Gom Applications In Aerospace Testing
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Transcript of Gom Applications In Aerospace Testing
GOM The Use of Optical Metrology in the Aerospace Industry September 2, 2014
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The Use of Optical Metrology in the Aerospace Industry GOM
GOM – Industrial 3D Measuring Techniques Company Overview
· Development, manufacturing and sales
· Over 300 employees
· 7 GOM branch offices in Europe
· 45 dedicated partner offices worldwide
· More than 8,000 installations
· Measurement technology for companies from the automotive and aerospace industries as well as from the consumer goods sector
GOM is a global partner for optical 3D metrology with over 20 years' experience
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The Use of Optical Metrology in the Aerospace Industry GOM
GOM Customers (Extract)
Automobile manufacturers · Audi D · Avtovaz RU · Bentley UK · BMW AT, D, UK · Chrysler USA · Daimler D · Fiat IT · Ford BE, D, UK, USA, BR · Freightliner USA · General Motors AU, AT, BR, USA · Honda CN, JP, USA · Hyundai KR · Isuzu JP · Jaguar UK · Kia KR · Land Rover UK · McLaren UK · Modenas MY · NAZA MY · Nissan JP, UK, USA · Opel D · Porsche D · PSA FR · Renault FR, ES, TR · Seat ES · Skoda CZ · Subaru JP · Suzuki CN · Tata Motors Limited IN · Toyota D, J, TR, USA, CA · Volkswagen CN, D, MX, PL · Volvo SE · Temsa TR
Automotive suppliers · Autopal CZ · Batz ES · Bertone IT · Bertrandt D · Bosch D, CH · Bridgestone JP · Carcoustics LI · DAAZ RU · Delphi JP · Faurecia D, FR · FES D · Goodyear USA · Hella Leuchtensysteme D · IAV D · Italdesign-Giugiaro IT · Kautex Textron D · Läpple D · LUK D · Magna CA, AT · Mahle D · Matador SK · Matrici ES · Metalbages ES · Michelin FR · Montupet FR · Nothelfer DE · OLHO Technik DE · Pierburg Kolbenschmidt AG, D · Pininfarina IT · Solvay BE · ThyssenKrupp D
Aerospace · Airbus D · Airforce Research Laboratories USA · Aselsan TR · Boeing USA · Cessna USA · Chrom Alloy USA, TH · DLR D · EADS D, FR · ELBAR SULZER NL · Eurocopter D · Federal Aviation Administration USA · FOI SE · Gorbynov Aviation Production RU · Honeywell IE, USA · Howmet UK, USA, JP · IMA Dresden DE · IMPO RU · Lockhead Martin USA · MTU D · NASA USA · Northrop Grumman Systems Corp. USA · ONERA FR · Pratt & Whitney USA, NO · RollsRoyce UK, USA · Saturn RU · Snecma Propulsion Solide FR · Solar Turbines USA · Triumph USA · Turbine Services USA · Vulcan Air IT · VZLÚ CZ
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The Use of Optical Metrology in the Aerospace Industry GOM
Material manufacturers · ACTech DE · Alcan (Alusuisse) CH · Arcelor BE · BASF DE · Bayer DE · DuPont US · Hydro (VAW) DE · Salzgitter DE · Tata Steel IN · Thyssen Krupp DE · Thyssen Nirosta DE · Tokai Rubber Industries JP · Voest Alpine Stahl AT
Others · Alfa Laval SE · Bundeskriminalamt DE · Corning US · EXXON US · Hidrostal CH · Sea Ray Boats US
Consumer goods · 3B Scientific DE · Adidas DE, USA, KR + 13 suppliers · Apache Footwear DE · Asics JP · Balda CN · BenQ CN · Blaupunkt DE · Bosch DE, CH · Braun DE, CN · Ching Luh Shoes CN · Ecco DK · Embraco BR · FisherPrice USA · Fuji JP · Green Point CN, TW · Head Tyrolia AT · Hitachi Taga JP · Lego DK · LG Electronic KR · Luxottica IT · Mattel Tools MY · Microsoft USA · Nolato SE · Oakley US · Olympus JP · Playworks USA · Samsung, KR · Siemens DE, DK · SonyEricsson SE · Sony JP, USA · Sun Microsystems USA · VDO DE · Vertu UK · Villeroy+Boch LU, DE · Walt Disney USA
Research · BAM DE · EPFL Lausanne CH · ETH Zürich CH · Forschungszentrum Karlsruhe DE · Fraunhofer DE · GKSS Geestacht DE · Imperial College UK · Int. Automotive Research Centre, UK · Istanbul Technical University TR · IUC SE · Kaitech KR · KTH SE · KU Leuven BE · Laurence Livermore National Labs USA · Max Plank Institute DE · Nagasaki Industrial Research Center JP · Naval Research Lab USA · Nottingham University UK · PCC Leoben AT · Queen Mary College UK · RWTH Aachen DE · Sandia National Lab USA · Shenyang Aircraft Research Inst CN · TU Delft NL · TU Dresden DE · TU Eindhoven NL · TU Graz AT · TU München DE · Uni Padova IT · US Army Research Lab USA · Warwick University UK
GOM Customers (Extract)
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The Use of Optical Metrology in the Aerospace Industry GOM
GOM – Industrial 3D Measuring Techniques Measurement systems
· Material Testing · 3D Coordinate Measurement · Component Testing
ATOS
ATOS ScanBox
TRITOP
ARAMIS
PONTOS
PONTOS
ARAMIS
TRITOP ARGUS
Viewing and evaluation software
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The Use of Optical Metrology in the Aerospace Industry GOM
GOM – Industrial 3D Measuring Techniques Measurement systems
Full-field 3D Digitizing
ATOS
3D Shape and Dimension Inspection
Material Testing
Dynamic Component Testing
Full-field 3D Strain Measurement
ARAMIS
Deformation Analysis in Sheet Metal Forming
ARGUS
Mobile Optical CMM
TRITOP
Dynamic 3D Analysis
PONTOS
Measurement Systems Overview
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The Use of Optical Metrology in the Aerospace Industry GOM
ATOS 3D Surface Measurement
· Static measurements of any 3D geometry / surface
· Full-field component measurement · Inspection / GD&T ·Quality control · Reverse engineering / design · Rapid manufacturing
· Evaluation in
· Injection molding und plastics industry · Sheet metal and forming industry · Casting industry · Tooling and molding
3D Digitizing
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The Use of Optical Metrology in the Aerospace Industry GOM
· Complete 3D measuring machine in two light weight cases
· 100% mobile ·Minimal hardware efforts
