Automation in production integrated NDT using thermography NDT in Aerospace - Augsburg Thomas Schmidt, Somen Dutta

Transcription

1 Automation in production integrated NDT using thermography NDT in Aerospace - Augsburg 2012 Thomas Schmidt, Somen Dutta

2 Chart 2 NDT in Aerospace 2012 > Automation in production integrated NDT using thermography > Content - Introduction - State of the Art in Aerospace - Challenges for NDT - Approach production integrated, automated Thermography as a choice - Realisation - Conclusion

3 Chart 3 NDT in Aerospace 2012 > Automation in production integrated NDT using thermography > DLR Center for Lightweight Production Technology ZLP Site Stade Stade Bremen- Varel Nordenham Hamburg Braunschweig ZLP Site Augsburg ZLP Pfinztal Karlsruhe Stuttgart Augsburg München Oberpfaffenhofen

4 Objectives: Chart 4 NDT in Aerospace 2012 > Automation in production integrated NDT using thermography > DLR Center for Lightweight Production Technology Maximum floor-to-floor efficiency by high placement rate and robust placement devices at a highest quality level Placement rate: > 100 kg/h Augsburg - Robot based textile placement - VARI, VAP & Thermoplastics - Production-Integrated QA Stade - Parallel automated fiber placement devices - Autoclave technology with integrated process control Source: KUKA, DLR

5 Chart 5 NDT in Aerospace 2012 > Automation in production integrated NDT using thermography > Composite Production ZLP Augsburg Enablers for integrated process development -Materials & Processes -Handling devices -Placement devices -Tooling concepts - -Robot-robot collaboration -Robot-human cooperation -Offline programming strategy -Device integration - Robotics & Mechatronics Composites manufacturing processes Production- Integrated QA -Development of QA strategies -Assessment of NDT methods -Integration of NDT and corrections -Data management for closed loop - All enablers are inseparably linked to get an optimised composite production

6 Chart 6 NDT in Aerospace 2012 > Automation in production integrated NDT using thermography > Content - Introduction - State of the Art in Aerospace - Challenges for NDT - Approach production integrated, automated Thermography as a choice - Realisation - Conclusion

7 Chart 7 NDT in Aerospace 2012 > Automation in production integrated NDT using thermography > State of the art in aerospace Present production and quality strategy (large components) Cutting Visual inspection Handling & Preforming Visual inspection Vacuum Bagging Acoustic inspection Process Parameter VAP/VARI Debagging/Demoulding Visual inspection Machining NDT - Quality Check Visual inspection Present process chain dominated by manual work incl. human senses with one physical quality check (NDT) at the end

8 Chart 8 NDT in Aerospace 2012 > Automation in production integrated NDT using thermography > State of the art NDT in aerospace - Water coupled ultrasonic inspection - Submersion technology - Squirter technology - Sampled Phased Array - Transmission and Impuls/Echo - Gantry solutions with linear and rotational axis Sources: National Composites Network, Premium Aerotec, IntelligeNDT, HPI

9 Chart 9 NDT in Aerospace 2012 > Automation in production integrated NDT using thermography > Content - Introduction - State of the Art in Aerospace - Challenges for NDT Quality Assurance - Approach production integrated, automated Thermography as a choice - Realisation - Conclusion

10 Chart 10 NDT in Aerospace 2012 > Automation in production integrated NDT using thermography > Challenges for NDT Improving production and quality strategy - Quality - Improved rework rate - Detailed documentation (engineering loop & continuous improvement) - Control proper quality indicators - Cost efficiency - Improved output rate (parts/h) - Improved rework rate - Final quality check on samples to be certified - Higher degree of automation optimum to be adapted to SOA - Enable continuous improvement Integrated production and quality assurance rather than local improvements Automated production with integrated QA is needed to meet market expectations

11 Chart 11 NDT in Aerospace 2012 > Automation in production integrated NDT using thermography > Challenges for NDT Future production and quality strategy storage Material Parameter Cutting Handling & Preforming Vacuum Bagging VAP/VARI Integrated QA Debagging/Demoulding Machining Quality Check delivery Integrated QA Future process chain needs optimised degree of automation with integrated physical quality checks along the process

12 Chart 12 NDT in Aerospace 2012 > Automation in production integrated NDT using thermography > Content - Introduction (Status and Challenge) - State of the Art in Aerospace - Challenges for NDT Quality Assurance - Approach production integrated, automated Thermography as a choice - Realisation - Conclusion

13 Chart 13 NDT in Aerospace 2012 > Automation in production integrated NDT using thermography > Approach production integrated, automated Thermography as a choice Objectives: Reduction of QA cost (today 20% of component RC) Reduction of QA lead time Reduction of rework after final NDT check Integration into manufacturing process Achievement of robust processes Point-to-point analysis along production chain Thermography as a contactless method Able to measure textile preforms as well as cured composite parts Failure analysis and interpretation Defect localization even on large structures Integrated QA is a key factor for cost efficient, high quality composite production

