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3D Scanning Methods & Equipment for Reverse Engineering Airplane OMLs Michael Raphael President & Chief Engineer www.direc...
<ul><li>There are many reasons why firms need to model the exterior contour of existing aircraft OMLs (Outer Mold Lines). ...
rapid solutions to 3D problems... Direct Dimensions, Inc. <ul><li>Leading Experts in Close-Range 3D Imaging </li></ul><ul>...
Technical Expertise Areas Military/Aerospace Automotive Industrial Consumer Products Medical Art/Architecture 1000’s of Pr...
Products and Capabilities <ul><li>Hardware </li></ul><ul><li>Portable CMMs & Laser Line Scanners  </li></ul><ul><li>Variou...
 
Embraer EMB-120 Turbo Prop Project Overview <ul><li>January 9, 1997 – Comair Flight 3272, an Embraer EMB-120 Brasilia, cra...
Embraer EMB-120 Turbo Prop Project Overview <ul><li>Dimensions:  Wing span 19.8m/65ft, length 20.0m/66ft, height 6.4m/21ft...
Embraer EMB-120 Turbo Prop Project Overview
Embraer EMB-120 Turbo Prop Project Overview
Embraer EMB-120 Turbo Prop Project Overview
Aircraft Hulks for Flight Simulators Project Overview <ul><li>Multiple platforms: fixed wing, rotary wing, ground vehicles...
Aircraft Hulks for Flight Simulators Project Overview
Aircraft Hulks for Flight Simulators Project Overview
Aircraft Hulks for Flight Simulators Project Overview
Aircraft Hulks for Flight Simulators Project Overview
Aircraft Hulks for Flight Simulators Project Overview
Aircraft Hulks for Flight Simulators Project Overview
 
 
<ul><li>In early 2001, Northrop Grumman Flight Test Group in Baltimore, MD installs a large side-mounted fiberglass radome...
<ul><li>Dimensions:  Wing span 27m/88ft, length 28.5m/93ft, height 7.5m/25ft </li></ul><ul><li>Tools:  API Laser Tracker w...
BAC 1-11 Radar Test Plane Project Overview
BAC 1-11 Radar Test Plane Project Overview
BAC 1-11 Radar Test Plane Project Overview
 
Sabreliner Test Plane Project Overview <ul><li>Dimensions:  Wing span 13.5m/45ft, length 14m/47ft, height 5m/16ft </li></u...
Sabreliner Test Plane Project Overview
Sabreliner Test Plane Project Overview
Sabreliner Test Plane Project Overview
Sabreliner Test Plane Project Overview
 
NASA F15 & F16 Test Planes  Project Overview <ul><li>Dimensions:  Wing span 27m/88ft, length 28.5m/93ft, height 7.5m/25ft ...
NASA F15 Test Plane  Project Overview
NASA F15 Test Plane  Project Overview
NASA F15 Test Plane  Project Overview
NASA F16 Test Plane  Project Overview
NASA F16 Test Plane  Project Overview
NASA F16 Test Plane  Project Overview
 
NASA Gulfstream II  Project Overview
NASA Gulfstream II  Project Overview
NASA Gulfstream II  Project Overview
NASA ER-2  Project Overview
NASA ER-2  Project Overview
NASA ER-2  Project Overview
NASA ER-2  Project Overview
NASA ER-2  Project Overview
 
Air Force C-5a  Project Overview
Air Force C-5a  Project Overview
Air Force C-5a  Project Overview
Air Force C-5a  Project Overview
Air Force C-5a  Project Overview
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
Michael Raphael President & Chief Engineer www.directdimensions.com [email_address] 410-998-0880 Thank You! Questions? 3D ...
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DDI Aircraft OML Scanning and Modeling Presentation Oct 2009

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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.

