Category: Aerospace Tech Review

CAPTURE 3D, a ZEISS company and provider of 3D digitizing solutions in the U.S., announced the ZEISS ATOS LRX—a new large-volume 3D scanning sensor with an ultra-bright laser light source that captures up to 2 × 12 million coordinate points with one scan, quickly delivering precise, full-field data from very large parts. With a measuring area of up to four square meters, the ZEISS ATOS LRX is ideal for applications such as aerospace structural components like fuselage, wings, wing ribs, and tail, MRO, automotive design, tool making, and crash testing, machine building, marine propellers, rotor blades and molds, and wind turbine housings.

The ZEISS ATOS LRX is a complete solution for applications requiring rapid, high-quality 3D data and large-volume measurement beyond what conventional fringe projection systems, laser trackers, and laser radars provide. By delivering large-volume digitalization quickly, the ZEISS ATOS LRX closes a gap in the metrology industry not yet met by current technology. Designed for industrial applications, the ZEISS ATOS LRX includes robust sensor housing to protect against dust and water splash allowing it to work reliably and precisely even in harsh production environments. With this development, industries like heavy casting, shipbuilding, aerospace, automotive and wind energy can now measure very large parts quickly and efficiently.

Next Generation Laser Light Source

The ZEISS ATOS LRX draws upon proven ATOS 5X technology by utilizing an extremely bright blue laser light source generated by an advanced integrated laser light compressor, creating a uniform, non-coherent, speckle-free light resistant to ambient light conditions. The light projects over a measuring area spanning 2000 x 1600 mm for short exposure times, even for dark or shiny surfaces. Like existing sensors in the ATOS 5 lineup of blue light 3D scanners, the ZEISS ATOS LRX quickly captures high-resolution data with precision and detail, including complex geometrics and freeform surfaces.

Dynamic Radar-Based Operator Safety

The ZEISS ATOS LRX utilizes a class 2 laser for maximum operator safety. An integrated sensor uses radar to monitor the safety distance to the user, automatically reducing the luminous intensity as necessary if the distance is not maintained or if it detects movement in the critical area. The safe laser protection class 2 allows the 3D scanner to operate without further protective measures. The projector light can also be reduced to utilize interactive features such as a touch probe, live tracking and back projection.

Fast On-Site Recalibration with HyperScale

The ZEISS ATOS LRX features the new HyperScale software function designed for fast on-site calibration and the compensation of undesired effects of temperature changes. A calibration cross CC50/2000 that remains folded together for easy setup is included. A single measurement of a DAkkS-certified length standard completes sensor calibration, and the sensor self-monitors its calibration status throughout scanning.

Single Software Solution

Users complete scanning, inspection, and reporting in the ZEISS ATOS LRX software within GOM Inspect Pro, a part of the ZEISS Quality Suite. The software supports 3D scanning and inspection processes by providing detailed analyses and reporting functions. Users can control the sensor by computer or remote control.

Cert-Trace is a green blockchain-powered tool offering document management, archiving, and sharing capabilities. Its features include the ability to handle any file format, access for authorized individuals or companies through a QR code, and browser-based operation that ensures compatibility with any device and operating system.

Unlike traditional blockchain systems that consume vast resources, Cert-Trace employs a “Green Blockchain” approach. It secures the fingerprint of the document and stores the document separately in the world’s most secure cloud storage, AWS. A document can only be accessed when its fingerprint from the blockchain matches the document from AWS. Cert-Trace is developed and managed by Helmes, one of the largest software development companies in the Baltics, ensuring its reliability. Their client roster includes companies like ALA SpA, ALA Germany, and the company says it is supported by Airbus.

Bill Holler, the founder of TraCert and ALA Germany GmbH, brings his experience in the aerospace and fastener industries to the company. A former chairman of DIN (NL) and ASD-STAN, and CEO of the former SMI manufacturing plant, Holler has shaped international aerospace norms and continues to drive innovation in the industry.