· Non-contact
· No contact of the object during the measurement
· High accuracy
· No wear and tear elements · No decrease of the accuracy
· Easy handling
· Flexible measuring system · Independent of environmental influences (climate chamber, outdoor)
TRITOP Optical 3D Coordinate Measurement Machine
Optical CMM
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ARAMIS Material- and Component Testing
· 3D deformation measurement
· Determination of material properties · Component testing
· Flexibility for all applications · Standard applications, e.g. tensile tests, … · High temperature measurements · High speed measurements · Validation of FE simulation · Real-Time measurements
· Integration in existing testing environment · Tensile testing devices, load frames, … · Replacement for extensometers and strain gauges
3D Deformation Analysis
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The Use of Optical Metrology in the Aerospace Industry GOM
PONTOS Dynamic Deformation Analysis
· Dynamic deformation analysis · Deformation (Torsion, bending, displacement, etc.)
· Velocity · Acceleration · Analysis of vibration
· Dynamic behavior of components, e.g.
· Deformation in wind tunnel · Drop tests · Crash tests · Structural vibrations
Dynamic Analysis of 3D Coordinates
Numerical Simulations
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The Use of Optical Metrology in the Aerospace Industry GOM
Verification of Numerical Simulations
· Numerical simulations are today widely used in the development of aerospace components
Finite Element Simulation vs. ARAMIS Measurement
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Verification of Numerical Simulations
· Numerical simulations are today widely used in the development of aerospace components
· Optical metrology supports the setup, verification and optimization of numerical simulations
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The Use of Optical Metrology in the Aerospace Industry GOM
Verification of Numerical Simulations
· Numerical simulations are today widely used in the development of aerospace components
· Optical metrology supports the setup, verification and optimization of numerical simulations
· 3D shape measurements · Input geometry · Position and shape verification
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The Use of Optical Metrology in the Aerospace Industry GOM
Verification of Numerical Simulations
· Numerical simulations are today widely used in the development of aerospace components
· Optical metrology supports the setup, verification and optimization of numerical simulations
· 3D shape measurements · Input geometry · Position and shape verification
· 3D deformation measurements
· Material parameters · Boundary conditions · Verification of
· Position · Shape · Displacement / deformation · Strain
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Verification of Numerical Simulations
· Application webinar „Verification of Numerical Simulations“
· https://support.gom.com/x/0gkwAQ
3D Digitizing Quality Control
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The Use of Optical Metrology in the Aerospace Industry GOM
CNC Processing
Data for following processes
Quality Control
Rapid Manufacturing
Reverse Engineering
High-quality 3D mesh (STL) · High resolution for finest details · Measurement of small radii
Full-field 3D Coordinate Measurement Applications
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Full-field 3D Coordinate Measurement Control of Shape and Dimensions - Trend analysis
Production & wear monitoring · Determination of process capability · Identification of part and tool wear trends · Repair & maintenance
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Full-field 3D Coordinate Measurement Inspection of Airfoil Properties
· Max. profile thickness, centroid, mean line,…
· Twist analysis, leading & trailing edge points,…
· Flow inlet & exit angle, chord line with stagger angle,…
· …and user defined inspection principles
3D Digitizing Reverse Engineering
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Reverse Engineering Black Hawk Upgrade Program
· Black Hawk upgrade program of the Australian Army for electronics upgrades
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Reverse Engineering Black Hawk Upgrade Program
· Black Hawk upgrade program of the Australian Army for electronics upgrades
· Due to the age of helicopters the existing CAD models were too inaccurate to plan the integration of the new equipment
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Reverse Engineering Black Hawk Upgrade Program
· Black Hawk upgrade program of the Australian Army for electronics upgrades
· Due to the age of helicopters the existing CAD models were too inaccurate to plan the integration of the new equipment
· Objectives:
·Measure the external airframe and produce 3D scan data to within an accuracy of 0.1 mm
·Measure certain internal and external areas of interest to the same accuracy
· Produce an integrated set of data within the same coordinate frame work
·Model the aircraft using the scan data and produce an integrated 3D model for CAD analysis
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Reverse Engineering Black Hawk Upgrade Program
· Measurement of external airframe
· 3D coordinates evaluated with Photrogrammetry (TRITOP)
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The Use of Optical Metrology in the Aerospace Industry GOM
Reverse Engineering Black Hawk Upgrade Program
· Measurement of external airframe
· 3D coordinates evaluated with Photrogrammetry (TRITOP)
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Reverse Engineering Black Hawk Upgrade Program