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Transcript of "DDI Aircraft OML Scanning and Modeling Presentation Oct 2009"

  1. 1. 3D Scanning Methods & Equipment for Reverse Engineering Airplane OMLs Michael Raphael President & Chief Engineer www.directdimensions.com [email_address] 410-998-0880
  2. 2. <ul><li>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. </li></ul><ul><li>  </li></ul><ul><li>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.  </li></ul><ul><li>  </li></ul><ul><li>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. </li></ul>3D Scanning Methods & Equipment for Reverse Engineering Airplane OMLs Abstract
  3. 3. rapid solutions to 3D problems... Direct Dimensions, Inc. <ul><li>Leading Experts in Close-Range 3D Imaging </li></ul><ul><li>Widest Toolset for Portable 3D Metrology </li></ul><ul><li>Specialists in Manufacturing Problems </li></ul><ul><li>Reverse Engineering to CAD Models </li></ul><ul><ul><li>Raw Data into Surfaces & Solids </li></ul></ul><ul><ul><li>Engineering for “Design Intent” </li></ul></ul><ul><li>Complex 3D Inspection and FAI’s </li></ul><ul><li>Thousands of Successful Projects </li></ul><ul><li>14+ years of Experience, Staff over 20 </li></ul><ul><li>One-Stop-Shop for Expert 3D Scanning </li></ul>
  4. 4. Technical Expertise Areas Military/Aerospace Automotive Industrial Consumer Products Medical Art/Architecture 1000’s of Projects for 100’s of Customers Direct Dimensions, Inc.
  5. 5. Products and Capabilities <ul><li>Hardware </li></ul><ul><li>Portable CMMs & Laser Line Scanners </li></ul><ul><li>Various Model 3D Scanning Cameras </li></ul><ul><li>Mid & Long-Range Spherical Scanners </li></ul><ul><li>DCC CMMs w/Laser Line Scanner </li></ul><ul><li>Photogrammetry & Camera Tools </li></ul><ul><li>Haptic Freeform Modeling Tools </li></ul><ul><li>Software </li></ul><ul><li>PolyWorks </li></ul><ul><li>Geomagic </li></ul><ul><li>RapidForm </li></ul><ul><li>Pointools </li></ul><ul><li>Imageware </li></ul><ul><li>SolidWorks </li></ul><ul><li>3D Studio Max </li></ul><ul><li>Mechanical Desktop </li></ul><ul><li>ProEngineer </li></ul><ul><li>Verisurf </li></ul><ul><li>3D Doctor </li></ul><ul><li>Rhino3D </li></ul>Direct Dimensions, Inc.
  6. 7. Embraer EMB-120 Turbo Prop Project Overview <ul><li>January 9, 1997 – Comair Flight 3272, an Embraer EMB-120 Brasilia, crashes near Ida, Michigan during a snowstorm. All 29 on board die. </li></ul><ul><li>The NTSB determined that the probable cause was inadequate icing operation standards while in flight, specifically inadequate minimum airspeeds for icing conditions. </li></ul><ul><li>Led to a loss of control when the airplane accumulated a thin, rough accretion of ice on its lifting surfaces. </li></ul><ul><li>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. </li></ul><ul><li>DDI contracted by engineering investigation team supporting the legal case. </li></ul><ul><li>Deliverable: OML CAD model of same model airplane for icing CFD analysis. </li></ul>
  7. 8. Embraer EMB-120 Turbo Prop Project Overview <ul><li>Dimensions: Wing span 19.8m/65ft, length 20.0m/66ft, height 6.4m/21ft </li></ul><ul><li>Tools: Two 8-ft FaroArms, AnthroCAM software, tripods, Imageware </li></ul><ul><li>Personnel: 2 engineers </li></ul><ul><li>Location: Mena, AK </li></ul><ul><li>Date: Summer 1998 </li></ul><ul><li>On-Site Time: 4 days including travel </li></ul><ul><li>Modeling Time: 4 weeks </li></ul><ul><li>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. </li></ul>
  8. 9. Embraer EMB-120 Turbo Prop Project Overview
  9. 10. Embraer EMB-120 Turbo Prop Project Overview
  10. 11. Embraer EMB-120 Turbo Prop Project Overview
