COE Final Report Presentation

Slide 2: 

Remote-Controlled Underwater Camera System for Real-Time Monitoring of Fatigue Damage in Fuselage Panels Andrew C. Bergan (MEM) Prince T. Codjoe (ECE) David S. Schubert (MEM) Mark A. Shuck (ECE) Ross A. Staszak (ECE) Arudra Venkat (ECE) Senior Design Final Report MEM-08, ECE-22 Presented on June 2, 2010 Advisors Jonathan Awerbuch (MEM), John Bakuckas (FAA), Timothy P. Kurzweg (ECE), Karkal Prabhu (ECE), Tein-Min Tan (MEM)

Presentation Overview : 

Presentation Overview 6/2/2010 3 Remote-Controlled Underwater Camera System for Real-Time Monitoring of Fatigue Damage in Fuselage Panels Background Objectives Approach FAA tests airframes to predict damage tolerance Image inside of test panel in real-time Measure fatigue crack growth using images (Test fixture pressure applied with water) Camera must operate in hostile environment Systems Engineer Top-Down Design High resolution camera with enclosure Submersible remotely controlled 5 DOF support structure Integrated windows control software Image measurement GUI tool Functionality: Optical measurement of fatigue crack growth Solution

Presentation Outline : 

Presentation Outline Background Information Aloha Accident FAA FASTER Facility Problem Statement Systems engineering approach Sub-system design Project Management Remote-Controlled Underwater Camera System for Real-Time Monitoring of Fatigue Damage in Fuselage Panels 4 Next Speaker: Ross Staszak (ECE) 6/2/2010

Aloha Accident : 

Aloha Accident Remote-Controlled Underwater Camera System for Real-Time Monitoring of Fatigue Damage in Fuselage Panels 5 Multiple-Site Damage (MSD): Characterized by the Simultaneous Presence of Fatigue Cracks in the Same Structural Element NTSB & FAA Investigations Revealed that Interaction of Small Cracks at Rivet Holes Contributed to the Fuselage Failure Aircraft Accident Report - Aloha Airlines, Flight 243.  Boeing 737-200, N73711, Near Maui, Hawaii, April 28, 1988. NTSB/AAR-89/03. 6/2/2010

FAA FASTER Facility : 

FAA FASTER Facility Remote-Controlled Underwater Camera System for Real-Time Monitoring of Fatigue Damage in Fuselage Panels 6 FAA Full-Scale Aircraft Structural Test Evaluation and Research (FASTER) Facility established in 1998 Provides data to substantiate fatigue and damage tolerance assessment of aircraft fuselage structures for mandating airframe inspection intervals Equipped with a Remote-Controlled Crack Monitoring (RCCM) system Developed and Designed NEW Underwater Crack Monitoring (UCM) system Testing Retained Data 6/2/2010

Fixture Pressure Box : 

Fixture Pressure Box Remote-Controlled Underwater Camera System for Real-Time Monitoring of Fatigue Damage in Fuselage Panels 7 Operating Area Axial: 85” Z: 12 ” Hoop: 32” Limited space 6/2/2010

Problem Statement : 

Problem Statement Remote-Controlled Underwater Camera System for Real-Time Monitoring of Fatigue Damage in Fuselage Panels 8 Problem Statement Design, integrate, and build an underwater (25psi ) camera system with a support structure and a comprehensive, flexible, and versatile control system for optical inspection of damage during testing at the FASTER facility UCM Features Free Range of Motion: X,Y,Z,360 ̊ (Pan), 180 ̊ (Tilt) GUI for Motion/Camera Control GUI Measurement Tool High Resolution + .001” Measurement Accuracy 6/2/2010

Presentation Outline : 

Presentation Outline Background Information Problem Statement Systems engineering approach Integrated system design Interface design Sub-system design Project Management Remote-Controlled Underwater Camera System for Real-Time Monitoring of Fatigue Damage in Fuselage Panels 9 6/2/2010

Systems Engineering Approach : 

Validation testing (Drexel, May 2010) Acceptance testing (FAA) Procure off-the-shelf components Build developmental components Assemble system Developmental component design requirements Refine interfaces Iterative component design – review process Subsystem requirements, functional diagram, interfaces Identify design space Stakeholder Needs  Target Specs System functional diagram Off-the-shelf vs. developmental components Systems Engineering Approach Remote-Controlled Underwater Camera System for Real-Time Monitoring of Fatigue Damage in Fuselage Panels 10 Challenge: Complex, coupled nature of this engineering problem Conceptual Design Preliminary Design Detailed Design Construction Testing & Refinement System Specification Subsystem & Interface Design Component Design Working Device Final Product Key Deliverables On going 6/2/2010