· Measurement of internal and external areas of interest
· Digitizing with the ATOS system using the external airframe measurement from TRITOP as reference
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The Use of Optical Metrology in the Aerospace Industry GOM
Reverse Engineering Black Hawk Upgrade Program
· Coordinate frame work alignment and CAD model generation
Applications in Aerospace Testing
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Optical 3D Metrology In Aerospace Testing and Engineering
Image by courtesy of the NLR, Netherlands
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Optical 3D Metrology In Aerospace Testing and Engineering
· Material Research
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The Use of Optical Metrology in the Aerospace Industry GOM
Optical 3D Metrology In Aerospace Testing and Engineering
· Elements / Structural Details
· Material Research
Image by courtesy of the NLR, Netherlands
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Optical 3D Metrology In Aerospace Testing and Engineering
· Sub-Components
· Elements / Structural Details
· Material Research
Image by courtesy of the NLR, Netherlands
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Optical 3D Metrology In Aerospace Testing and Engineering
· Full Components
· Sub-Components
· Elements / Structural Details
· Material Research
Image by courtesy of the NLR, Netherlands
Material Testing Application Tensile Test
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Material Testing Tensile Test
· Material testing with ARAMIS
· Tensile tests
· Full-field strain evaluation
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Material Testing Tensile Test
· Material testing with ARAMIS
· Tensile tests
· Full-field strain evaluation
· Stress-strain curves
· Engineering stress
· True stress
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Material Testing Tensile Test
· Material testing with ARAMIS
· Tensile tests
· Full-field strain evaluation
· Stress-strain curves
· Young‘s modulus
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Material Testing Tensile Test
· Material testing with ARAMIS
· Tensile tests
· Full-field strain evaluation
· Stress-strain curves
· Young‘s modulus
· Yield strength
· Tensile strength
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Material Testing Tensile Test
· Material testing with ARAMIS
· Tensile tests
· Full-field strain evaluation
· Stress-strain curves
· Young‘s modulus
· Yield strength
· Tensile strength
· Poisson‘s ratio
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Material Testing Tensile Test
· Material testing with ARAMIS
· Tensile tests
· Full-field strain evaluation
· Stress-strain curves
· Young‘s modulus
· Yield strength
· Tensile strength
· Poisson‘s ratio
· Metals: R-value and N-value
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Material Testing Applications in Material Testing
· Material testing with ARAMIS
· Tensile tests
· Shear tests
· 3-point / 4-point bending tests
· Torsion tests
· Fatigue tests
·…
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Material Testing Applications in Material Testing
· Material testing with ARAMIS
· Tensile tests
· Shear tests
· 3-point / 4-point bending tests
· Torsion tests
· Fatigue tests
·…
· For the determination of material parameters and the development of accurate material models
Element / Structural Details and Sub-Component Testing
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Element and Sub-Component Testing Verification of Numerical Simulations
· Element / structural details and sub-component testing
·Measurement of structural details
Images and results by courtesy of the NLR, Netherlands
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Element and Sub-Component Testing Verification of Numerical Simulations
· Element / structural details and sub-component testing
·Measurement of structural details
Images and results by courtesy of the NLR, Netherlands
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The Use of Optical Metrology in the Aerospace Industry GOM
Element and Sub-Component Testing Verification of Numerical Simulations
· Element / structural details and sub-component testing
·Measurement of structural details
Images and results by courtesy of the NLR, Netherlands
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Element and Sub-Component Testing Verification of Numerical Simulations
· Element / structural details and sub-component testing
·Measurement of structural details
Images and results by courtesy of the NLR, Netherlands
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Element and Sub-Component Testing Verification of Numerical Simulations
· Element / structural details and sub-component testing
·Measurement of structural details
· Full field deformation analysis with ARAMIS
Images and results by courtesy of the NLR, Netherlands
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Element and Sub-Component Testing Verification of Numerical Simulations
· Element / structural details and sub-component testing
·Measurement of structural details
· Full field deformation analysis with ARAMIS
· Verification of numerical simulations
Images and results by courtesy of the NLR, Netherlands
Element / Structural Details and Sub-Component Testing Connections - Rivets
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Element and Sub-Component Testing Connections - Rivets
· Element / structural details and sub-component testing
· Evaluation of rivet connections
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The Use of Optical Metrology in the Aerospace Industry GOM
