intact aircraft robotic ndi - sae international€¦ · in the late 1970s at sacramento alc: x-ray...
TRANSCRIPT
Ogden Air Logistics Complex
Intact Aircraft Robotic NDI (A Proposal)
Dr. David S. Hansen
Director, 309 Maintenance Support Group
Hill AFB, UT 14 November 2012
O G D E N A I R L O G I S T I C S C O M P L E X
Challenge
Robotic Inspection of intact fighter aircraft began in the late 1970s at Sacramento ALC: X-Ray and N-Ray
BRACC ‘95 closure of Sacramento ALC
F-15 Facility at Robins ALC – not intact inspection
5th Generation Fighters highly LO dependent – maintenance activities breaking LO envelope are expensive
Inspection capabilities without rupturing LO envelope should provide huge cost savings
Current inspection methods solve need – but at the cost of the LO restoration, large MX hours
O G D E N A I R L O G I S T I C S C O M P L E X
Intact Aircraft Robotic NDI
Baseline sustainment for aging aircraft
Opportunities for growth with new aircraft
Monitor individual/fleet aircraft health
Rapid throughput
Trend analysis
Data fusion
Holistic Health
One-stop shop
Consistent inspection data
Ensured readiness
O G D E N A I R L O G I S T I C S C O M P L E X
PROS • Able to Locate Subsurface Skin
Disbonds, Core Splice Disbonds, Crushed Core, & Other Defect Types essential to Aircraft Structural Integrity
• Potential to Fully Automate via
Robotic Coordinate System • Data can be Integrated into NDI
Equipment Database
CONS • Very influenced and negated by very
minor vibrational conditions • Foot Traffic • Transportation • Facility Vibration
• Not good for crack detection • No Probability of Detection Data to
prove capability • Portability and Miniaturization still
In-Work
Shearography
O G D E N A I R L O G I S T I C S C O M P L E X
PROS • Able to Locate Surface and Sub-Surface
Structural Cracks, Corrosion, Heat Damage Material Properties essential Aircraft Structural Integrity
• Some Small Scale Robotic System currently In-Use in AF and Commercially
• Extensive Data Library on Probability of Detection
• Data can be Integrated into NDI Equipment Database
• All Metallic Material Capabilities
CONS • Subject to Material Property
Changes • Permeability • Conductivity • Surface Conditions
• Highly sophisticated robotics are
necessary to achieve defect size and location estimation
• Not Effective for Composite Materials or Non-Conductive Materials
Eddy Current
Flexible/Conformal Differential Coil
Provides Coverage of Entire Radius
Surface
O G D E N A I R L O G I S T I C S C O M P L E X
PROS • Able to Detect Substructure Anomalies
such as Over-Expanded Core, Crushed Core, Plugged Cells, Corrosion, or Other Conditions
• Uses Relative Low Energy X Radiation • Ability to Digitize Legacy X-Ray Film for
Electronic Storage and Data Fusion • Some Real Time Radiography Capability
Exists
• Can be Integrated into NDI Analysis Data Base – Used for Data Management & Trend
Analysis
CONS • Not ideal for crack detection
• Safety costs/concerns due to Radiation
• Lack of Probability of Detection Data
• Pinpoint Location accuracy for robotics is
necessary to achieve defect size and location estimation
Real-Time Radiography
O G D E N A I R L O G I S T I C S C O M P L E X
PROS • Ability to Detect Skin Delaminations, Porosity, Voids, &
Skin-to-Core Disbonds in Composites and Metallics
• Can do both….. • Thru-Transmission C-Scan Technique • Pulse Echo Dual Transmission & Analysis
• Effective on Highly Curved Composites & Metallic
Structures
• CUSS Provides Reliable Repeatable Inspections
• AUSS V Stores Inspection Data Digitally for Future
• Has both Portable and Stationary Versions
• Good Data on Probability of Detection
Computed Ultrasonic Scan Systems
CONS • Water based inspection process
• Some Metallic Corrosion Risk • Moisture entrapment in Composites and
Honeycomb Risk
• Water Collection System Required
• Not Good for Crack Detection
O G D E N A I R L O G I S T I C S C O M P L E X
BE AMERICA’S BEST
Minuteman Stage 3
PROS • Able to Detect Substructure Anomalies
such as Propellant Voids, Case to Liner Disbonds FOD, Cracks, and Other Conditions
• Time Proven capability for: • 3 D Imaging • Data Fusion • Defect Recognition Software • Electronic Storage • Legacy Data
• Great for Baseline and Trend Analysis
Data
CONS • Not ideal for small crack detection
• Major Safety costs/concerns due to
potential Radiation Exposure
• Limited if any Probability of Detection Data
• High Level of accuracy for robotics is necessary to achieve defect size and location estimation
Computed Tomography
O G D E N A I R L O G I S T I C S C O M P L E X
Intact Aircraft Examination
Faster Maintenance Flow Days
Potential 6K+ hours savings in LO restoration
Trend Analysis, Fleet Condition Prediction
Early Defect Detection
Technicians removed from possible hazards
Customized inspections, if needed
Integration with Engineering Analysis
Inspection consistency and repeatability
Data Fusion*
Potential Mx Benefits
O G D E N A I R L O G I S T I C S C O M P L E X
Questions?
O G D E N A I R L O G I S T I C S C O M P L E X
BE AMERICA’S BEST
Backup Slides
O G D E N A I R L O G I S T I C S C O M P L E X
BE AMERICA’S BEST
NDI Data Fusion
Multi-NDI Modality –
Digital image based data Digital Radiography
C-Scan Ultrasound
Shearography
Thermography
Phase 2 SBIR Extension
“Data Fusion of NDE Images”
Initial contract 2006
Successfully stored data
fusion
Major Benefits Reduce costs of manf. &
maint.
Improve A/C avail.
Improved aircraft safety
NDT Image Data Fusion
“Google Maps for NDI Data” Software would be used to Organize,
Archive and Analyze inspection data
Future of NDI Data
Collection Vehicle Heath Monitoring
ASIP Risk Mgt. Tool
Hot Spot Trending
Structures Re-Design Tool
STAKEHOLDERS
NDI Program Mgt. Office
NDI Production
System Program Offices
AFRL
ASC/EN
O G D E N A I R L O G I S T I C S C O M P L E X
Raw inspection
data mapped
directly to
structure
Inspector
annotations
marked with
designated dots
Detailed
information about
selected
notes/defects
Database
interface to
customize search
NDI Data Fusion
BE AMERICA’S BEST