  11. 12. Aircraft Hulks for Flight Simulators Project Overview <ul><li>Multiple platforms: fixed wing, rotary wing, ground vehicles, etc. </li></ul><ul><li>Numerous customers: US Navy/Army/Air Force; commercial firms including J.F. Taylor, Lockheed Martin, CAE, etc. </li></ul><ul><li>Purpose: To capture the OML contours and some interior geometry for use in manufacturing designs for accurate flight simulator units. </li></ul><ul><li>Dates: late 90’s and into 2005 </li></ul><ul><li>Tools: Conventional FaroArms, AnthroCam software </li></ul><ul><li>On-Site Time: Typical hulk in 1 day, 2-persons </li></ul><ul><li>Modeling Time: less than 1 week </li></ul>
  12. 13. Aircraft Hulks for Flight Simulators Project Overview
  13. 14. Aircraft Hulks for Flight Simulators Project Overview
  14. 15. Aircraft Hulks for Flight Simulators Project Overview
  15. 16. Aircraft Hulks for Flight Simulators Project Overview
  16. 17. Aircraft Hulks for Flight Simulators Project Overview
  17. 18. Aircraft Hulks for Flight Simulators Project Overview
  18. 21. <ul><li>In early 2001, Northrop Grumman Flight Test Group in Baltimore, MD installs a large side-mounted fiberglass radome on BAC 1-11. </li></ul><ul><li>During flight test, disturbed airflow causes in-flight engine stall </li></ul><ul><li>Critical military radar development program is grounded pending fix. </li></ul><ul><li>DDI contracted by NG to create accurate OML model for CFD. </li></ul>BAC 1-11 Radar Test Plane Project Overview
  19. 22. <ul><li>Dimensions: Wing span 27m/88ft, length 28.5m/93ft, height 7.5m/25ft </li></ul><ul><li>Tools: API Laser Tracker with man lift </li></ul><ul><li>Personnel: 2 engineers with assistants </li></ul><ul><li>Location: Northrop Grumman Flight Test Group - Baltimore, MD </li></ul><ul><li>Date: Summer 2001 </li></ul><ul><li>On-Site Time: 6 working days </li></ul><ul><li>Modeling Time: 4 weeks </li></ul>BAC 1-11 Radar Test Plane Project Overview
  20. 23. BAC 1-11 Radar Test Plane Project Overview
  21. 24. BAC 1-11 Radar Test Plane Project Overview
  22. 25. BAC 1-11 Radar Test Plane Project Overview
  23. 27. Sabreliner Test Plane Project Overview <ul><li>Dimensions: Wing span 13.5m/45ft, length 14m/47ft, height 5m/16ft </li></ul><ul><li>Tools: FARO LS Laser Scanner </li></ul><ul><li>Personnel: 2 technicians </li></ul><ul><li>Location: Northrop Grumman Flight Test Group - Baltimore, MD </li></ul><ul><li>Date: Fall 2006 </li></ul><ul><li>On-Site Time: 1 evening </li></ul><ul><li>Modeling Time: 2 weeks </li></ul>
  24. 28. Sabreliner Test Plane Project Overview
  25. 29. Sabreliner Test Plane Project Overview
  26. 30. Sabreliner Test Plane Project Overview
  27. 31. Sabreliner Test Plane Project Overview
  28. 33. NASA F15 & F16 Test Planes Project Overview <ul><li>Dimensions: Wing span 27m/88ft, length 28.5m/93ft, height 7.5m/25ft </li></ul><ul><li>Tools: FARO LS Laser Scanner </li></ul><ul><li>Personnel: 2 technicians </li></ul><ul><li>Location: NASA – Dryden Flight Research Center at Edwards AFB, Calif. </li></ul><ul><li>Date: Summer 2006 </li></ul><ul><li>On-Site Time: 5 working days for both including travel </li></ul><ul><li>Modeling Time: 4 weeks each plane </li></ul>
  29. 34. NASA F15 Test Plane Project Overview
  30. 35. NASA F15 Test Plane Project Overview
  31. 36. NASA F15 Test Plane Project Overview
  32. 37. NASA F16 Test Plane Project Overview
  33. 38. NASA F16 Test Plane Project Overview
  34. 39. NASA F16 Test Plane Project Overview
  35. 41. NASA Gulfstream II Project Overview
  36. 42. NASA Gulfstream II Project Overview
  37. 43. NASA Gulfstream II Project Overview
  38. 44. NASA ER-2 Project Overview
  39. 45. NASA ER-2 Project Overview
  40. 46. NASA ER-2 Project Overview
  41. 47. NASA ER-2 Project Overview
  42. 48. NASA ER-2 Project Overview
  43. 50. Air Force C-5a Project Overview
  44. 51. Air Force C-5a Project Overview
  45. 52. Air Force C-5a Project Overview
  46. 53. Air Force C-5a Project Overview
  47. 54. Air Force C-5a Project Overview
  48. 75. Michael Raphael President & Chief Engineer www.directdimensions.com [email_address] 410-998-0880 Thank You! Questions? 3D Scanning Methods & Equipment for Reverse Engineering Airplane OMLs
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