Element and Sub-Component Testing Connections - Rivets
· Element / structural details and sub-component testing
· Evaluation of rivet connections
· The evaluation of load over time shows that at 280s the load drops due to rivet failure
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
Page 55
Page 55
The Use of Optical Metrology in the Aerospace Industry GOM
Element and Sub-Component Testing Connections - Rivets
· Element / structural details and sub-component testing
· Evaluation of rivet connections
· The evaluation of load over time shows that at 280s the load drops due to rivet failure
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
Page 56
Page 56
The Use of Optical Metrology in the Aerospace Industry GOM
Element and Sub-Component Testing Connections - Rivets
· Element / structural details and sub-component testing
· Evaluation of rivet connections
· The evaluation of load over time shows that at 280s the load drops due to rivet failure
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
Page 57
Page 57
The Use of Optical Metrology in the Aerospace Industry GOM
Element and Sub-Component Testing Connections - Rivets
· Element / structural details and sub-component testing
· Evaluation of rivet connections
· The evaluation of load over time shows that at 280s the load drops due to rivet failure
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
Page 58
Page 58
The Use of Optical Metrology in the Aerospace Industry GOM
Element and Sub-Component Testing Connections - Rivets
· Element / structural details and sub-component testing
· Evaluation of rivet connections
· The evaluation of load over time shows that at 280s the load drops due to rivet failure
·Major strain evaluation
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
Page 59
Page 59
The Use of Optical Metrology in the Aerospace Industry GOM
Element and Sub-Component Testing Connections - Rivets
· Element / structural details and sub-component testing
· Evaluation of rivet connections
· The evaluation of load over time shows that at 280s the load drops due to rivet failure
·Major strain evaluation
· Time of rivet failure
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
Page 60
Page 60
The Use of Optical Metrology in the Aerospace Industry GOM
Element and Sub-Component Testing Connections - Rivets
· Element / structural details and sub-component testing
· Evaluation of rivet connections
· The evaluation of load over time shows that at 280s the load drops due to rivet failure
·Major strain evaluation
· Time of rivet failure
· Maximum strain directions visualized for the area of the three rivets on the top left
Element / Structural Details and Sub-Component Testing Shear Panel Testing
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
Page 62
Page 62
The Use of Optical Metrology in the Aerospace Industry GOM
Element and Sub-Component Testing Shear Panel Testing
· Element / structural details and sub-component testing
·Measurement of sub-components
Images and results by courtesy of IMA Dresden
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
Page 63
Page 63
The Use of Optical Metrology in the Aerospace Industry GOM
Element and Sub-Component Testing Shear Panel Testing
· Element / structural details and sub-component testing
·Measurement of sub-components
· Testing of panels under shear load for the verification of numerical simulations
Images and results by courtesy of IMA Dresden
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
Page 64
Page 64
The Use of Optical Metrology in the Aerospace Industry GOM
Element and Sub-Component Testing Shear Panel Testing
· Element / structural details and sub-component testing
·Measurement of sub-components
· Testing of panels under shear load for the verification of numerical simulations
· Shear panel testing demonstrator
Images and results by courtesy of IMA Dresden
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
Page 65
Page 65
The Use of Optical Metrology in the Aerospace Industry GOM
Element and Sub-Component Testing Shear Panel Testing
· Element / structural details and sub-component testing
·Measurement of sub-components
· Testing of panels under shear load for the verification of numerical simulations
· Shear panel testing demonstrator
· Result from numerical simulation · Out-of-plane displacement (buckling)
Finite element simulation – Out-of-plane displacement
Images and results by courtesy of IMA Dresden
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
Page 66
Page 66
The Use of Optical Metrology in the Aerospace Industry GOM
Element and Sub-Component Testing Shear Panel Testing
· Element / structural details and sub-component testing
·Measurement of sub-components
· Testing of panels under shear load for the verification of numerical simulations
· Shear panel testing demonstrator
· Result from numerical simulation · Out-of-plane displacement (buckling)
· Full-field measurement results
· Out-of-plane displacement (buckling) aligned to CAD data set
Finite element simulation – Out-of-plane displacement
ARAMIS measurement result – Out-of-plane displacement
Images and results by courtesy of IMA Dresden
Element / Structural Details and Sub-Component Testing Rotor Blade Bending Test
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
Page 68
Page 68
The Use of Optical Metrology in the Aerospace Industry GOM
Element and Sub-Component Testing Rotor Blade Bending Test
· Helicopter drone rotor blade
· Blade length: 1540 mm
· CFRP composite rotor
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
Page 69
Page 69
The Use of Optical Metrology in the Aerospace Industry GOM
Element and Sub-Component Testing Rotor Blade Bending Test
· Helicopter drone rotor blade