CAPTURE 3D, a ZEISS company and the leading provider of innovative 3D digitizing solutions in the U.S. announced the ZEISS ScanBox Series 5— the latest addition to its collection of automated 3D scanning and inspection solutions designed and developed for industrial environments. The new series replaces the former proven and successful ScanBox Series 5 models with further enhanced optical 3D measuring machines featuring a modular concept designed to meet the demands of modern production, such as a new faster robot module for increased scanning speed, an integrated control tower for greater efficiency, a rotation table with a load capacity of up to two tons, and modular components for an adaptable floorplan layout.

Developing a reliable automation strategy continues to be a critical success factor for modern manufacturers to meet the demands of the changing landscape while improving quality control and dimensional inspection, whether near-line, at-line, or in-line production. The ZEISS ScanBox Series 5 solves this need with its ATOS 5 high-speed 3D sensor compatibility and an easy-to-program and operate interface to program complex measurements with the touch of a button.

“In today’s manufacturing environment, having the right automation strategy is key to increasing throughput and productivity while minimizing costs. The ZEISS ScanBox Series 5 capitalizes on strengths that already have made the series part of our customers’ success while upgrading essential features to deliver an automated solution that saves companies time and money,” said CAPTURE 3D General Manager Richard White.

The new model series consists of three off-the-shelf versions for different part or tooling size requirements: ZEISS ScanBox 5110, ZEISS ScanBox 5120, and ZEISS ScanBox 5130. The previous ScanBox Series 5 solutions are widely used within the aerospace, automotive, consumer goods, medical, and power generation industries to digitize and inspect parts ranging from turbine blades, knee implants, injection molded components, assemblies, and automotive sheet metal panels, to aerospace structures.

Meets the ScanBox Standard: Integration of Hardware and Software for Full Automation
ZEISS ScanBox Series 5 features the ATOS 5 blue light 3D scanner for the fast digitalization of various complex parts such as plastics, metals, or castings. The automated solution offers two entrance options to fit the user’s unique needs. The robot module consists of a FANUC M20iD/25 robotic arm secured on a floor mount. Users with little to no robotics experience can easily plan and program measuring sequences using the Virtual Measuring Room (VMR) software module. By programming the measuring routine within the VMR, the robot intuitively moves the ATOS 5 sensor to optimal scanning positions, enabling the fully automated execution of measurement sequences. After importing the CAD data and the corresponding measurement plan, the software computes the required sensor positions and robot paths. With a complete, detailed geometric digital twin of the physical part, users can compare the data against the CAD model and visualize GD&T deviations and details like trimming and hole positions. Users can display inspection results in a comprehensive report with images, tables, diagrams, texts and graphics for detailed trend/SPC analysis.

Adaptable Modular Concept
The control tower, rotation table and robot modules are identical across each ZEISS ScanBox Series 5 model, allowing users to expand the layout by adding additional working areas or components as needs change. The entrance of the 5110 and 5120 models can be equipped with either a door or a safety light curtain. The 5130 model is always supplied with a safety light curtain to accommodate larger test components, such as automotive sheet metal closures. A pallet loading system can supplement the ZEISS ScanBox 5120 and 5130 models. Positioning pins enable the fast and reproducible loading of pallets for increased throughput.

Ergonomically Optimized Features
The operator station includes a new variable swivel arm incorporated into the control tower. The swivel arm allows the user to adjust the table height to operate the automated 3D scanning solution either sitting or standing.

ZEISS ScanBox Series 5 is available now through CAPTURE 3D.

The future of validating and improving aerospace and autonomous vehicle design relies on hardware in the loop (HWIL or HIL) testing, according to Teledyn FLIR. This approach involves connecting a control module—for example, a missile guidance, navigation, and control—to software that generates a simulated environment that “tricks” the control module into acting as though it’s engaging with a real environment. This allows R&D teams to run hundreds or thousands of varying test scenarios without the costs, time, or potential risks associated with field testing. HWIL testing as it is applied to hypersonics research applications requires bleeding edge technology, and Chip Design Systems is leading improvements in the area of infrared scene projectors for these tests.

