Improving ASIP Analysis Using Structural Data Visualization Organization and Archival Techniques

Transcription

1 Improving ASIP Analysis Using Structural Data Visualization Organization and Archival Techniques Gary Steffes AFRL/RXCA (937) Shane Paredes NAVAIR ISSC North Island (619)

2 Acknowledgements Charles Buynak (AFRL/RXCA) Steven Turek (AF Mantech) Josh Hodges (T-38 Hill AFB) Greg Ferrell, Robert Pilarczyk (A-10 Hill AFB) Chris Root, Tomas Barber (NAVAIR FRCSW) Thomas Sharp, Gary Coyan (Etegent Technologies)

3 Outline Background: Need for improved engineering analyses Analytical feature development foundation NLign software overview Engineering analyses applications USAF NAVAIR Future Directions Conclusions 3

4 Background Engineering Analysis Historical perspective Aging fleet drives increased inspection frequency and damage findings Increased repair demand necessitates a more robust evaluation tool for engineers Manual based methods are commonly being utilized to evaluate and analyze damaged components Motivation from Engineering Streamlining of workload reduces Non-Value-Added work hours and engineering Turn-Around-Time (TAT) Robust archival of previous analyses drastically reduces redundant workload Engineering man hours are free to work other high priority tasks 4

5 Analytical Feature Development Foundation Air Force SBIR-II (2007) with Etegent Technologies Executed SBIR-I plan Align NDI data to a CAD-like model of structure Facilitate communication between maintainers and engineers Navy SBIR-II (2009) with Etegent Technologies Align digital images to various models Expedite engineering evaluations and dispositions Efforts culminated in development of software called NLign Efforts continue to build a robust tool for multiple weapon systems 5

6 NLign Software - Overview Collect Organize Archive Analyze Automatically collect digital data Extract raw inspection data Extract Metainformation Align to CAD model Store to Archive Archive Reporting Visualization Trending Coverage checking Analysis integration Software organized into four modules Support both 2-D line drawings and full 3-D CAD models 6

7 Software Overview Collect-Organize-Archive-Analyze Reference Data 2D & 3D CAD FEA models Design specific models Manufacturing specific models Paper Forms Scanned Forms Smart Pens NDI Logs Machine Data Machine Tool Log files Tool Path Data Digital Images NDI C-scan Images Most standard digital cameras Other Data Legacy databases Dimensional data Process data Laptops Tablets Manual data entry Collect Automatically collect digital data 7

8 Software Overview Collect-Organize-Archive-Analyze Map ultrasound C-Scan to 3-D model with trending (colored dots) to find problem areas Map digital radiography to 2-D model with trending and show trending results (colored dots) to identify problem areas Analyze Reporting Visualization Trending Coverage checking Analysis integration Integrated reporting Tools Scatter plots Histograms Bar charts Line charts Excel Export Map eddy current C- scan to model to check for inspection coverage Repair design tool shows multiple layers of data Distribution A: Approved for public release; USAF 88ABW , NAVAIR SPR

9 USAF Integration Applications Ogden Air Logistics Complex - Hill AFB A-10 and T-38 Trending Visualization Link to maintenance data Analytical data exports

10 Data Screen Initial data sample loaded from excel spreadsheet Center wing box 147 different tail numbers Provides Three views into data 3D, Live charts and Tabular 10

11 3D View Window 3D window shows location of trendable indications Dots show location Numerals show total number of features per area Selecting dot highlights row(s) in table 11

12 Live Charts and Tabular View Customizable charting tool Charts can be configured and saved for later analyses Supports bar, clustered bar, line, scatter, and other types Table tool Provides access to detailed damage data Columns can be sorted Selecting row highlights location on model Data can be exported to Excel if needed 12

13 Visual Referencing CAD CAD Model with displayed trendables Uses same a/c coordinates Data displayed includes sources from NDI logs and AFMC 202 forms

14 Visual Referencing Tech Order Regions Separate assets can be added that correspond to Tech Order locations Built from parent CAD model and use same A/C coordinates Can be viewed as desired

15 Link Back to NDI Data 15

16 NAVAIR Integration Applications Fleet Readiness Center Southwest (North Island) Shane Paredes F-18 flight control structures Mapping Historical precedents Management Checking configuration

17 Traditionally Performed by Engineer Inspection Locate Damage on All Reference Data Look for Previous Analyses & Designs Perform Repair Analysis & Design Generate Repair Instructions Paper descriptions of damage Digital Images Mylar tracing PowerPoint files s Phone tag/discussions Ply Boundaries FEM Elements Loading Conditions Repair Zones Weight Limitations Substructure Fastener Locations Folder-based PDF Archiving To Be Performed by NLign To Be Performed by Engineer Inspection Locate Damage on All Reference Data Look for Previous Analyses & Designs Perform Repair Analysis & Design Generate Repair Instructions

18 NAVAIR Data Collection Pieces Digital Images Reference Data Finite Element Model(s) Composite Ply Geometry Standard Repair Zones Local Engineering Reference Specified Zones Data Weight Limited Areas Fastener Locations Substructure Geometry Any other 2D or 3D-Representable Data Damage extraction & mapping Archived Data Previous Damage Mappings Aircraft Specific Damages Component Specific Damages Previous Analyses & Designs Digital Images Evaluate Rapidly Evaluate Damage Condition Immediate historical knowledge Fast and Accurate assessment of damages