· Blade length: 1540 mm
· CFRP composite rotor
· Objectives
· Verification of strain gauge positions derived from numerical simulation
Strain gauges
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
Page 70
Page 70
The Use of Optical Metrology in the Aerospace Industry GOM
Element and Sub-Component Testing Rotor Blade Bending Test
· Helicopter drone rotor blade
· Blade length: 1540 mm
· CFRP composite rotor
· Objectives
· Verification of strain gauge positions derived from numerical simulation
· Verification of the numerical simulation
Strain gauges
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
Page 71
Page 71
The Use of Optical Metrology in the Aerospace Industry GOM
Element and Sub-Component Testing Rotor Blade Bending Test
· Helicopter drone rotor blade
· Blade length: 1540 mm
· CFRP composite rotor
· Objectives
· Verification of strain gauge positions derived from numerical simulation
· Verification of the numerical simulation
· Replacing strain gauges with optical measuring system ARAMIS
Strain gauges
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
Page 72
Page 72
The Use of Optical Metrology in the Aerospace Industry GOM
Element and Sub-Component Testing Rotor Blade Bending Test
· Helicopter drone rotor blade
· Blade length: 1540 mm ·CFRP composite rotor
Strain gauges
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
Page 73
Page 73
The Use of Optical Metrology in the Aerospace Industry GOM
Element and Sub-Component Testing Rotor Blade Bending Test
· Helicopter drone rotor blade
· Blade length: 1540 mm ·CFRP composite rotor
· Full-field strain evaluation in Y-direction of coordinate system
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
Page 74
Page 74
The Use of Optical Metrology in the Aerospace Industry GOM
Element and Sub-Component Testing Rotor Blade Bending Test
· Helicopter drone rotor blade
· Blade length: 1540 mm ·CFRP composite rotor
· Full-field strain evaluation in Y-direction of coordinate system
· Strain gauge are not positioned in maximum strain areas
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
Page 75
Page 75
The Use of Optical Metrology in the Aerospace Industry GOM
Element and Sub-Component Testing Rotor Blade Bending Test
· Helicopter drone rotor blade
· Blade length: 1540 mm ·CFRP composite rotor
· Full-field strain evaluation in X-direction of coordinate system
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
Page 76
Page 76
The Use of Optical Metrology in the Aerospace Industry GOM
Element and Sub-Component Testing Rotor Blade Bending Test
· Helicopter drone rotor blade
· Blade length: 1540 mm ·CFRP composite rotor
· Full-field strain evaluation in X-direction of coordinate system
· Non homogeneous strain distribution in root area of the rotor blade
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
Page 77
Page 77
The Use of Optical Metrology in the Aerospace Industry GOM
Element and Sub-Component Testing Rotor Blade Bending Test
· Helicopter drone rotor blade
· Strain gauge positioned to measure in X-direction
· Comparison ARAMIS against strain gauges
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
Page 78
Page 78
The Use of Optical Metrology in the Aerospace Industry GOM
Element and Sub-Component Testing Rotor Blade Bending Test
· Further investigation focused on root area to provide a better local resolution of the measurement results
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
Page 79
Page 79
The Use of Optical Metrology in the Aerospace Industry GOM
Element and Sub-Component Testing Rotor Blade Bending Test
· Further investigation focused on root area to provide a better local resolution of the measurement results
· Strain in X-direction
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
Page 80
Page 80
The Use of Optical Metrology in the Aerospace Industry GOM
Element and Sub-Component Testing Rotor Blade Bending Test
· Further investigation focused on root area to provide a better local resolution of the measurement results
· Strain in X-direction
· Non homogeneous local deformation behavior
· Strain gauge was positioned next to maximum strain area
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
Page 81
Page 81
The Use of Optical Metrology in the Aerospace Industry GOM
Element and Sub-Component Testing Rotor Blade Bending Test
· Further investigation focused on root area to provide a better local resolution of the measurement results
· Strain in X-direction
· Comparison of strain gauge measurements with ARAMIS point-wise results
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
Page 82
Page 82
The Use of Optical Metrology in the Aerospace Industry GOM
Element and Sub-Component Testing Rotor Blade Bending Test
· Further investigation focused on root area to provide a better local resolution of the measurement results
· Evaluation of principle strain (Major Strain)
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
Page 83
Page 83
The Use of Optical Metrology in the Aerospace Industry GOM
Element and Sub-Component Testing Rotor Blade Bending Test
· Further investigation focused on root area to provide a better local resolution of the measurement results
· Evaluation of principle strain (Minor Strain)
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
Page 84
Page 84
The Use of Optical Metrology in the Aerospace Industry GOM
Element and Sub-Component Testing Rotor Blade Bending Test
· Comparison of results from numerical simulation and ARAMIS measurement
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
Page 85
Page 85
The Use of Optical Metrology in the Aerospace Industry GOM
Element and Sub-Component Testing Rotor Blade Bending Test
· Why using ARAMIS?