System Functions & Target Specifications : 

System Functions & Target Specifications Remote-Controlled Underwater Camera System for Real-Time Monitoring of Fatigue Damage in Fuselage Panels 11 Stakeholder Needs (87 Needs identified) View entire desired area on test panel Target Specifications (47 Derived from both needs and functions) Axial translation distance: 80 inches Hoop translation distance: 40 inches System Functions (19 Derived from stakeholder needs) Translate in axial direction Translate in hoop direction Result: Unambiguous description of ideal system  filter for alternatives 6/2/2010

System Design: Alternatives : 

3) Computer Vision 1) Cross Hair Pixel Limited 2) Laser Measurement 4) High Res. Camera (custom enclosure req.) 1)Underwater Camera Package 2) Camera Retrofit 3) Individual Components System Design: Alternatives Remote-Controlled Underwater Camera System for Real-Time Monitoring of Fatigue Damage in Fuselage Panels 12 Camera Measurement Positioning 3) Electric Stepping Motor w/ lead screw Prone to Leaks Too Complex Maintenance Issue Insufficient Resolution Accuracy Issues Tedious Operation 6/2/2010

Integrated System Design : 

Integrated System Design Remote-Controlled Underwater Camera System for Real-Time Monitoring of Fatigue Damage in Fuselage Panels 13 Uncoupled the design of the sub systems allowing each sub system to be design separately 6/2/2010

Interface Design : 

Interface Design Designed Each Interface Mechanical Electrical Software Compiled into an Interface Control Document (ICD) Remote-Controlled Underwater Camera System for Real-Time Monitoring of Fatigue Damage in Fuselage Panels 14 Uncoupled the design of the sub systems allowing each sub system to be design separately 19 Wiring Diagrams 6/2/2010

Presentation Outline : 

Presentation Outline Background Information Problem Statement Systems engineering approach Sub-system design Camera System Project Management Remote-Controlled Underwater Camera System for Real-Time Monitoring of Fatigue Damage in Fuselage Panels 15 6/2/2010

Slide 16: 

Consulted 37 Machine Vision and Robotics Vision Specialists Solution Requires a Combination of 3 Companies Imaging System Component Selection Remote-Controlled Underwater Camera System for Real-Time Monitoring of Fatigue Damage in Fuselage Panels 16 6/2/2010

Camera System : 

Camera System Remote-Controlled Underwater Camera System for Real-Time Monitoring of Fatigue Damage in Fuselage Panels 17 WFOV Lens Cameras NFOV Lens Minimum Working Distance: 4.330” Satisfies: Minimum Depth of Field: 0.236” 5 Mega Pixel Resolution: 15.7µm Resolve Field of View Range 1.5”-15.0” 6/2/2010

NFOV Lens Double Telecentric Solution : 

NFOV Lens Double Telecentric Solution 6/2/2010 Remote-Controlled Underwater Camera System for Real-Time Monitoring of Fatigue Damage in Fuselage Panels 18 Image Size and Magnification Independent of Distance to Object and Distance to Sensor Zero Degree Telecentric Angle Eliminates Image Depth Perception 140mm 89mm This Property Allows Precise Measurement of Objects Regardless of Position. Image Plane 0 degree Chief Ray Telecentric Lens Object Plane No Size Change WD1 WD2 WD3 Conventional Telecentric Working Distance mm 1.50” DOF

Illumination : 

Illumination 6/2/2010 Remote-Controlled Underwater Camera System for Real-Time Monitoring of Fatigue Damage in Fuselage Panels 19 Prosilica Camera Spectral Sensitivity Range 560nm = Green NFOV Telecentric Lens blocks Infrared and works best at 550nm WFOV Schneider Lens produces best quality between 500-700nm = Custom Green LED Lighting System Electrical Layout/CNC Etch Physical Product Post Construction 3x2mm

Presentation Outline : 

Presentation Outline Background Information Problem Statement Systems engineering approach Sub-system design Camera Enclosure Structure Motor Torque Calculations Project Management Remote-Controlled Underwater Camera System for Real-Time Monitoring of Fatigue Damage in Fuselage Panels 20 6/2/2010

Camera Enclosure : 

Camera Enclosure Remote-Controlled Underwater Camera System for Real-Time Monitoring of Fatigue Damage in Fuselage Panels 21 Camera enclosure development: Design – SolidWorks model Analysis – FEA using Abaqus Manufacturing – CNC in Hess Lab Testing – Submerged, 50 psi for 24 hr Complete camera enclosure 6/2/2010

Support Structure : 

Support Structure Remote-Controlled Underwater Camera System for Real-Time Monitoring of Fatigue Damage in Fuselage Panels 22 Support Structure development: Design – SolidWorks model Analysis – Beam deflection Manufacturing – Over 40 parts Complete structure Team members spent 150 hours machining parts 6/2/2010

