DDI Aircraft OML Scanning and Modeling Presentation Oct 2009
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The document discusses 3D scanning methods and equipment used for reverse engineering the outer mold lines (OMLs) of aircraft, highlighting the importance of accurate modeling for various applications, including legal cases and flight simulator designs. Direct Dimensions, Inc. shares their extensive experience with a wide range of tools, techniques, and successful projects in the military and aerospace sectors. The presentation covers the evolution of 3D scanning technologies and emphasizes the practical applications, costs, and quality improvement over time.
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DDI Aircraft OML Scanning and Modeling Presentation Oct 2009
- 1. 3D Scanning Methods & Equipment for Reverse Engineering Airplane OMLs Michael Raphael President & Chief Engineer www.directdimensions.com [email_address] 410-998-0880
- 2. 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
- 3. 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
- 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. 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.
- 7. 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.
- 8. Embraer EMB-120 Turbo Prop Project Overview 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.
- 9. Embraer EMB-120 Turbo Prop Project Overview
- 10. Embraer EMB-120 Turbo Prop Project Overview
- 11. Embraer EMB-120 Turbo Prop Project Overview
- 12. 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
- 13. Aircraft Hulks for Flight Simulators Project Overview
- 14. Aircraft Hulks for Flight Simulators Project Overview
- 15. Aircraft Hulks for Flight Simulators Project Overview
- 16. Aircraft Hulks for Flight Simulators Project Overview
- 17. Aircraft Hulks for Flight Simulators Project Overview
- 18. Aircraft Hulks for Flight Simulators Project Overview
- 21. 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
- 22. 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 Modeling Time: 4 weeks BAC 1-11 Radar Test Plane Project Overview
- 23. BAC 1-11 Radar Test Plane Project Overview
- 24. BAC 1-11 Radar Test Plane Project Overview
- 25. BAC 1-11 Radar Test Plane Project Overview
- 27. 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 Modeling Time: 2 weeks
- 28. Sabreliner Test Plane Project Overview
- 29. Sabreliner Test Plane Project Overview
- 30. Sabreliner Test Plane Project Overview
- 31. Sabreliner Test Plane Project Overview
- 33. 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
- 34. NASA F15 Test Plane Project Overview
- 35. NASA F15 Test Plane Project Overview
- 36. NASA F15 Test Plane Project Overview
- 37. NASA F16 Test Plane Project Overview
- 38. NASA F16 Test Plane Project Overview
- 39. NASA F16 Test Plane Project Overview
- 41. NASA Gulfstream II Project Overview
- 42. NASA Gulfstream II Project Overview
- 43. NASA Gulfstream II Project Overview
- 44. NASA ER-2 Project Overview
- 45. NASA ER-2 Project Overview
- 46. NASA ER-2 Project Overview
- 47. NASA ER-2 Project Overview
- 48. NASA ER-2 Project Overview
- 50. Air Force C-5a Project Overview
- 51. Air Force C-5a Project Overview
- 52. Air Force C-5a Project Overview
- 53. Air Force C-5a Project Overview
- 54. Air Force C-5a Project Overview
- 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