· Replacement of strain gauges · Time and cost saving · With ARAMIS there is no need to know where to measure
· Full-field verification of numerical simulations
· ARAMIS delivers in addition to the strain values 3D coordinates (shape) and 3D displacements (3D motion) at the same time
3D Shape
Strain
Displacement
Component Testing Wind Tunnel Testing with Delta Wing Model
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
Page 87
Page 87
The Use of Optical Metrology in the Aerospace Industry GOM
Component Testing Deformation Measurement in Wind Tunnel
· Delta wing aircraft model
·Measurements at a speed of Mach 0.8 for the analysis of the wing deformation with different angles of attack towards the air flowing direction
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
Page 88
Page 88
The Use of Optical Metrology in the Aerospace Industry GOM
Component Testing Deformation Measurement in Wind Tunnel
· Delta wing aircraft model
·Measurements at a speed of Mach 0.8 for the analysis of the wing deformation with different angles of attack towards the air flowing direction
· The measurement is carried out in a wind tunnel, thus the optical measuring system is positioned in front of a windows recording images through the glass window
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
Page 89
Page 89
The Use of Optical Metrology in the Aerospace Industry GOM
Component Testing Deformation Measurement in Wind Tunnel
· Delta wing aircraft model
·Measurements at a speed of Mach 0.8 for the analysis of the wing deformation with different angles of attack towards the air flowing direction
· The measurement is carried out in a wind tunnel, thus the optical measuring system is positioned in front of a windows recording images through the glass window
· Point-wise evaluation of the wing tip deflection
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
Page 90
Page 90
The Use of Optical Metrology in the Aerospace Industry GOM
Component Testing Deformation Measurement in Wind Tunnel
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
Page 91
Page 91
The Use of Optical Metrology in the Aerospace Industry GOM
Component Testing Deformation Measurement in Wind Tunnel
· Delta wing aircraft model
· Point group (component) definition over markers attached to hull and both wings 3D coordinates are calculated from the attached measurement markers
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
Page 92
Page 92
The Use of Optical Metrology in the Aerospace Industry GOM
Component Testing Deformation Measurement in Wind Tunnel
· Delta wing aircraft model
· Point group (component) definition over markers attached to hull and both wings 3D coordinates are calculated from the attached measurement markers
· Coordinate system alignment · X-direction: Direction of air flow · Y-direction: Left to right wing · Z-direction: Hull in viewing direction
X
Y
Z
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
Page 93
Page 93
The Use of Optical Metrology in the Aerospace Industry GOM
Component Testing Deformation Measurement in Wind Tunnel
· Delta wing aircraft model
· Point group (component) definition over markers attached to hull and both wings 3D coordinates are calculated from the attached measurement markers
· Coordinate system alignment · X-direction: Direction of air flow · Y-direction: Left to right wing · Z-direction: Hull in viewing direction
· To calculate only the wing tip deflection relatively to the hull a rigid body motion compensation is calculated using the 3D coordinates derived from the markers positioned on the hull
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
Page 94
Page 94
The Use of Optical Metrology in the Aerospace Industry GOM
Component Testing Deformation Measurement in Wind Tunnel
· Delta wing aircraft model
· Deflection of the wing tips relatively to the hull
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
Page 95
Page 95
The Use of Optical Metrology in the Aerospace Industry GOM
Component Testing Deformation Measurement in Wind Tunnel
· Delta wing aircraft model
· Deflection of the wing tips relatively to the hull
Component Testing Aerodynamic Testing of Sample Return Capsule in Wind Tunnel
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
Page 97
Page 97
The Use of Optical Metrology in the Aerospace Industry GOM
Component Testing Aerodynamics of Sample Return Capsule
· Devices to return rock or dust samples from space are so called sample return capsules
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
Page 98
Page 98
The Use of Optical Metrology in the Aerospace Industry GOM
Component Testing Aerodynamics of Sample Return Capsule
· Devices to return rock or dust samples from space are so called sample return capsules
· Return capsules are designed to protect a sample container, which is stored inside the capsule, from the extreme heat produced during the re-entry into the atmosphere
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
Page 99
Page 99
The Use of Optical Metrology in the Aerospace Industry GOM
Component Testing Aerodynamics of Sample Return Capsule
· Devices to return rock or dust samples from space are so called sample return capsules
· Return capsules are designed to protect a sample container, which is stored inside the capsule, from the extreme heat produced during the re-entry into the atmosphere
· The return velocity of approximately 45000 km/h (13 km/s) must be drastically reduced before the capsule enters lower layers of the atmosphere to prevent overheating
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
Page 100
Page 100
The Use of Optical Metrology in the Aerospace Industry GOM
Component Testing Aerodynamics of Sample Return Capsule
· Devices to return rock or dust samples from space are so called sample return capsules
· Return capsules are designed to protect a sample container, which is stored inside the capsule, from the extreme heat produced during the re-entry into the atmosphere
· The return velocity of approximately 45000 km/h (13 km/s) must be drastically reduced before the capsule enters lower layers of the atmosphere to prevent overheating
· A blunt geometry of the capsule is thus mandatory to produce enough resistance for velocity reduction in higher atmosphere layers
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
Page 101
Page 101