Motor Torque Calculation : 

Motor Torque Calculation Motor choice: requires calculating motor torque load, T Force opposing carriage motion Key assumption: Value of Coefficient of friction (from DuPont for Teflon) Results: Motor choice: Empire Magnetics, WP-U22 (Trans + Pan) Empire Magnetics, WP-U32 (Tilt) Pan gearbox: 20:1, motor load torque = 10.5 oz-in Remote-Controlled Underwater Camera System for Real-Time Monitoring of Fatigue Damage in Fuselage Panels 23 6/2/2010

Presentation Outline : 

Presentation Outline Background Information Problem Statement Systems engineering approach Sub-system design Interface Software Motion Control Project Management Remote-Controlled Underwater Camera System for Real-Time Monitoring of Fatigue Damage in Fuselage Panels 24 6/2/2010

Interface Software - Motion Control : 

Interface Software - Motion Control Remote-Controlled Underwater Camera System for Real-Time Monitoring of Fatigue Damage in Fuselage Panels 25 SAVE feature for coordinates Direct ‘GO’ to coordinates Forward / Backward Buttons for 5 DOF Select Motion Velocity Dock MOTION CONTROL: 6/2/2010

Interface Software – Camera : 

Interface Software – Camera Remote-Controlled Underwater Camera System for Real-Time Monitoring of Fatigue Damage in Fuselage Panels 26 6/2/2010

Interface Software - Archiving : 

Interface Software - Archiving Remote-Controlled Underwater Camera System for Real-Time Monitoring of Fatigue Damage in Fuselage Panels 27 LIST VIEW 6/2/2010

Presentation Outline : 

Presentation Outline Background Information Problem Statement Systems engineering approach Sub-system design Image Measurement System Summary Project Management Remote-Controlled Underwater Camera System for Real-Time Monitoring of Fatigue Damage in Fuselage Panels 28 6/2/2010

Image Measurement GUI : 

Image Measurement GUI Cycle through images Measure images Single Line Multiple Line Annotate images Adjust annotating settings Save Image Remote-Controlled Underwater Camera System for Real-Time Monitoring of Fatigue Damage in Fuselage Panels 29 10.006 6/2/2010

System Operation : 

System Operation Remote-Controlled Underwater Camera System for Real-Time Monitoring of Fatigue Damage in Fuselage Panels 30 Axial Hoop Z Pan Tilt 6/2/2010

Presentation Outline : 

Presentation Outline Background Information Problem Statement Systems engineering approach Sub-system design Project Management Budget System Documentation Remote-Controlled Underwater Camera System for Real-Time Monitoring of Fatigue Damage in Fuselage Panels 31 6/2/2010

Custom Project Budget : 

Custom Project Budget Remote-Controlled Underwater Camera System for Real-Time Monitoring of Fatigue Damage in Fuselage Panels 32 6/2/2010

System Documentation : 

System Documentation Remote-Controlled Underwater Camera System for Real-Time Monitoring of Fatigue Damage in Fuselage Panels 33 http://www.faaseniordesign.com System user manual Installation and removal procedure Software user manual System Specification All design and development documents Vendor information Maintenance requirements Final report 6/2/2010

Conclusions : 

Conclusions Remote-Controlled Underwater Camera System for Real-Time Monitoring of Fatigue Damage in Fuselage Panels 34 Electrical Optics Fabrication 6/2/2010

We Could not Have Done it without You : 

We Could not Have Done it without You Advisors Dr. Awerbuch (MEM) John Bakuckas (FAA) Dr. Kurzweg (ECE) Dr. Prabhu (ECE) Dr. Tan (MEM) FAA Technical Staff Drexel Machine Shop Special Thanks to: Mike Bartholomew Doug Pfeil Remote-Controlled Underwater Camera System for Real-Time Monitoring of Fatigue Damage in Fuselage Panels 35 6/2/2010

Questions? : 

Questions? Remote-Controlled Underwater Camera System for Real-Time Monitoring of Fatigue Damage in Fuselage Panels 36 6/2/2010

Window thickness : 

Window thickness FEA to verify 0.25” thickness is acceptable 12/1/2009 Remote-Controlled Underwater Camera System for Real-Time Monitoring of Fatigue Damage in Fuselage Panels 37 Acrylic E = 40,600 psi ν = 0.35 Yield Stress = 11,700 psi

Camera Window : 

Camera Window Cast Acrylic for optical clarity O-ring gasket for sealing Mounting bracket holds the window in place

Lighting Board mounting : 

