automation in production integrated ndt using thermography
TRANSCRIPT
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Automation in production integrated NDT using thermography NDT in Aerospace - Augsburg 2012
Thomas Schmidt, Somen Dutta
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Content
- Introduction
- State of the Art in Aerospace
- Challenges for NDT
- Approach production integrated, automated Thermography as a choice
- Realisation
- Conclusion
www.DLR.de Chart 2 NDT in Aerospace 2012 > Automation in production integrated NDT using thermography > 13.11.2012
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Stuttgart
Oberpfaffenhofen
AugsburgMnchen
PfinztalKarlsruhe
ZLP
HamburgBremen-
Stade
BraunschweigVarel
Nordenham
ZLP Site Augsburg
ZLP Site Stade
DLR Center for Lightweight Production Technology
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Source: KUKA, DLR
Objectives: Maximum floor-to-floor efficiency by high placement rate and robust placement devices at a highest quality levelPlacement rate: > 100 kg/h
- Robot based textile placement- VARI, VAP & Thermoplastics- Production-Integrated QA
Augsburg- Parallel automated fiber
placement devices- Autoclave technology
with integratedprocess control
Stade
DLR Center for Lightweight Production Technology
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Composite Production Technology @ ZLP AugsburgEnablers for integrated process development
Composites manufacturing
processes
Production-Integrated
QARobotics &
Mechatronics
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-Materials & Processes
-Handling devices
-Placement devices
-Tooling concepts
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-Robot-robot collaboration
-Robot-human cooperation
-Offline programming strategy
-Device integration
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-Development of QA strategies
-Assessment of NDT methods
-Integration of NDT and corrections
-Data management for closed loop
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All enablers are inseparably linked to get an optimised composite production
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Content
- Introduction
- State of the Art in Aerospace
- Challenges for NDT
- Approach production integrated, automated Thermography as a choice
- Realisation
- Conclusion
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State of the art in aerospacePresent production and quality strategy (large components)
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Vacuum Bagging VAP/VARI
Debagging/Demoulding
Handling & PreformingCutting
Machining NDT - Quality Check
Visualinspection
Visualinspection
Acousticinspection
Visualinspection
Visualinspection
ProcessParameter
Present process chain dominated by manual work incl. human senseswith one physical quality check (NDT) at the end
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State of the art NDT in aerospace
- Water coupled ultrasonic inspection- Submersion technology- Squirter technology- Sampled Phased Array- Transmission and Impuls/Echo
- Gantry solutions with linear and rotationalaxis
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Sources: National Composites Network, Premium Aerotec, IntelligeNDT, HPI
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Content
- Introduction
- State of the Art in Aerospace
- Challenges for NDT Quality Assurance
- Approach production integrated, automated Thermography as a choice
- Realisation
- Conclusion
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Challenges for NDTImproving production and quality strategy
- Quality- Improved rework rate- Detailed documentation (engineering loop & continuous improvement)- Control proper quality indicators
- Cost efficiency- Improved output rate (parts/h)- Improved rework rate- Final quality check on samples to be certified- Higher degree of automation optimum to be adapted to SOA- Enable continuous improvement
Integrated production and quality assurance rather than localimprovements
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Automated production with integrated QA is needed to meet market expectations
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Challenges for NDTFuture production and quality strategy
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Vacuum Bagging VAP/VARI
Debagging/Demoulding
Handling & PreformingCutting
Machining Quality Check delivery
MaterialParameter
Future process chain needs optimised degree of automationwith integrated physical quality checks along the process
storage
Integrated QA
Integrated QA
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Content
- Introduction (Status and Challenge)
- State of the Art in Aerospace
- Challenges for NDT Quality Assurance
- Approach production integrated, automated Thermography as a choice
- Realisation
- Conclusion
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Objectives: Reduction of QA cost (today 20% of component RC)Reduction of QA lead timeReduction of rework after final NDT checkIntegration into manufacturing processAchievement of robust processes
Point-to-point analysis along production chain Thermography as a contactless methodAble to measure textile preforms as well as cured composite partsFailure analysis and interpretationDefect localization even on large structures
Approach production integrated, automated Thermography as a choice
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Integrated QA is a key factor for cost efficient, high quality composite production
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Ply location & orientationRovings orientation
2D- Defects3D- Defects with limitations
Production integrated, automated ThermographyOptically excited Lockin-Thermography
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NDT methods need just the right abilities to deliver the specified quality
(a) Missing Roving (b) Fuzzball
(c) Roving orientation on curved partsSource: edevis Source: DLR
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Potential defectsAt preform stage
