WIMO

Outer Wing Metrology

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 Obiettivo del progetto (Objective)

The demand for reduction of the fuel consumption of aircraft leads to new technologies. One of them is reduction of turbulences on wings by manufacturing the surface with high quality. This means with a low waviness and without gaps and steps. During manufacturing of this surfaces an adequate quality control is mandatory. At present no measurement system exists which is capable of measuring large areas with high lateral and depth resolution. The WiMo-project aims at the strategy to combine different measurement systems to a single one which allows for measuring large areas with the necessary resolution. In addition new strategies for handling the huge amount of data and evaluate them will be developed. The project result can therefore fulfill the requirements of a quality control in a production line for the natural laminar flow wing.

Introduzione (Teaser)

Natural laminar flow (NLF) wings that reduce turbulence could significantly reduce fuel consumption and associated emissions. Scientists are developing the currently lacking quality control system to support the manufacturing and assembly effort.

Descrizione progetto (Article)

Achieving tight tolerances on wing waviness and roughness during production is a seemingly simple and low-technology route. In reality, measuring large areas during manufacture and assembly with high lateral and depth resolution is no easy task and no system capable of doing so currently exists.

EU-funded scientists are providing an in-line quality control solution by combining different measurement systems into a single unit within the scope of the project 'Outer wing metrology' (WIMO). Development requires not only the instrumentation for measurement but also innovative strategies for analysing the huge amount of data. The team is thus developing the required imaging, roughness and laser tracker systems as well as the fast and automated algorithms for data management.

The stereo camera system for metrology has now been successfully validated using the industry standard National Physical Laboratory (NPL) large freeform verification artefact made of carbon composite materials. The testing enabled establishment of spatial resolution and absolute coordinate uncertainty. In addition, calibration of the stereo system has been improved and made more mobile, having been successfully transported to and used in an experimental campaign in the United Kingdom and returned to Germany.

Software integration of the laser tracker that accurately measures parameters of large objects such as aircraft wings and acts as the global reference coordinate system is complete. Significant improvements in the automatic finding procedure have been made and correct functioning of the interfaces and reference point recording has been confirmed.

The team further refined the methods to extract and present waviness data and errors. Analyses comparing design data with measured point clouds were used to evaluate adherence to specifications and automation efforts are underway.

WIMO is well on its way to delivery of a groundbreaking integrated metrology system to ensure wing surface quality during production of the new NLF wing. The resulting smooth laminar flow during flight will significantly reduce fuel consumption and associated emissions for greener air transport. Enhanced capabilities will also boost the competitiveness of the EU aerospace industry in a large global market.