accurate project
TRANSCRIPT
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ACCURATe project
Vicki James
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Introduction
Aerospace
Composite
Components
Ultrasonic
Robot
Assisted
Testing
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Project Work Packages
Current Work Packages
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The ACCURATe Project - Background
Part of Clean Sky 2 framework
Specifically “More Affordable Composite Fuselage”
EU’s Horizon 2020 research and innovation programme
c. €2M grant funding received
44 month project
Project commenced June 2017
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The ACCURATe Project - Overview
Composites are key to reducing fuel costs andemissions
State of the art aircraft contain up to 80% by weight ofcomposites in their load bearing structures
Two key barriers to overcome: (i) High cost of manufacture (ii) Increased risks of both internal defects and impact
damage leading to structural failure
Hence the requirement for more efficient, effectiveand comprehensive inspection processes and systems
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The history of LUT in Aerospace
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Why Laser ultrasonic testing?
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Project Partners
ACCURATe Consortium
Topic Manager
LEONARDO AIRCRAFT
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Laser Ultrasonic testing-LUT
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The challenges of LUTDefect detection in highly dampening materials and therefore requiring the detection of weak signals (caused by highly ultrasonic damping dampening materials) the project has aimed to create innovations to improve the Signal to noise ratio:
Austrian nationally funded project: K-Project ZPT+, courtesy by RECENDT GmbH.
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Advantages of Laser UT
High speed inspection process
Lightweight scanning head with small footprint
Broadband UT frequency generation
Low maintenance
High accuracy
Non contact
No couplant
Offline path planning and simulation for efficientworking
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Project Aims
Develop a prototype laser ultrasonic testing (LUT) system fornon-destructive inspection (NDI) of :
Large scale aircraft hybrid and thick composite structures
Structures containing acoustic damping materials
Materials which highly attenuate ultrasound
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Challenges of the project
Laser & robot safety
Inspection speed critical
Laser power optimisation
System vibration & noise
Multiple systems integration
Physical space constraints and robot reach
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System Overview
6-axis robot mounted onlinear track
Fibre coupled, pulsedgeneration and detectionlasers
Interferometer and signalprocessing unit
Fully integrated software forlaser & robot control, dataacquisition and data analysis
Two position superpanelmounting fixture
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Specification and performance*
Inspection cell size (m): 8 x 7 x 5 (W x D x H) Inspection material types: Hybrid composite laminates Largest component: c. 17m2
Maximum component thickness: 30ply + additional layers Inspection rate: >8m2/h Minimum detectable defect size: 6mm square Robot positional accuracy: ±0.7mm Robot pose repeatability: ±0.1mm Minimum robot step size: 0.1mm Scanning index: 0.5 - 3 mm (0.5 mm increments)
* Design parameters
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Robotic system
KR30-L16 robot manipulator
KL1000 Linear Track with2700mm travel
KRC4 Robot Controller
5200mm wide loading doors &cell access doors
Integrated Fortress Interlockdoor locking / access system
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Laser SystemsGeneration Laser:
Type: diode pumped solid state laser
Wavelength: 532 nm
Pulse length: 10 ns
Pulse repetition rate: 400 Hz
Beam diameter: 4 mm
Pulse energy 30 mJ (at fibre output)
Detection Laser:Type: diode pumped continuous wave /Nd:YAG laser
Wavelength: 1064 nm
Pulse repetition rate: 400 Hz
Pulse length: 50 µs
Pulse energy 29mJ (at fibre output)
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Optical Systems Passive optical laser head
Fibre coupled to stationery two wavemixing (TWM) interferometer unit
Back scattered light from samplesurface converted to amplitudechanges
Amplitude changes measured byphotodetectors (photodiodes)
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Software Bespoke software for data acquisition, analysis and
visualisation of inspection results
Display and analyse data in A-scan, B-Scan and 3D view
Offline data processing & visualisation
Full interaction with the 3D model
Indication logging and reporting
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Software functions
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A scan features
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Measurement of flaws
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Offline Path Planning & Simulation
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Superpanel Fixture design
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Initial Testing of the LUT system
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The CS2 reference panel
The CS2 reference panel contains• Artificial flaws 6 x 6mm• Artificial flaws 17 x 17mm• Visco-elastic layers• 8 ply and 30 ply sections• Fiberglass sections• Copper mesh sections
Viscoelastic region
Black paint region
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System Testing
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LUT results GATE
A SCAN B SCAN C SCAN
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Colour coding of artificial flaws
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Flaw detection by viewing B scan-cross section
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Histogram function
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System Testing-Scrap fuselage panel
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System Testing
Rear views of the panel showing stringers and ribs
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LUT results
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Scrap fuselage panel detailedresults
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Programme & Progress
Current status: Prototype LUT system commissioned LUT data acquisition and analysis software passed initial testing Proof of concept Completed integrated system tests
Next steps: Improvement of Signal to Noise ratio via electronic
amplification Installation at Topic Manager site System validation trials & performance tests CE Marking Completion – Q1 2021
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Thank you for listening
[email protected]+44 (0)1639 873100+44 (0)7843 688102
Questions ?www.accurate-project.eu