ddi aircraft oml scanning and modeling presentation oct 2009

3D Scanning Methods & Equipment for Reverse Engineering Airplane OMLsMichael Raphael

President & Chief Engineer

[email protected]

There are many reasons why firmsneed to modelthe 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 modelthese 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 freelyshared with the audience in order todevelop an appreciation for the selection of such tools for these projects.3D Scanning Methods & Equipment for Reverse Engineering Airplane OMLsAbstract

rapid solutions to 3D problems...Direct Dimensions, Inc.Leading Experts in Close-Range 3D ImagingWidest Toolset for Portable 3D MetrologySpecialists in Manufacturing ProblemsReverse Engineering to CAD ModelsRaw Data into Surfaces & SolidsEngineering for Design IntentComplex 3D Inspection and FAIsThousands of Successful Projects14+ years of Experience, Staff over 20One-Stop-Shop for Expert 3D Scanning

Technical Expertise AreasMilitary/AerospaceAutomotiveIndustrialConsumer ProductsMedicalArt/Architecture1000s of Projects for 100s of CustomersDirect Dimensions, Inc.

Products and CapabilitiesHardwarePortable CMMs & Laser Line Scanners Various Model 3D Scanning CamerasMid & Long-Range Spherical ScannersDCC CMMs w/Laser Line ScannerPhotogrammetry & Camera ToolsHaptic Freeform Modeling ToolsSoftwarePolyWorks GeomagicRapidFormPointoolsImagewareSolidWorks3D Studio MaxMechanical DesktopProEngineerVerisurf3D DoctorRhino3DDirect Dimensions, Inc.

Embraer EMB-120 Turbo PropProject OverviewJanuary 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.

Embraer EMB-120 Turbo PropProject OverviewDimensions: Wing span 19.8m/65ft, length 20.0m/66ft, height 6.4m/21ftTools: Two 8-ft FaroArms, AnthroCAM software, tripods, ImagewarePersonnel: 2 engineersLocation: Mena, AKDate: Summer 1998On-Site Time: 4 days including travelModeling Time: 4 weeksDescription: 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.

Embraer EMB-120 Turbo PropProject Overview

Aircraft Hulks for Flight SimulatorsProject OverviewMultiple 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 90s and into 2005Tools: Conventional FaroArms, AnthroCam softwareOn-Site Time: Typical hulk in 1 day, 2-personsModeling Time: less than 1 week

Aircraft Hulks for Flight SimulatorsProject 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 stallCritical military radar development program is grounded pending fix.DDI contracted by NG to create accurate OML model for CFD.

BAC 1-11 Radar Test PlaneProject Overview

Dimensions: Wing span 27m/88ft, length 28.5m/93ft, height 7.5m/25ftTools: API Laser Tracker with man liftPersonnel: 2 engineers with assistantsLocation: Northrop Grumman Flight Test Group - Baltimore, MDDate: Summer 2001On-Site Time: 6 working daysModeling Time: 4 weeks


Sabreliner Test PlaneProject OverviewDimensions: Wing span 13.5m/45ft, length 14m/47ft, height 5m/16ftTools: FARO LS Laser ScannerPersonnel: 2 techniciansLocation: Northrop Grumman Flight Test Group - Baltimore, MDDate: Fall 2006On-Site Time: 1 eveningModeling Time: 2 weeks

Sabreliner Test PlaneProject Overview

NASA F15 & F16 Test Planes Project OverviewDimensions: Wing span 27m/88ft, length 28.5m/93ft, height 7.5m/25ftTools: FARO LS Laser ScannerPersonnel: 2 techniciansLocation: NASA Dryden Flight Research Center at Edwards AFB, Calif.Date: Summer 2006On-Site Time: 5 working days for both including travelModeling 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

[email protected] You!Questions?3D Scanning Methods & Equipment for Reverse Engineering Airplane OMLs

ddi aircraft oml scanning and modeling presentation oct 2009

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