The Use of Optical Metrology in the Aerospace Industry GOM
Component Testing Aerodynamics of Sample Return Capsule
· Devices to return rock or dust samples from space are so called sample return capsules
· Return capsules are designed to protect a sample container, which is stored inside the capsule, from the extreme heat produced during the re-entry into the atmosphere
· The return velocity of approximately 45000 km/h (13 km/s) must be drastically reduced before the capsule enters lower layers of the atmosphere to prevent overheating
· A blunt geometry of the capsule is thus mandatory to produce enough resistance for velocity reduction in higher atmosphere layers
· Blunt geometries are tending to be aerodynamically instable and are starting to swing, especially when decelerated to the speed of sound and below
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
Page 102
Page 102
The Use of Optical Metrology in the Aerospace Industry GOM
Component Testing Aerodynamics of Sample Return Capsule
· The use of parachutes was not considered due to the complexity and costs of the capsule
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
Page 103
Page 103
The Use of Optical Metrology in the Aerospace Industry GOM
Component Testing Aerodynamics of Sample Return Capsule
· The use of parachutes was not considered due to the complexity and costs of the capsule
· To protect the sample container the capsule must not impact the ground with the top face and must stay within a specific angle from the trim position
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
Page 104
Page 104
The Use of Optical Metrology in the Aerospace Industry GOM
Component Testing Aerodynamics of Sample Return Capsule
· The use of parachutes was not considered due to the complexity and costs of the capsule
· To protect the sample container the capsule must not impact the ground with the top face and must stay within a specific angle from the trim position
· To evaluate the aerodynamic behavior different capsules were tested in the vertical wind tunnel at the DLR in Köln
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
Page 105
Page 105
The Use of Optical Metrology in the Aerospace Industry GOM
Component Testing Aerodynamics of Sample Return Capsule
· Aerodynamic behavior of capsule in vertical wind tunnel at free fall conditions before impact
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
Page 106
Page 106
The Use of Optical Metrology in the Aerospace Industry GOM
Component Testing Aerodynamics of Sample Return Capsule
· Aerodynamic behavior of capsule in vertical wind tunnel at free fall conditions before impact
· The possible rigid body motion of the used stereo camera sensor inside the wind tunnel is compensated using 3D measurement points from the nozzle (green points)
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
Page 107
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The Use of Optical Metrology in the Aerospace Industry GOM
Component Testing Aerodynamics of Sample Return Capsule
· Aerodynamic behavior of capsule in vertical wind tunnel at free fall conditions before impact
· The possible rigid body motion of the used stereo camera sensor inside the wind tunnel is compensated using 3D measurement points from the nozzle (green points)
· The 3D coordinate system alignment is done with a coordinate alignment to the CAD data set of the nozzle
· Y-axis in flow direction
· For visualization purposes the CAD data set from the capsule is additionally imported into the measuring project
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
Page 108
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The Use of Optical Metrology in the Aerospace Industry GOM
Component Testing Aerodynamics of Sample Return Capsule
· Capsule motion in 3D space
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
Page 109
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The Use of Optical Metrology in the Aerospace Industry GOM
Component Testing Aerodynamics of Sample Return Capsule
· Capsule motion in 3D space
· 6 degree of freedom analysis
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
Page 110
Page 110
The Use of Optical Metrology in the Aerospace Industry GOM
Component Testing Aerodynamics of Sample Return Capsule
· Capsule motion in 3D space
· 6 degree of freedom analysis
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
Page 111
Page 111
The Use of Optical Metrology in the Aerospace Industry GOM
Component Testing Aerodynamics of Sample Return Capsule
· Capsule motion in 3D space
· 6 degree of freedom analysis
· Trajectory from capsule center point in the first 5 seconds of the test
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
Page 112
Page 112
The Use of Optical Metrology in the Aerospace Industry GOM
Component Testing Aerodynamics of Sample Return Capsule
· Capsule motion in 3D space
· 6 degree of freedom analysis
· Trajectory from capsule center point in the first 5 seconds of the test
· Displacement Y over displacement X
Vibration Measurement Ground Vibration Testing with Full Scale Aircraft
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
Page 114
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The Use of Optical Metrology in the Aerospace Industry GOM
Structural Vibration Analysis Ground Vibration Test on Aircraft
· Structural vibration analysis of an aircraft
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
Page 115
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The Use of Optical Metrology in the Aerospace Industry GOM
Structural Vibration Analysis Ground Vibration Test on Aircraft
· Structural vibration analysis of an aircraft
· Controlled excitation at nose and wing tip using a white noise within 5Hz – 35 Hz
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
Page 116
Page 116
The Use of Optical Metrology in the Aerospace Industry GOM
Structural Vibration Analysis Ground Vibration Test on Aircraft
· Structural vibration analysis of an aircraft
· Controlled excitation at nose and wing tip using a white noise within 5Hz – 35 Hz
· Objectives:
· Modal analysis of one wing
· Comparison with traditional accelerometer measurement system
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
Page 117
Page 117
The Use of Optical Metrology in the Aerospace Industry GOM
Structural Vibration Analysis Ground Vibration Test on Aircraft