14 Chart 14 NDT in Aerospace 2012 > Automation in production integrated NDT using thermography > Production integrated, automated Thermography Optically excited Lockin-Thermography (a) Missing Roving (b) Fuzzball Source: edevis (c) Roving orientation on curved parts Ply location & orientation Rovings orientation Source: DLR 2D- Defects 3D- Defects with limitations NDT methods need just the right abilities to deliver the specified quality

15 Chart 15 NDT in Aerospace 2012 > Automation in production integrated NDT using thermography > Potential defects At preform stage Roving gaps Roving accumulation

16 Chart 16 NDT in Aerospace 2012 > Automation in production integrated NDT using thermography > Potential defects Cured parts Delaminations Porosity

17 Chart 17 NDT in Aerospace 2012 > Automation in production integrated NDT using thermography > Content - Introduction (Status and Challenge) - State of the Art in Aerospace - Challenges for NDT Quality Assurance - Approach production integrated, automated Thermography as a choice - Realisation - Conclusion

18 Chart 18 NDT in Aerospace 2012 > Automation in production integrated NDT using thermography > Realisation Integration into Manufacturing Cell (MFZ) Operative in m Storage Cutter Placement Vacuum infiltration Heat treatment Production integrated non-destructive testing Source: DLR/KUKA Flexible infrastructure for a wide range of lightweight structure production technologies

19 Chart 19 NDT in Aerospace 2012 > Automation in production integrated NDT using thermography > Realisation Integration into Manufacturing Cell (MFZ) Operative in m Storage Cutter Placement Vacuum infiltration Heat treatment Production integrated non-destructive testing Flexible infrastructure for a wide range of lightweight structure production technologies -DLR/KUKA

20 Chart 20 NDT in Aerospace 2012 > Automation in production integrated NDT using thermography > Realization Principal design of a thermography system Signal Generator Controller Industrial PC OLT PT Module Flash generator A/D Interface Vis Trigger Images Dim Pack A/D Interface Flash Generator Power Supply Data - Com

21 Chart 21 NDT in Aerospace 2012 > Automation in production integrated NDT using thermography > Realization Evaluation on multiple Scenarios 1 2 Advantage Easy to integrate in robotic cell Measurement & data analysis in real time Drawback To locate the center of gravity of endeffctor robot inaccuracy Required more than 50m long cable for data transmission No more flexible enough to measure complex parts Required special heavy weight robot

22 Chart 22 NDT in Aerospace 2012 > Automation in production integrated NDT using thermography > Realization Evaluation on multiple Scenarios 3 Advantage Measurement & data analysis in real time Accessibility through lean end effector Less change to existing configuration High system accuracy due to low weight and moment of inertia Drawback Requires more than 50m long cable for data transmission Complex solution to integrate into large robotic working cell (MFZ)

23 Chart 23 NDT in Aerospace 2012 > Automation in production integrated NDT using thermography > Realization System Integration

24 Chart 24 NDT in Aerospace 2012 > Automation in production integrated NDT using thermography > Experimental tools: Concept of measurement scenario

25 Chart 25 NDT in Aerospace 2012 > Automation in production integrated NDT using thermography > Automation along the process chain Process preparation for quality check Cutting Handling, Preforming Vacuum bagging Infusion Debagging, Demoulding NDT Quality Check Machining, Assembly Automated QA by means of Thermography Feedback to Engineering Data Evaluation Scrap Parts Measurement Input for Measurement Software Offline Programming for Final QA Measurement Strategy

26 Chart 26 NDT in Aerospace 2012 > Automation in production integrated NDT using thermography > Offline Programming

27 Chart 27 NDT in Aerospace 2012 > Automation in production integrated NDT using thermography > Offline Programming

28 Chart 28 NDT in Aerospace 2012 > Automation in production integrated NDT using thermography > Content - Introduction (Status and Challenge) - State of the Art in Aerospace - Challenges for NDT Quality Assurance - Approach production integrated, automated Thermography as a choice - Realization - Conclusion

29 Chart 29 NDT in Aerospace 2012 > Automation in production integrated NDT using thermography > Conclusion - Enormous challenges ahead for lightweight structure production - Need for cost efficient composite production for aircraft Industry automation of production and quality assurance - Steep and robust ramp-up essential for future aircraft programs mitigation of industrial risks - Increasing rate of aircrafts and parts to be expected - Local improvements in quality assurance are not sufficient to fulfill needs - Next step of innovation: Integration and overall optimization of processes - New production, quality (and engineering) strategies to be developed - Emphasize research on relevant process sensitivities - Facing the challenges - Know-How & Infrastructure being built to cover required technology readiness level - Production processes and integrated QA are permanently under development

30 Special thanks for financial and political support goes to: - The Free State Bavaria - The City of Augsburg - The initiative AUGSBURG Innovationspark - The Federal Ministry of Economics and Technology and to our partners in industry, research and science as well as the team of ZLP Augsburg