Lighting Board mounting 12/1/2009 Remote-Controlled Underwater Camera System for Real-Time Monitoring of Fatigue Damage in Fuselage Panels 39 Board (purple) LED (green)

MD Tether Connector Box : 

MD Tether Connector Box Several cables connected through one connector Problem: Difficult to create seal

MD Tether Connector Box : 

MD Tether Connector Box Connection at pressure box wall Limited number of holes in pressure box desired Multiple channels; one connector Connector Box Water sealing issues due to space between conductors

Z-assembly : 

Z-assembly 12/1/2009 Remote-Controlled Underwater Camera System for Real-Time Monitoring of Fatigue Damage in Fuselage Panels 42

Z-assembly : 

Z-assembly 12/1/2009 Remote-Controlled Underwater Camera System for Real-Time Monitoring of Fatigue Damage in Fuselage Panels 43

Pan bearing : 

Pan bearing 12/1/2009 Remote-Controlled Underwater Camera System for Real-Time Monitoring of Fatigue Damage in Fuselage Panels 44 Teflon washers Carriage mount Z-bracket base Sprocket Pan shaft Journal bearing

Slide 45: 

12/1/2009 Remote-Controlled Underwater Camera System for Real-Time Monitoring of Fatigue Damage in Fuselage Panels 45

Previous Senior Design Project : 

Previous Senior Design Project Remote-Controlled Underwater Camera System for Real-Time Monitoring of Fatigue Damage in Fuselage Panels 46 Remote-Controlled Crack Monitoring (RCCM) Redesign in 2006 by a Drexel Senior Design team of 2 CS and 3 MEM students Awarded first place in MEM, CS, and COE competitions RCCM measures external cracks 2500 cycles 3250 cycles 1500 cycles FWD AFT 0.037 inch 0.041 inch 0.082 inch 0.082 inch 0.111 inch 0.115 inch Notch 1 Notch 2 Notch 1 3 inch Hoop Axial RCCM Images & Measurements Cameras and Structure GUI Software 5/17/2010

Old Underwater Camera Crawler : 

Old Underwater Camera Crawler Remote-Controlled Underwater Camera System for Real-Time Monitoring of Fatigue Damage in Fuselage Panels 47 Underwater Camera Images & Measurements 600 cycles 0.1528” 1000 cycles 0.1763” 3200 cycles 0.2233” N: ∆a: Display Crawler controller Camera controller Camera: Poor Resolution Pan & tilt; crawler positioning Analog controlled Poor image quality Manual measurements Test Panel Camera & lights Track Crawler 5/17/2010

FASTER Facility Testing : 

FASTER Facility Testing Remote-Controlled Underwater Camera System for Real-Time Monitoring of Fatigue Damage in Fuselage Panels 48 Major Modes of Loading Exterior Interior Knowing the crack growth rate, the FAA mandates inspection intervals so that cracks will be identified before catastrophic failure 5/17/2010

Imaging Through Water : 

Imaging Through Water 12/1/2009 Remote-Controlled Underwater Camera System for Real-Time Monitoring of Fatigue Damage in Fuselage Panels 49 Air Only Water & Air Measured Length: 0.507” Measured Length: 0.503”

Key Feature of Pan : 

Key Feature of Pan Pan provides the ability to view the axial ends of the pressure box for maintenance inspection 12/1/2009 Remote-Controlled Underwater Camera System for Real-Time Monitoring of Fatigue Damage in Fuselage Panels 50 Example of pan operation: For viewing panel, User Expects: Tilt Normal to panel Pan 90° and tilt to see end of pressure box But they get:

Camera Enclosure : 

Camera Enclosure 12/1/2009 Remote-Controlled Underwater Camera System for Real-Time Monitoring of Fatigue Damage in Fuselage Panels 51 Camera Enclosure Requirements Waterproof to 30psi Size as small possible Cameras easily removable Cameras rigidly mounted Camera lenses close to the window Given cameras and lenses: What is the optimal packaging?

Project Schedule : 

Project Schedule Remote-Controlled Underwater Camera System for Real-Time Monitoring of Fatigue Damage in Fuselage Panels 52 Final testing will be completed on campus by the end of May 2010 5/17/2010

Life Cycle Assessment : 

Life Cycle Assessment Remote-Controlled Underwater Camera System for Real-Time Monitoring of Fatigue Damage in Fuselage Panels 53 Goal Definition To validate airworthiness of aircraft structures Life Cycle Inventory (LCI) Inputs during fabrication and running shall be stainless steel parts and electrical energy Impact Analysis No measurable negative impact on the environment Interpretation No notable quantities pollutants released during fabrication and assemble of the system No non-eco-friendly by-products Primary purpose was to ensure safe air travel and shall aid in doing so 5/17/2010