CNC Gantry Laser Scanning for Fast Accurate Large-Part Inspection

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Solution Overview

Problem

Current methods for inspecting large parts in aircraft manufacturing are time-consuming and require significant operator expertise, with conventional laser trackers limiting accuracy and efficiency due to distance limitations and susceptibility to temperature fluctuations, and existing systems fail to provide fast and accurate scanning for predictive shimming or shimless manufacturing.

Innovation Solution

A system comprising a laser scanner connected to a CNC gantry tool, utilizing a connection assembly for high global accuracy and precision, with real-time processing and wireless communication to reduce setup time and cable noise, enabling high-speed and accurate scanning of large parts for predictive shim generation or shimless manufacturing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If conventional laser trackers are used for inspection, then operator expertise is required and setup time is significant, but inspection accuracy is limited and inspection time is long

Engineering Contradiction:

Improveinspection accuracyVSAvoidinspection time

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The patent replaces conventional laser trackers with a laser scanner integrated on a CNC gantry tool. This substitution eliminates the need for manual operator positioning and measurement operations, achieving automated high-accuracy scanning. The CNC-controlled laser scanner provides both high measurement precision and reduced inspection time by automating the data collection process along programmed paths.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The laser scanner is integrated onto the CNC gantry tool platform, allowing the same system to perform both manufacturing operations and inspection functions. This multi-functionality eliminates the need for separate inspection equipment and operators, reducing both inspection time and the expertise requirement while maintaining high accuracy through automated scanning.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If conventional laser trackers are used, then setup procedures are required, but operator time and expertise are consumed

Engineering Contradiction:

Improvemeasurement reliabilityVSAvoidoperator effort

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The CNC-controlled laser scanner system performs self-positioning and self-measurement along programmed gantry paths. The automated system eliminates the need for operators to manually set up and operate complex laser tracker equipment, significantly reducing operator effort while maintaining measurement reliability through consistent automated execution.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

Manual operator operations for setup and measurement are replaced by automated CNC control systems. The programmed gantry movements and automated scanning eliminate the need for operator intervention in setup procedures, reducing operator effort while ensuring reliable measurements through systematic automated processes.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If fast scanning is implemented, then inspection time is reduced, but accuracy may be compromised

Engineering Contradiction:

Improvescanning speedVSAvoidscan accuracy

Core Design Contradiction:

ProductivityVSMeasurement precision

Solution Approach 1:

Manual laser tracker operations are replaced by automated CNC-controlled laser scanning. The automated system maintains consistent scanning speed and positioning accuracy through programmed gantry movements, achieving both high productivity and high measurement precision simultaneously without the trade-off present in manual operations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The laser scanner continuously collects measurement data along the entire gantry path without interruption or repositioning. This continuous scanning operation maintains constant high speed while ensuring complete coverage and high accuracy through uninterrupted data collection, eliminating the start-stop nature of manual inspection.

Inventive Principle:

Principle #20Continuity of useful action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The system significantly reduces inspection time from hours to minutes, enhances accuracy, and minimizes operator effort, achieving cost-effective and efficient scanning for aircraft parts, thereby reducing manufacturing costs and time.

Implementation Method 1

A system comprising a laser scanner connected to a CNC gantry tool

Methodology Applied

Scientific EffectLaser: Laser

Implementation Method 2

scanning a first surface of a part with the laser scanner

Methodology Applied

Scientific EffectLight reflection: Reflection

Data Source

PatentEP3531221B1Laser scanner scanning using a computer numerical controlled (CNC) system for movement

Publication Date: 2022.09.14 THE BOEING CO

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AI summary

A first surface of a part is scanned with a laser scanner as a platform of a computer numerical controlled (CNC) gantry tool moves relative to the part to form scan data, in which the laser scanner is connected to the platform of the computer numerical controlled (CNC) gantry tool. Differences between the first surface and design for the first surface are determined using the scan data.