METROLOGY

Overview

METROLOGY is an automated metrology system presented as a valuable addition to non-destructive testing and is also used in aerospace manufacturing processes such as trimming, drilling and countersinking. Optical measuring systems with a high variety of accuracies and FoV are available, and AI-assisted image processing algorithms can be applied to image data in addition to point cloud processing. A key component is an optical reconstruction system which uses either structured light or laser triangulation depending on the process needs, and the solution is described as a contactless surface reconstruction method. Features include a multimodality approach (combination with ultrasonic, thermography or X-ray inspection), an automated tool changer FLEXCHANGE, dedicated path planning algorithms implemented in FILL STUDIO, and 3D offline simulation and programming. Accuracy of 0,05mm can be achieved; a HEXAGON tracker AT960 in combination with an AS-1 scanner is used to acquire high precision data, POLYWORKS is used to perform alignment with the 3D data, and measuring reports can be generated automatically; the machine is designed according to customer-specific requirements and resulting technical data are defined in collaboration with the customer. METROLOGY is used to teach in, reconstruct unknown surfaces, and perform CAD replication & comparison for contactless surface reconstruction. Referencing determines the position of a specimen inside the inspection area automatically and trajectories can be defined in FILL STUDIO, while Validation automatically scans the specimen and calls the corresponding program to maximize process safety and to identify the correct part type from unique part features. The part reconstruction module in FILL STUDIO performs a meshing algorithm on the acquired point cloud and outputs a *.step file for offline programming and subsequent path planning, and structured light measuring is used to perform contactless measurement of geometrical attributes (for example bonding areas and holes); reverse engineering is applied to CFRP parts to address deviation from CAD files and spring back phenomena.