z Bulletin board
APRIL 2015
102 |^ AEROSPACETESTINGINTERNATIONAL.COM
A portable non-contact
electronic gap tool from
Capacitec Gapman Gen3 can
replace feeler gauge measurement
methods in aircraft shimming
applications at Airbus, Boeing,
Bombardier and Embraer, as well
as military aircraft such as JSF.
A Gapman and ‘thin wand’
(0.2mm) design is important
because it measures small
entrance gaps that transition to
larger internal gap locations. Feeler
gauges can fail at this job and
create a manufacturing process.
It can greatly speed up electronic
measurements when there is a non-
parallel part relationship. Increased
aircraft use of very rigid CFRP
materials has made the Gapman
very popular due to the multiple
composite part interfaces creating
unwanted air gaps, especially on
new aircraft builds, such as wing
skins. New gap technology
particularly benefits aircraft
assembly, quality and throughput
when semi-automated shimmingoperations are added for CFRP/
CFRP and CFRP/metal assemblies.
To date, the Gapman has
achieved a gap measurement/
shimming operation build-rate
improvement amounting to five
times faster than with manual
feeler gauges. Additional benefits
are: reduced overall shimming
scrap cost, enhanced structural
integrity of aircraft components,
and a shim gap database to assist
users in process improvements.
Datalogged gap values can now
be communicated from the Gapman
via the wireless to customer-driven
template data programs for direct
control of the gap-filling process.High-speed cameras are
often used in store separation
recordings and provide essential
insight into the mechanical and
aerodynamical processes taking
place. An increasing demand
to mount cameras in remote
locations on a test aircraft has lead
to the development of a compact,
small camera with a sensor that is
positioned to provide a 90° view
from the camera axis.
The Q-MIZE FH is an ideal
instrument for mounting on AIM-9
pods or similar models. The
diameter of the camera matches
the inner dimensions of the pods.
When mounted, the camera can
record the scene directly without
the need for 90° mirror optics,
where only a limited resolution of
the 3MP sensor can be used. This
is made possible by using the
compact micro four-third optics.
The dimensions of the lenses
mean the camera is ultra-compactand few mechanical precautions
have to be taken when mounting
the Q-MIZE FH in the proper
positions.
The Q-MIZE is designed and
certified to withstand g-forces in
excess of 100g, and spikes of up
to 200g. Certified according to the
MIL810 standard for vibration and
environmental conditions, the
camera optionally comes with
MS27473 series standard plugs.
Semi-customized housing is
available to fit existing structures
for ease of integration.Two important R&D initiatives
have been sponsored by the
Spanish Centre for Industrial
Technological Development (CDTI).
TARGET was a four-year project
that was concluded in November
2014, with the objective of
investigating new intelligent and
environmentally sustainable
technologies for a generation of
structures using composite
materials. In particular, the research
focused on materials and new
techniques necessary for the
development of new machinery
concepts. Tecnatom, the Spanish
engineering company, participated
by applying advanced NDT, a critical
activity when producing structures
based on these materials. Tecnatom
has demonstrated the efficiency of
NDT-improved methods and
algorithms in the inspection of
composite complex geometries andtheir influence in the optimization
of the manufacturing phases.
The second initiative, ESTENEA,
another new project, has the
objective of achieving cost-effective
and high-productivity technologies
in the manufacturing of composite
parts. The NDT industrialization
objective includes the
implementation of inspection of
aero-parts by using air-coupling
ultrasonics (ACUT), laser
ultrasonics (LUS) and
thermography, in an automated
way. These use contactless
techniques that avoid the use of
water when scanning the parts,
and in particular ACUT and
thermography allow scanning of
large areas in one single sweep.
Meanwhile, LUS is an advanced
technique that is very useful when
scanning small parts, and difficult
and integrated geometries.The inspection of turbine
blades is an essential and
extremely sophisticated task
because of their complex design.
Currently, x-ray technology is the
most reliable inspection method,
and the Yxlon MU56 TB has been
designed especially for this type of
challenging application.
The system, in combination
with the proven Yxlon software
PXV5000 and imaging software
Yxlon Image 3500, is the
established tool for automated
defect recognition in the foundry
industry for aircraft parts. It creates
superior image processing,
providing objective, repeatable
image analysis and automatic
archiving. It is ideal for serial
inspection within the production
line and supports the process
optimization. With the combination
of the Yxlon MU56 TB and these
software options, the Review
Workstation allows an operator toevaluate the results independently
from the continuous, full-
automated inspection process.
The Variofocus x-ray tube,
together with the state-of-the-art
digital flat-panel detector, provide
the best image quality. The
variable focal spot is the ideal
solution for applications with high
demands for detail recognition, as
well as applications requiring high-
power operation.
Yxlon MU56 TB is perfectly
suited for the inspection of vanes
and various other components in
the aerospace sector.
The precondition to fulfill the
high safety standards in the
aerospace industry is optimal
detail resolution, and is the basis
for raising efficiency and quality
improvements in the production
process. Yxlon MU56 TB is
compliant with industrial standards
like ASTM and MAI, and also fulfills
the Nadcap requirements.GAPMAN GEN3 MEASURES
COMPOSITE GAPS
Q-MIZE FH – A HIGH-SPEED
R&D INITIATIVES FOCUS ON CAMERA WITH A VIEW
LATEST TECHNOLOGIES
X-RAY ROBOT SYSTEM FOR
TURBINE BLADES
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