DDI Aircraft OML Scanning and Modeling Presentation Oct 2009

3D Scanning Methods & Equipment for Reverse Engineering Airplane OMLs Michael Raphael President & Chief Engineer www.directdimensions.com [email_address] 410-998-0880

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 Reverse Engineering Airplane OMLs Abstract

rapid solutions to 3D problems... 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 Areas Military/Aerospace Automotive Industrial Consumer Products Medical Art/Architecture 1000’s of Projects for 100’s of Customers Direct Dimensions, Inc.

Products 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.

Embraer EMB-120 Turbo Prop Project 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.

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.

Aircraft Hulks for Flight Simulators Project 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 Simulators Project 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 Plane Project 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

BAC 1-11 Radar Test Plane Project Overview

Sabreliner Test Plane Project 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

Sabreliner Test Plane Project Overview

NASA F15 & F16 Test Planes Project 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 Project Overview

NASA F16 Test Plane Project Overview

NASA Gulfstream II Project Overview

NASA ER-2 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 Scanning Methods & Equipment for Reverse Engineering Airplane OMLs