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3D Process Analy0cs for Carbon Composite Manufacturing Tom Sharp
NLign Analy0cs A Division of Etegent Technologies, Ltd.
Copyright 2013 Etegent Technologies, Ltd. 1
3D Process Analy0cs for Carbon Composite Manufacturing
Outline: • Composite Manufacturing Process Data • NLign Overview • Discussion of Data Mapping Techniques • Case Studies
Overview
1
Copyright 2013 Etegent Technologies, Ltd. 2
An Unprecedented Amount of Process Data is Generated and Collected
Composite Manufacturing Process Data
Process Data
Material Machine People Inspec0on Models
Copyright 2013 Etegent Technologies, Ltd. 3
• This Data is Difficult to use for Process Analysis/Improvement • In many different forms
• Paper, Text files, Proprietary data formats, etc.
• Not meaningfully organized • File cabinets, File systems • Excel spreadsheets, Legacy Databases, ERP/MES system
• Large volume
• What if this Data Could be Meaningfully Tied to a 3D Model?
Composite Manufacturing Process Data
Copyright 2013 Etegent Technologies, Ltd. 4
NLign Overview
Data is then automa0cally aligned to CAD model and stored in an archive database
Models Structural Molds Fixtures
FEA Models Specifica0ons
Inspec0on Data
Process Data Tool Set Number Machine Log Files Resin Proper0es
Etc.
Digital Pictures
Dimensional Data
Manufacturing
Maintenance
Align & Archive
Process Improvement/
RCCA
MRB Process Improvement
Aircraft Structural Integrity
Structural Repair
Copyright 2013 Etegent Technologies, Ltd. 5
Analysis Tools
Visualize ultrasound C-‐Scan results
Visualize digital radiography on 2D Model
Overlay various models
Data Export: • Excel • Minitab • FEA • Per0nence PRD
Integrated Analysis Tools • Plo\ng • Basic sta0s0cs
Analyze
• Repor0ng • Visualiza0on • Trending • Root Cause Analysis • Process Improvement • Coverage checking • Analysis package integra0on
Copyright 2013 Etegent Technologies, Ltd. 6
Interac?ve Analysis Environment
Copyright 2013 Etegent Technologies, Ltd. 7
3D Process Analy0cs for Carbon Composite Manufacturing Outline: • Composite Manufacturing Process Data • NLign Overview • Discussion of Data Mapping Techniques • Interac0ve Analysis Environment • Case Studies
Overview
7
Copyright 2013 Etegent Technologies, Ltd. 8
• Goal is to Automa0cally Map all Data Back to a 3D Model
• This is Difficult Because: • Data contains minimal “loca0on” informa0on • Range of data from text, images, 0me histories, etc. • Range of image forma0on techniques
• Single image/Mul0ple images • Overlap/No overlap • Clear features/No clear features
• One Approach Will not Handle all Data Types
Discussion of Data Mapping Techniques
Copyright 2013 Etegent Technologies, Ltd. 9
Configurable Alignment System
• A Configurable System that Selects the Proper Alignment Algorithm for the Par0cular Data
• U0lizes a Library of Data Alignment Techniques
Incoming Data
Iden0fy Data Type
Alignment Method Database
Data/Image Alignment
Metadata Alignment
Archive
Copyright 2013 Etegent Technologies, Ltd. 10
• Data Alignment Library has Numerous Techniques • Will Discuss Several in Detail
• Robo0c • Turntable • Limited trajectory informa0on
• Dimensional data • Text transla0on
Data Mapping Techniques
Copyright 2013 Etegent Technologies, Ltd. 11
• Goal: determine x, y, z loca0on of each C-‐Scan pixel
• Handle two degrees of freedom case • Rota0on • Height
• x,y,z Determined by “Rolling” Aligned UT Data onto Model
Mapping Turntable Data
Copyright 2013 Etegent Technologies, Ltd. 12
• Goal: determine x, y, z loca0on of each C-‐Scan pixel
• Limited informa0on available on trajectory of sensor head