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Roving gaps Roving accumulation
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Potential defectsCured parts
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Delaminations Porosity
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Content
- Introduction (Status and Challenge)
- State of the Art in Aerospace
- Challenges for NDT Quality Assurance
- Approach production integrated, automated Thermography as a choice
- Realisation
- Conclusion
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Cutter
Source: DLR/KUKA
PlacementVacuum
infiltrationHeat
treatment
Production integrated non-destructive testing
Storage
29 m
Operative in 2013
RealisationIntegration into Manufacturing Cell (MFZ)
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Flexible infrastructure for a wide range of lightweight structure production technologies
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Cutter
-DLR/KUKA
PlacementVacuum
infiltrationHeat
treatment
Production integrated non-destructive testing
Storage
29 m
Operative in 2013
RealisationIntegration into Manufacturing Cell (MFZ)
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Flexible infrastructure for a wide range of lightweight structure production technologies
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RealizationPrincipal design of a thermography system
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ControllerSignal Generator
Dim Pack
Industrial PC
Flash Generator
ImagesTriggerModule
OLT PTFlash generator
A/D InterfaceVis
A/D Interface
Power Supply
Data - Com
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RealizationEvaluation on multiple Scenarios
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Advantage Easy to
integrate in robotic cell
Measurement & data analysis in real time
Drawback To locate the center of
gravity ofendeffctor robotinaccuracy
Required more than50m long cable fordata transmission
No more flexible enough to measurecomplex parts
Required specialheavy weight robot
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RealizationEvaluation on multiple Scenarios
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3Advantage Measurement &
data analysis in real time
Accessibility through lean end effector
Less change to existing configuration
High system accuracy due to low weight and moment of inertia
Drawback Requires more than
50m long cable for data transmission
Complex solution to integrate into large robotic working cell (MFZ)
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RealizationSystem Integration
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Experimental tools: Concept of measurement scenario
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Automation along the process chainProcess preparation for quality check
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Offline Programming for
Final QAMeasurement
Machining,AssemblyCutting
Handling,Preforming
Vacuumbagging Infusion
Debagging,Demoulding
NDT QualityCheck
Automated QA by means of Thermography
Scrap Parts
Measurement Strategy
Input for Measurement
Software
Data Evaluation
Feedback to Engineering
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Offline Programming
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Offline Programming
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Content
- Introduction (Status and Challenge)
- State of the Art in Aerospace
- Challenges for NDT Quality Assurance
- Approach production integrated, automated Thermography as a choice
- Realization
- Conclusion
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Conclusion
- Enormous challenges ahead for lightweight structure production- Need for cost efficient composite production for aircraft Industry
automation of production and quality assurance- Steep and robust ramp-up essential for future aircraft programs
mitigation of industrial risks- Increasing rate of aircrafts and parts to be expected
- Local improvements in quality assurance are not sufficient to fulfill needs- Next step of innovation: Integration and overall optimization of processes- New production, quality (and engineering) strategies to be developed- Emphasize research on relevant process sensitivities
- Facing the challenges- Know-How & Infrastructure being built to cover required technology
readiness level- Production processes and integrated QA are permanently under
development
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Special thanks for financial and political support goes to:
- The Free State Bavaria
- The City of Augsburg
- The initiative AUGSBURG
Innovationspark
- The Federal Ministry of
Economics and Technology
and to our partners in industry, research and science as well as the team of ZLP Augsburg
Automation in production integrated NDT using thermography NDT in Aerospace - Augsburg 2012ContentDLR Center for Lightweight Production TechnologyDLR Center for Lightweight Production TechnologyComposite Production Technology @ ZLP AugsburgEnablers for integrated process developmentContentState of the art in aerospacePresent production and quality strategy (large components)State of the art NDT in aerospaceContentChallenges for NDTImproving production and quality strategyChallenges for NDTFuture production and quality strategyContentApproach production integrated, automated Thermography as a choiceProduction integrated, automated ThermographyOptically excited Lockin-ThermographyPotential defectsAt preform stagePotential defectsCured partsContentRealisationIntegration into Manufacturing Cell (MFZ)RealisationIntegration into Manufacturing Cell (MFZ)RealizationPrincipal design of a thermography systemRealizationEvaluation on multiple ScenariosRealizationEvaluation on multiple ScenariosRealizationSystem IntegrationExperimental tools: Concept of measurement scenarioAutomation along the process chainProcess preparation for quality checkOffline ProgrammingOffline ProgrammingContentConclusionFoliennummer 30