Non-Contact Laser Device for Fastener Feature Measurement to Save Costs

The goal of this project was to develop a non-contact laser measurement device for measurement of surface feature flushness on the aircraft production floor. The first step consisted of developing a full set of requirements for a production device. Those requirements were then used to establish initial system parameters and component selection. Module level testing was used to verify that the components selected and the initial algorithms met the requirements set forth. Upon successful completion of module level testing, the full system was developed and tested. Testing of the full-scale system initially consisted of lab scale use and culminated in testing on the aircraft production floor. The final task consisted of manufacturing analysis and planning for the handheld scanner. The system was designed to measure the specific surface feature relative to the profile of the outer skin of the aircraft.

This system improves upon current surface measurement processes in terms of measurement quality and measurement time. Previously, only a couple of points on the surface feature were measured, while this system provides the capability to measure the entire surface of the feature of interest. Additionally, the previous system was highly dependent upon operator skill whereas this new system fully characterizes the surface feature without dependence on operator skill, producing a more accurate and repeatable measurement. Upon full implementation, this technology is estimated to result in a total cost savings of over $13M. Finally, the technology developed on this program can be transitioned to other measurement applications providing for an additional estimated cost savings of $13.2M.

The necessary steps were taken to ensure that a low-cost method of surface feature measurement was demonstrated that met the requirements of the program and was safe for operator use. A fully functional measurement hand tool was built and proven on production-equivalent aircraft parts. In addition, the cost benefits of adopting the technology on the production floor were quantified via (1) a refined estimate of inspection time and cost savings per aircraft, (2) pricing analysis for the FMT, and (3) evaluation of additional benefits provided by the technology. Implementation is expected late FY16.

*Prepared under ONR Contract xxxxxx-xx-x-xxxx as part of the Navy ManTech Program.

*DISTRIBUTION STATEMENT A. Approved for public release: distribution unlimited. DCN# xxxx-xxx-xx