Chip Design Systems (CDS for short) designs IR projectors that produce scenes made of IR light to run simulations for IR sensors—sort of like a VR headset for machines. CDS’s primary clients are government agencies; the projectors they create for these contracts must reach an astounding level of accuracy to meet their customers’ needs, often having to produce simulations for targets moving at supersonic speeds. To give a comparison, the average consumer monitor projects an image around 60 to 120 hertz while CDS’s projectors can display scenes at a rate of 50,000 hertz. On top of the high framerate, CDS can simulate temperatures exceeding 1000 Kelvin and at a resolution up to 2000 × 2000.

Actual projected IR imagery of a parrot from a CDS IR Scene Projector

The capabilities of CDS’s IR projection are clear but testing them poses a challenge: neither the human eye nor non-military grade cameras can capture all the data the projectors emit. To make sure the projectors work properly, CDS needed something capable of capturing as much IR information as their projectors can emit. Their solution was high speed, high-definition infrared science cameras from Teledyne FLIR (i.e., X-Series models).

One of CDS IR LED displays, a 2 in2 chip that can display 2048 × 2048 pixel imagery. The current largest LED scene projection system in the world.

CDS frequently runs tests in their lab to make sure the emitters are working correctly and push performance further. These tests involve aligning the FLIR camera with the emitter to capture the light and then, using FLIR research application software (ex. Research Studio), controlling the camera settings to optimize the capture and display the resulting imagery. To guarantee repeatability, CDS has also developed their own code by leveraging the FLIR Science Camera SDK to automate the testing process and avoid human error from camera operation.

CDS testing one of their projector systems with a FLIR SC8200. This specific projector system uses liquid nitrogen to perform at optimal levels. An equivalent FLIR model would be the FLIR X8580, a cooled midwave HD camera that can reach frame rates of 181 Hz.

“With the help of FLIR products, we are able to demonstrate HD resolutions, hypersonic frames rates, and hot apparent temperature of our IR projector system to our end users and customers,” says Fouad Kiamilev, CTO of Chip Design Systems.

One feature that particularly stood out to CDS was the camera’s ability to perform non-uniformity correction, NUC for short, on the images from their projectors. Performing NUC in the FLIR camera help CDS catch the occasional blemish in a scene or a faulty emitter. With the combination of the camera’s high resolution and non-uniformity correction, CDS can check every pixel in a scenes image to verify their projector is emitting accurately.

A Teledyne FLIR customer since 2010, Chip Design Systems currently owns four IR cameras in their lab with plans to implement more in the future. Kiamilev says that CDS is aiming to drive projector performance even further in the future with higher resolutions, faster frame rates, and lower costs.

https://www.flir.eu/discover/professional-tools/what-is-a-non-uniformity-correction-nuc/

About Teledyne FLIR
Teledyne FLIR, a Teledyne Technologies company, is a world leader in intelligent sensing solutions for defense and industrial applications with approximately 4,000 employees worldwide. Founded in 1978, the company creates advanced technologies to help professionals make better, faster decisions that save lives and livelihoods. For more information, please visit www.teledyneflir.com or follow @flir.

Greene Tweed, a manufacturer of high-performance sealing solutions, engineered components, and custom sealed connectors will be showcasing its products for the vertical aviation industry at the HAI Heli Expo 2023, from March 7-9th, 2023, at the Georgia World Congress Center in Atlanta, Georgia, USA, Booth C2231.

Greene Tweed’s innovative portfolio of high-performance components aimed at the vertical aerospace market includes thermoplastic composite aerospace brackets, custom-engineered sealing solutions, and fiber optic connectors. Using advanced materials and precision engineering, Greene Tweed products are designed to offer consistent and dependable performance in the harshest environments.

