key targets being under leaking pumps, necessitating various investigations on the accuracy impact of wet targets.

Remarkably, both projects achieved high precision, maintaining accuracies consistently within the range of 30 to 50 microns across the entire measurement volume. Photogrammetric techniques not only facilitated precise measurements but also enabled the development of comprehensive action plans. These plans, rooted in meticulous data analysis, reflected observed behaviours. The New Zealand case, with its repeated measurements, offered valuable insights into dynamic changes over time, while the Philippines project underscored the adaptability of photogrammetry in challenging conditions. The cumulative findings contribute significantly to advancing the understanding of the effects of process driven changes in force and geometry and enable proactive strategies for maintenance and optimization in power generation.


 Pieter Krige 
Turbine Specialist 
373 Waingaro str 
RD1, Ngaruawahia 
Waikato, New Zealand 
Pieter@pkengineeringnz.com 

 Giuseppe Ganci 
Photogrammetrist Gancell Pty. Ltd. 
27 Browning Street Moonee Ponds, Victoria 3039, Australia gganci@gancell.com 

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.

Off the shelf cameras, are typified by CMOS imaging sensors purchased either as printed circuit board level devices with small threaded lens mounts, as physically enclosed units with “C” mount and larger lens mounts packaged for working in harsh environments, or as stand-alone consumer photographic cameras operating under their own power with local camera control and storage capability. No matter what type of imaging system is selected, it is necessary to numerically model the systematic geometry of the photogrammetric light path from object space to image space. The widely accepted approach of using a bundle adjustment solution permits the combination of measurements made from one or more camera images and their uncertainties along with a reference frame definition and photogrammetric lens model to estimate coordinates, positions, and poses of objects which are in the combined viewing volume of the cameras when the image set was taken. The bundle adjustment process provides a rigorous least squares error propagation enabling the uncertainties of the required location, pose to be estimated.

This presentation will describe rigid object and scene-based camera calibration methods which can be deployed in either laboratory or factory spaces illustrating results with examples drawn from our research. We will include digital consumer cameras imaging with different generations of moderate wide angle lenses typical of “off-line” or single mobile camera photogrammetry highlighting the importance of 3D spaces and calibration objects, matching camera image quality with the features being used to support the calibration process, suitable image network geometries and image coverage to achieve a reliable calibration, the parameters from bundle adjustment that give most insight into the success of the calibration process. We will also look at the calibration results from a range of mid-range quality lenses optimised for imaging with the 20MP generation of “C” mount camera units considering camera calibration outputs with respect to different lens angles of view under constant magnification. The outcome will be a set of best practice hints, tips and tricks necessary to achieve reliable and accurate photogrammetric camera calibrations. The tables below give examples of some of the areas that will be discussed: (1) variation in target image quality with lens aperture and location in the image; (2) estimated calibration parameters for five different lenses fitted successively to the same camera body; (3) variations in the internal corelations between estimated camera calibration parameters for a near zero radial distortion lens; (4) image residuals following bundle adjustment overlaid from all images taken with a given camera and (5) 3D estimated coordinate uncertainty ellipsoids estimated from bundle adjustment output covariance matrices. 

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.

This presentation will go over the two innovative technologies and methods the team has developed for characterizing internal surfaces of fastener holes and validating external fastener flushness coating measurements, and how these tools enable producing a better and more affordable 5th Generation aircraft.


©2024 Lockheed Martin Corporation. All Rights Reserved

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.

The publication begins by highlighting the benefits and limitations of CAM compared to traditional metrology methods. Traditional metrology relies on manual measurement tools, such as calipers, micrometers, and gauges, which require human intervention and interpretation. Computer-aided metrology, on the other hand, utilizes advanced hardware and software systems, including coordinate measuring machines (CMMs), laser scanners, laser trackers, and optical measurement devices, which automate the measurement process and provide accurate and reliable data.

The publication digs into the various sources of uncertainties in CAM, including measurement equipment, software algorithms, and environmental factors. It explores the impact of these uncertainties on measurement accuracy and repeatability, emphasizing the importance of error analysis and uncertainty estimation in CAM processes. To bridge the gap between CAM and traditional metrology, the presentation proposes strategies to address uncertainties. These strategies may include calibration and verification of measurement equipment, validation of software algorithms, proper training, and implementation of quality control measures.

In conclusion, this publication provides valuable insights into addressing and minimizing uncertainties in CAM and traditional metrology. By understanding the sources of uncertainties and implementing effective strategies, organizations can maximize the potential of CAM while ensuring accurate and reliable measurements.

 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.