An Ensenso 3D camera integrated into an automated process chain ensures accurate detection and alignment of drilling positions in aircraft cabin assembly.
IDS: Digital precision transforms aircraft construction with Ensenso 3D vision
Case Study from | IDS Imaging Development Systems GmbH
In modern aircraft production, precision is everything. Every hole and every fixing point must be precisely positioned to ensure safety and quality. As part of the DiCADeMA project (Digital Cabin Architectures and Design for Manufacturing) led by the German Aerospace Centre (DLR), a novel, fully digitally networked process has been developed. Through intelligent automation, this approach elevates aircraft cabin manufacturing to a new level. A key component in this process is an Ensenso 3D camera from IDS Imaging Development Systems GmbH, which ensures highly precise detection and alignment of drilling positions.
Digital process chain from design to production
The aim of the project is to establish a continuous digital thread from design to production. Changes to the cabin design, such as seat spacing and the associated new position of the luggage compartments, are recorded directly in the digital design data and automatically transferred to production planning. Simulations allow these variants to be validated before any physical component is manufactured. Once digital validation is complete, production can begin immediately.
To make this digital process tangible, an automated system for marking drilling positions was developed on a mock-up of an aircraft frame structure. Several networked systems work together in this setup: An autonomous mobile robot (AMR) approaches the frame and positions itself near the target area. Mounted on the AMR is a lightweight robot that moves the marking unit, including the 3D camera, into the acquisition position. At this point, the Ensenso camera takes over the fine alignment. An integrated Manufacturing Execution System (MES) controls all sub-processes.
Frame construction and mobile robot including superstructures.
The role of the 3D camera
Lightweight robot with marking unit and 3D camera
The Ensenso camera becomes a key link between digital design and real-world manufacturing: It recognizes local geometries, in this case several rivets and the surface on which they are set and compares the captured point clouds with reference data from the CAD. This comparison is made possible, among other things, by hand–eye calibration and an iterative minimization process. The result is a transformation matrix that precisely describes the correction required for the drilling position. By applying this correction value, the drilling position can be set precisely.
An operator follows the vehicle and drills the hole immediately afterwards at the marked spot. This process is repeated for each installation point, while robots and humans can work safely in close proximity to one another.
Different views of a plate with rivets: actual plate (left), CAD point cloud (center), 3D camera point cloud (right)
Benefits for manufacturing
Point clouds in target/actual comparison
Outlook
The demonstration on the mock-up clearly illustrates the potential that lies in combining the digital process chain, robotics and 3D image processing. In further project steps, the accuracy of the system and the performance of the evaluation algorithms will be examined in greater detail. This will involve not only the camera itself, but also the optimization of the mathematical methods used to align nominal and actual point clouds.
What is currently being tested in aircraft manufacturing may also be applied in other industries in the future. The system impressively demonstrates how optical sensor technology and intelligent Software are paving the way for a new era in manufacturing: networked, efficient and precisely on target.
For more details, see the project video: https://www.youtube.com/watch?v=rtJUdiuvUOU
Customer
The German Aerospace Centre (DLR) is the Federal Republic of Germany's research center for aerospace. Its research and development work in aviation, aerospace, energy, transport and security is integrated into national and international collaborations.
https://www.dlr.de/en
Project DiCADeMA
The content & opinions in this article are the author’s and do not necessarily represent the views of RoboticsTomorrow
IDS Imaging Development Systems Inc.
World-class image processing and industrial cameras "Made in Germany". Machine vision systems from IDS are powerful and easy to use. IDS is a leading provider of area scan cameras with USB and GigE interfaces, 3D industrial cameras and industrial cameras with artificial intelligence. Industrial monitoring cameras with streaming and event recording complete the portfolio. One of IDS's key strengths is customized solutions. An experienced project team of hardware and software developers makes almost anything technically possible to meet individual specifications - from custom design and PCB electronics to specific connector configurations. Whether in an industrial or non-industrial setting: IDS cameras and sensors assist companies worldwide in optimizing processes, ensuring quality, driving research, conserving raw materials, and serving people. They provide reliability, efficiency and flexibility for your application.
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