Products on display at Booth C2231 will include Xycomp® DLF™ high performance, thermoplastic composite brackets. Developed as part of Greene Tweed’s role as innovators in the evolution of aerospace, these brackets can endure the substantial demands of aerospace environments, while offering significant weight savings over metallic parts. They are 35 to 50 percent lighter than competitive metallic components, making them an excellent replacement for metal materials.

Greene Tweed uses its proprietary compression molding system to produce complex-contour shapes for near-net, intricate geometry with molded-in features, such as bushings or attachment points. The material meets fire, smoke, and toxicity (FST) safety requirements for interior aerospace parts, and offers excellent resistance to aerospace solvents, high temperatures, and high vibrations for extended component life. In addition, Xycomp® DLF™ brackets can be recycled upon removal from an aircraft.

Also on display will be Greene Tweed’s extensive range of custom-engineered sealing solutions, manufactured from high-performance elastomers and thermoplastics. Manufactured from materials like Arlon PEEK and Avalon PTFE, the sealing solutions from Greene Tweed offer excellent resistance to extreme temperature, pressure, corrosive chemicals, and other forms of damage/degradation aircraft components and systems routinely face. The portfolio for the helicopter market includes O-Rings, GT series of T-Seals and bearings, V-Rings and V-Stacks, double-acting Rod & Piston Seals, and Metal Spring Energized (MSE) sealing solutions.

With an extensive electrical and fiber optic portfolio, Greene Tweed will showcase the Seal-Connect catalog at HAI Heli Expo 2023. Notable products include the FC DRY HP and ST DRY HP series connectors, adapters, permanent bulkhead feedthroughs, dust caps, and Fiber Protec series of armored fiber optic cables. All components are available in standard as well as custom design options to provide hermetic seal integrity against moisture and particulates, under temperatures ranging from 55C to 85C, and keep fiber connectivity intact.

Seal-Connect electrical connectors can improve thermal and electrical properties with significant weight savings, when compared to traditional glass to metal sealed bulkhead connectors. Seal-Connect will also feature electrical connectors manufactured with Arlon 3000XT, a proprietary cross-linked PEEK, for increased mechanical properties at extreme temperatures ranging from 260C to 300C.

Greene Tweed products for the vertical aerospace market are designed to provide highly customizable component solutions guaranteed to provide excellent performance under extremely challenging operating conditions.

Arnold Magnetic Technologies, a subsidiary of Compass Diversified and manufacturer of high-performance magnets, magnetic assemblies, precision thin metals and highly loaded composites, announced its range of titanium foils and alloys. Arnold offers thin cold-rolled titanium in a variety of CP Grades and alloys and a broad range of thicknesses and widths for many aerospace and defense related applications that require a strong, lightweight, corrosion-resistant material that is highly workable, ductile, and weldable.

As a global leader in ultra-thin cold-rolled metal strip and foil, Arnold achieves unmatched thinness while maintaining controlled, consistent mechanical and physical quality. Arnold’s “Ultra Thin Gauge” foil is available in thickness down to 2 µm (0.00008“), in addition to the “Thin Gauge” options (0.020” – 0.0005“).

Widths are available up to 17.5”, depending on thickness. For example, foil 0.0029” – 0.001” thick has a maximum width of 16.5”. Widths as narrow as 0.031” can be achieved through slitting.

Arnold offers multiple Commercially Pure (CP) grades with 99%+ pure titanium. Options include Grade 1 which has the highest purity of commercially available titanium with excellent corrosion resistance to chlorides, and Grade 2, the most commonly specified grade of CP titanium, which has good ductility with excellent corrosion resistance especially to seawater and Grade 4 which is the strongest CP grade and is certified per AMS standards.

Available titanium alloys include Grade 9, 15-3-3-3, Grade 23, and Beta21s, a high strength material engineered specifically to improve resistance to oxidation and creep along with enhanced elevated temperature strength and stability.