19 Traditional Damage Reporting System Local Reporting Hand Annotated Damage Location Drawings Less accurate Time consuming Routinely requires secondary verification by engineers Tabular Damage Descriptions Extremely time consuming Prone to typographical errors by submitter or engineer evaluator 19

20 Traditional Damage Reporting System Fleet Reporting DAMAGE MAPPING FORM Prepared By: John Doe Date: 18-Sep-09 Component: Door XXXX Buno: P/N: XXXX-XXXX Component Flight Hours: S/N: 0 #### Type of Damage: Puncture and Delamination Damage Moldline: x x Upper Moldline Lower Moldline Description of Reference Point: Forward Outboard Corner. Measured Distance From Reference Point to (0,0) Coordinate Point on Mylar is: 0 Inches Descriptions of +X and +Y Directions: +X Running Forward To Aft Along Outboard Edge. +Y Running Outboard to Inboard Along Leading Edge. Gridded Mylar Coordinate Reporting X-Y Coordinates reported along damage edge Less accurate for contoured components Recreated by Engineers at separate facility Redundant work efforts NO List of Coordinate Points (X,Y) of the Damage X Y NO. X Y NO. X Y 9 3/4 1 1/ / / / / / / /4 1 1/ /4 1 3/ / / /4 1 1/ /2 1 1/ X-Y Coordinate Reporting Form Time consuming Prone to typographical errors by submitter or engineer evaluator 20

21 NLign Reporting Requirements Reporting Requirements Digital image of component with damages marked on component Repair request will include critical information: Component Serial Number Aircraft Tail Number Damage types and numbers Etc All dimensional information is captured within the digital image and no additional forms are required 21

22 Engineer Evaluation NLign Alignment User identifies point correlations Software algorithm performs 2D to 3D alignment 22

23 Engineering Evaluation Damage Mapping Combined User / Software detection of damage indications projects damage locations from the 2D picture to the 3D model. 23

24 Engineer Evaluation: Data Aggregation Immediate visual representation on all relevant reference information required for analysis. Finite Element Model Weight and Repair Limited Zones Composite Ply Boundaries Minimal engineering time required to fully understand and evaluate damage indications. Error-Adverse Process 24

25 Engineer Evaluation: Previous Analyses All previously mapped damages are searchable for historical repair precedents Searchable by: Location, Damage Type, Serial Number, Aircraft Tail Number, Left/Right Hand, Repair Document ID, and/or any other user defined criteria. Redundant analysis work is minimized or eliminated by having access to a model-based representation of all previous damages and repairs Many repairs acceptable by previous analysis similarity 25

26 Additional Uses: Configuration Evaluation Model based alignment allows for quick and visual representations of the effects of configuration changes. Software was used to evaluate potential short edge distance conditions caused by replacing an older longeron with a newer configuration. Original Configuration Configuration Change Evaluation Potential Short Edge Distance Locations 26

27 Additional Uses: Inspection / Repair Evaluation Cracks are found during inspection and a known repair exists in the area. How to evaluate if crack indications are within repair area criteria? Photograph Damage Align to Model Evaluate Indication Crack Marking Damage Extraction Standard Repair Cutout Area Crack Mapping 27

28 Overall Benefits Increased accuracy in damage evaluation and analysis Improved aircraft health monitoring and damage trend recognition Fewer Engineering man-hours per repair disposition Reduced repair queue time and turn-around-time (TAT) Less duplicate work effort by use of a more robust archive capability Engineers are freed up to work other priority tasks! Reduction in shop and fleet effort required to report damages Reduced Aircraft-on-Ground (AOG) time Improved Engineering support efficiency to maintenance overhaul lines All the above lead to annual cost savings 28

29 Common Concerns / Questions We do not have 3D Models on our platform! This is common on older platforms A combination of reverse engineering tools and loft data can generate a quality representative model in approximately 2-3 days Almost all F/A-18 platform models used in NLign were generated using this approach How accurate is this mapping? Accuracy is a function of the picture: Closer picture yields high accuracy, farther picture yields lower accuracy. Accuracy can vary from ±0.005 to ±0.250 depending on picture distance Similar holds true for NDI data Does the software require the use of specific cameras/ndi systems? No, new off-the-shelf camera properties as well as other NDI data can be loaded into the software by working with Etegent. 29

30 NLign Capability Summary Data organized by alignment to CAD Models Semi-Automated Alignment 3D Alignment enables utilization of multiple types of reference data Analysis Capabilities Multimodal NDI data sources Rapid Analytical Evaluation Archiving of data and previous analyses Trending Configuration and Inspection Evaluation With repair archiving, the software efficiency continuously improves due to an expanding archive 30

31 Future Directions Apply tool to additional weapon systems Implement NLign into Navy & AF IT networks Challenges Continuous improvement of engineering analysis tools Build links with configuration management software Move toward Digital Thread concept As-manufactured to as-maintained state Maintenance induction planning 31

32 Conclusions All organizations should take advantage of data and technology available to manage aircraft USAF and USN invested in Etegent Technologies and NLign via SBIR to address this need Provides semi-automated organizational, archival, and analysis capabilities Only requires data and model Implementation onto broad network of users is key Streamline communication Capabilities exist to collect various data forms and analyze in many different ways for asset management 32