• Use Nominal Trajectory to Develop 3D -‐> 2D map
• Image Features Used to Op0mize Alignment in 2D
• Map 2D Aligned Data to 3D
Limited Trajectory Informa?on
Copyright 2013 Etegent Technologies, Ltd. 13
• Goal: Improve Visualiza0on of Varia0ons in Dimensional Data
• Aggregate Dimensional Measurements Across Mul0ple Parts
• Problem: Posi0on Error can be Mul0ple Orders of Magnitude Smaller than Dimension of Parts • Error vector created between nominal and actual
• Error vector scaled (e.g., 100 X) • Measurement shown on model at scaled offset from nominal
Dimensional Data
Copyright 2013 Etegent Technologies, Ltd. 14
• Goal: Convert Text Based Loca0on Informa0on into X, Y, Z
• Loca0on Can be Specified in Mul0ple Ways • Hole number • Stringer/Body sta0on • Distance from some point
• Each Type Requires Different Approach • Look up tables • Parameterized curves • Ad-‐Hoc
Text Data Mapping
Copyright 2013 Etegent Technologies, Ltd. 15
3D Process Analy0cs for Carbon Composite Manufacturing Outline: • Composite Manufacturing Process Data • NLign Overview • Discussion of Data Mapping Techniques • Case Studies
Overview
15
Copyright 2013 Etegent Technologies, Ltd. 16
• Six Case Studies • Monitor tool degrada0on • Porosity root cause analysis • Track thickness/compac0on over units • Missed inspec0ons • Track thickness/compac0on • MRB Process Improvement • MRB Analysis
• All Data Shown is Fabricated • The Case Studies do Represent How NLign is Being Used
Case Studies
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• Porosity indica0ons shown as red dots on model
• Spa0al filter set to “watch” tool at known trouble area
• Report shows majority of porosity indica0on along seam are associated with one tool
Case Study – Monitor Tool Degrada?on
Copyright 2013 Etegent Technologies, Ltd. 18
Case Study – Root Cause Analysis
Cluster of porosity Findings (red)
Model showing location of tool seam
Point showing location of seam rework (green)
• Root cause of tool seam leaks were correlated to rework in the area • Rework process was corrected
Copyright 2013 Etegent Technologies, Ltd. 19
Case Study: Missed Inspec?ons
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• Ability to Track NDI Results at Specific Loca0on Over Time
• Select Loca0on on Model • Select NDI Parameter • Plot Shows Time-‐of-‐Flight Es0mate of Part Thickness
• Could Also be Used to Track Low Level Porosity
Case Study: Track Thickness/Compac?on
0.17
0.175
0.18
0.185
0.19
32 33 34 35 36 37 38 39 40 41 46
Copyright 2013 Etegent Technologies, Ltd. 21
Case Study: MRB Process Improvement
• OEM disposi0on taking over a month • Reduce risk of con0nued manufacturing
• Repository of acceptable defects • Confident decision to either
• Con0nue processing part while MRB analysis is being performed
• Stop processing part un0l MRB analysis is complete
• Yield: a significant rate increase while managing risk
Copyright 2013 Etegent Technologies, Ltd. 22
• Combine Non-‐conformance with design models • FEM Models • Ply Models • Historical Non-‐conformances
• Enable quick analysis of Non-‐conformance
Case Study: MRB Analysis
Copyright 2013 Etegent Technologies, Ltd. 23
• Aligning Process Data to 3D Models Makes this Data Much More Valuable • Visualizing data in 3D allows for spa0al pamerns to be quickly iden0fied
• Several Case Studies Discussed • Process monitoring • Root cause analysis
• The Tool Has Demonstrated that it can: • Reduce Scrap and Rework • Improve MRB processes • Improve In-‐service composite repair • Ensure Inspec0on coverage
Conclusions
Copyright 2013 Etegent Technologies, Ltd. 24
Ques?ons