To address the Air Force need for automated, affordable, accurate dimensional control of aircraft outer mold line (OML) structures, RAN Science & Technology, LLC, proposes to develop an innovative Optical Assembly Control (OAC) system. The OAC will offer precise metrology of assembly units, such as frame and skins, including both metal and composite parts, and compare these measurements to the CATIA CAD file. This information will be used to define and locate shims and project the information on the assembly, resulting in highly accurate assembly guidance together with digital storage of the metrology, "as-built" vs. "as-designed" information, recommended shim thickness and locations, and trend analysis of the differences. The OAC will store this information in a shared database that is compatible with InfinityQS and similar analysis systems, and can be accessed for statistical process control. Its touch-screen user interface will be intuitive and powerful, with all normal applications accessible with no more than three taps. During Phase I, we will design the hardware and specify the software and develop a preliminary manufacturing plan for the OAC. We will perform a demonstration of the breadboard in a relevant manufacturing environment, resulting in a system TRL 5 with susbsystems at TRL 6-8, and demonstrate the manufacturability of the device in our laboratory (MRL 4). During Phase II we will improve the OAC to a full production prototype, include the operation and interface software needed for ease of use, package it as a monolithic system, and demonstrate it at an aircraft manufacturing facility (TRL 7).
Benefit: When complete, the OAC will be a major step forward in automation of advanced, multipart vehicle assembly. The increased rate of vehicle assembly enabled by the OAC, together with its inherent error rate reduction, will improve the manufacturing efficiency of virtually all multipart systems, including commercial aircraft, high-performance boats, and automobiles.
Keywords: Outer Mold Line Control, Automation, White Light Metrology, Automated Fit, Shim Placement, As-Built