· Measurement preparation for the accelerometer measurement system
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
Page 118
Page 118
The Use of Optical Metrology in the Aerospace Industry GOM
Structural Vibration Analysis Ground Vibration Test on Aircraft
· Measurement preparation for the accelerometer measurement system
·Mounting and wiring of individual accelerometers
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
Page 119
Page 119
The Use of Optical Metrology in the Aerospace Industry GOM
Structural Vibration Analysis Ground Vibration Test on Aircraft
· Measurement preparation for the accelerometer measurement system
·Mounting and wiring of individual accelerometers
· Connecting amplifiers and data loggers
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
Page 120
Page 120
The Use of Optical Metrology in the Aerospace Industry GOM
Structural Vibration Analysis Ground Vibration Test on Aircraft
· Measurement preparation for the accelerometer measurement system
·Mounting and wiring of individual accelerometers
· Connecting amplifiers and data loggers
· Calibration of each individual accelerometer
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
Page 121
Page 121
The Use of Optical Metrology in the Aerospace Industry GOM
Structural Vibration Analysis Ground Vibration Test on Aircraft
· Measurement preparation for the optical point-wise measurement using PONTOS
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
Page 122
Page 122
The Use of Optical Metrology in the Aerospace Industry GOM
Structural Vibration Analysis Ground Vibration Test on Aircraft
· Measurement preparation for the optical point-wise measurement using PONTOS
· Application of ultra light-weight self-adhesive measurement markers
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
Page 123
Page 123
The Use of Optical Metrology in the Aerospace Industry GOM
Structural Vibration Analysis Ground Vibration Test on Aircraft
· Measurement preparation for the optical point-wise measurement using PONTOS
· Application of ultra light-weight self-adhesive measurement markers
· Optical stereo camera sensor calibration and positioning
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
Page 124
Page 124
The Use of Optical Metrology in the Aerospace Industry GOM
Structural Vibration Analysis Ground Vibration Test on Aircraft
· Measurement preparation for the optical point-wise measurement using PONTOS
· Application of ultra light-weight self-adhesive measurement markers
· Optical stereo camera sensor calibration and positioning
· Coordinate system transformation for result evaluation
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
Page 125
Page 125
The Use of Optical Metrology in the Aerospace Industry GOM
Structural Vibration Analysis Ground Vibration Test on Aircraft
· Measurement preparation for the optical point-wise measurement using PONTOS
· Application of ultra light-weight self-adhesive measurement markers
· Optical stereo camera sensor calibration and positioning
· Coordinate system transformation for result evaluation
· 3D coordinate measurement during the structural vibration test
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
Page 126
Page 126
The Use of Optical Metrology in the Aerospace Industry GOM
Structural Vibration Analysis Ground Vibration Test on Aircraft
· Measurement preparation for the optical point-wise measurement using PONTOS
· Application of ultra light-weight self-adhesive measurement markers
· Optical stereo camera sensor calibration and positioning
· Coordinate system transformation for result evaluation
· 3D coordinate measurement during the structural vibration test
· Data export in Universal File Format (UFF) for further modal analysis in e.g. ME’Scope, LMS, Matlab, etc.
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
Page 127
Page 127
The Use of Optical Metrology in the Aerospace Industry GOM
Structural Vibration Analysis Ground Vibration Test on Aircraft
· Modal evaluation of structural vibration test
· Amplitude frequency response curves for the evaluation in Z-direction with different excitation at nose and wing
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
Page 128
Page 128
The Use of Optical Metrology in the Aerospace Industry GOM
Structural Vibration Analysis Ground Vibration Test on Aircraft
· Modal evaluation of structural vibration test
· Amplitude frequency response curves for the evaluation in Z-direction with different excitation at nose and wing
· Further evaluation and visualization is carried out using third party software packages
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
Page 129
Page 129
The Use of Optical Metrology in the Aerospace Industry GOM
Structural Vibration Analysis Ground Vibration Test on Aircraft
· Comparison to accelerometer measurements
· Very good correlation of the optical measurement results to the accelerometer measurements
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
Page 130
Page 130
The Use of Optical Metrology in the Aerospace Industry GOM
Structural Vibration Analysis Ground Vibration Test on Aircraft
· Comparison to accelerometer measurements
· Very good correlation of the optical measurement results to the accelerometer measurements
· Point N136 shows a larger deviation which occurred due to a not perfectly mounted accelerometer
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
Page 131
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The Use of Optical Metrology in the Aerospace Industry GOM
Structural Vibration Analysis Ground Vibration Test on Aircraft
· Summary
· Fast test object preparation and system setup
· Fast calibration of the measurement system
· There is no need to calibrate each individual measurement point for each direction
· No influence on the test object from the measurement markers
· Useful extension to existing measuring setups
· Time and money saving for structural testing
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
2-Frame Setup / Frame 2 2-Frame Setup / Frame 1
3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3
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The Use of Optical Metrology in the Aerospace Industry GOM
Optical 3D Metrology In Aerospace Testing and Engineering
· Full Components
· Sub-Components
· Elements / Structural Details
· Material Research
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