Product category:
Non-contact, Optical and Laser measurement systems
News Release from: Quality Gauging Systems | Subject: Laser gauge
Edited by the Manufacturingtalk Editorial
Team on 29 June 2007
Laser gauge cuts fuselage measurement
time
The LaserGauge system from Quality Gauging Systems has cut the time taken to 'simulate' the radome interface on a Eurofighter fuselage, from 2.5 hours to just 15 minutes.
A portable LaserGauge system supplied by Quality Gauging Systems (QGS) has cut the time taken to 'simulate' the radome interface in relation to two fixed skins and six panels at the front end of the Eurofighter fuselage, from 2.5 hours using the previous manual feeler gauge method, to just 15 minutes - all with increased reliability and repeatability of measurement The front fuselage of the Eurofighter, along with the associated hydraulics and electronics is assembled at the Samlesbury facility of BAE Systems in Lancashire
This article was originally published on Manufacturingtalk on 23 Jul 2007 at 8.00am (UK)
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Ensuring that the various panels and skins that constitute the fuselage will align with the radome when it is subsequently assembled at another site is of paramount importance.
To help guarantee successful assembly, BAE Systems puts its recently acquired LaserGauge to good use.
By using a co-ordinate measuring machine to record 105 points taken from a master tooling gauge produced by BAE Systems, the resulting deviations can be input into the LaserGauge software.
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The LaserGauge can then be used to effectively 'simulate' the radome and ensure the skins and panels assembled at Samlesbury are positioned correctly to assist later operations.
"Before we had LaserGauge we used manual feeler gauge methods to undertake this task," explains digital inspection engineer, Charlie Wright.
"The need to record results by hand meant the job could often take two and a half hours.
It takes around 15 minutes using LaserGauge".
Another important use for LaserGauge at Samlesbury is the accurate measurement of 'steps and gaps' between the various Eurofighter skins, panels and doors in accordance with the aerodynamic specification demanded by the customer.
These steps and gaps have various tolerances depending on the zone of the aircraft, meeting which has a significant impact on the economy of flight.
Again, the traditional measurement method was feeler gauges, but these could sometimes damage the rubber interface (PRC seal) found at the skin edge.
This proved to be the initial catalyst for seeking a non-contact form of measurement, where LaserGauge was selected from a shortlist of two.
"Originally we did our own repeatability and reproducibility checks that tell us how much tolerance the measurement method uses," explains Mr Wright.
"We found that LaserGauge came top for both accuracy and ease-of-use".
In terms of the latter, operators of the LaserGauge at BAE Systems simply place the instrument on to a step or gap and take a reading.
From here the Laser Gauge formatter is used to electronically export measurement process information (including aircraft set, inspector identification, date and measurement point label) to a MS Excel template.
This saves a considerable amount of time in comparison with feeler gauge methods.
The Excel template is then electronically archived to enable a quality audit of aircraft builds.
LaserGauge is a truly portable, PC-based or on-line system that is suitable for the measurement of various surface contour features and characteristics such as gap, flush, pitting, corrosion, wear, fastener height, weld characteristics, angles, radius of curvature and more.
Each LaserGauge system consists of a controller and a sensor.
The sensor captures the profile of a surface and transmits it to the controller for processing.
Powerful yet flexible algorithms are used to extract measurements from the digitised image.
Each model of controller and sensor has different capabilities that can be matched to fit the unique requirements of each application.
LaserGaug e can be used for many different applications because its power and flexibility is in the software.
Standard dimensional measurements are made using software algorithms called Virtual Gauges, while complex or unique measurement requirements can be automated through custom-programmed algorithms called LGBasic Algorithms.
All Virtual Gauges and LGBasic Algorithms run on all models of controller.
LaserGauge comes with non-contact stand-offs that help the user transmit measured data to the controller faster.
Each LaserGauge uses notification LEDs to let the user know if the part has been sampled and recorded correctly in the system.
The special software algorithms convert data faster than conventional algorithms, thus deceasing point-to-point collection time.
BAE Systems has found a myriad of uses for its LaserGauge - in fact it is now importing digitised scans from CATIA directly into its LaserGauge, functionality described by the company as "a real plus".
Additionally the aerospace giant is currently considering the acquisition of a lightweight controller that can be strapped to an operator's body.
This is a totally wireless controller that interfaces to a host PC running either LGWispr or LGWorks RT.
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