intact aircraft robotic ndi - sae international€¦ · in the late 1970s at sacramento alc: x-ray...

Ogden Air Logistics Complex

Intact Aircraft Robotic NDI (A Proposal)

Dr. David S. Hansen

Director, 309 Maintenance Support Group

Hill AFB, UT 14 November 2012

[email protected]

O G D E N A I R L O G I S T I C S C O M P L E X

Challenge

Robotic Inspection of intact fighter aircraft began in the late 1970s at Sacramento ALC: X-Ray and N-Ray

BRACC ‘95 closure of Sacramento ALC

F-15 Facility at Robins ALC – not intact inspection

5th Generation Fighters highly LO dependent – maintenance activities breaking LO envelope are expensive

Inspection capabilities without rupturing LO envelope should provide huge cost savings

Current inspection methods solve need – but at the cost of the LO restoration, large MX hours


Intact Aircraft Robotic NDI

Baseline sustainment for aging aircraft

Opportunities for growth with new aircraft

Monitor individual/fleet aircraft health

Rapid throughput

Trend analysis

Data fusion

Holistic Health

One-stop shop

Consistent inspection data

Ensured readiness


PROS • Able to Locate Subsurface Skin

Disbonds, Core Splice Disbonds, Crushed Core, & Other Defect Types essential to Aircraft Structural Integrity

• Potential to Fully Automate via

Robotic Coordinate System • Data can be Integrated into NDI

Equipment Database

CONS • Very influenced and negated by very

minor vibrational conditions • Foot Traffic • Transportation • Facility Vibration

• Not good for crack detection • No Probability of Detection Data to

prove capability • Portability and Miniaturization still

In-Work

Shearography


PROS • Able to Locate Surface and Sub-Surface

Structural Cracks, Corrosion, Heat Damage Material Properties essential Aircraft Structural Integrity

• Some Small Scale Robotic System currently In-Use in AF and Commercially

• Extensive Data Library on Probability of Detection

• Data can be Integrated into NDI Equipment Database

• All Metallic Material Capabilities

CONS • Subject to Material Property

Changes • Permeability • Conductivity • Surface Conditions

• Highly sophisticated robotics are

necessary to achieve defect size and location estimation

• Not Effective for Composite Materials or Non-Conductive Materials

Eddy Current

Flexible/Conformal Differential Coil

Provides Coverage of Entire Radius

Surface


PROS • Able to Detect Substructure Anomalies

such as Over-Expanded Core, Crushed Core, Plugged Cells, Corrosion, or Other Conditions

• Uses Relative Low Energy X Radiation • Ability to Digitize Legacy X-Ray Film for

Electronic Storage and Data Fusion • Some Real Time Radiography Capability

Exists

• Can be Integrated into NDI Analysis Data Base – Used for Data Management & Trend

Analysis

CONS • Not ideal for crack detection

• Safety costs/concerns due to Radiation

• Lack of Probability of Detection Data

• Pinpoint Location accuracy for robotics is

necessary to achieve defect size and location estimation

Real-Time Radiography


PROS • Ability to Detect Skin Delaminations, Porosity, Voids, &

Skin-to-Core Disbonds in Composites and Metallics

• Can do both….. • Thru-Transmission C-Scan Technique • Pulse Echo Dual Transmission & Analysis

• Effective on Highly Curved Composites & Metallic

Structures

• CUSS Provides Reliable Repeatable Inspections

• AUSS V Stores Inspection Data Digitally for Future

• Has both Portable and Stationary Versions

• Good Data on Probability of Detection

Computed Ultrasonic Scan Systems

CONS • Water based inspection process

• Some Metallic Corrosion Risk • Moisture entrapment in Composites and

Honeycomb Risk

• Water Collection System Required

• Not Good for Crack Detection


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Minuteman Stage 3

PROS • Able to Detect Substructure Anomalies

such as Propellant Voids, Case to Liner Disbonds FOD, Cracks, and Other Conditions

• Time Proven capability for: • 3 D Imaging • Data Fusion • Defect Recognition Software • Electronic Storage • Legacy Data

• Great for Baseline and Trend Analysis

Data

CONS • Not ideal for small crack detection

• Major Safety costs/concerns due to

potential Radiation Exposure

• Limited if any Probability of Detection Data

• High Level of accuracy for robotics is necessary to achieve defect size and location estimation

Computed Tomography


Intact Aircraft Examination

Faster Maintenance Flow Days

Potential 6K+ hours savings in LO restoration

Trend Analysis, Fleet Condition Prediction

Early Defect Detection

Technicians removed from possible hazards

Customized inspections, if needed

Integration with Engineering Analysis

Inspection consistency and repeatability

Data Fusion*

Potential Mx Benefits


Questions?


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Backup Slides


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NDI Data Fusion

Multi-NDI Modality –

Digital image based data Digital Radiography

C-Scan Ultrasound

Shearography

Thermography

Phase 2 SBIR Extension

“Data Fusion of NDE Images”

Initial contract 2006

Successfully stored data

fusion

Major Benefits Reduce costs of manf. &

maint.

Improve A/C avail.

Improved aircraft safety

NDT Image Data Fusion

“Google Maps for NDI Data” Software would be used to Organize,

Archive and Analyze inspection data

Future of NDI Data

Collection Vehicle Heath Monitoring

ASIP Risk Mgt. Tool

Hot Spot Trending

Structures Re-Design Tool

STAKEHOLDERS

NDI Program Mgt. Office

NDI Production

System Program Offices

AFRL

ASC/EN


Raw inspection

data mapped

directly to

structure

Inspector

annotations

marked with

designated dots

Detailed

information about

selected

notes/defects

Database

interface to

customize search

NDI Data Fusion

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intact aircraft robotic ndi - sae international€¦ · in the late 1970s at sacramento alc: x-ray...

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