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New Inspection Facility Boosts GKN Westland Helicopters

BIRMINGHAM, UK - July 28, 2000 - The first measurement system of its type in the UK has given helicopter manufacturer GKN Westland Helicopters the potential for a major boost to its productivity. This new system is based on VSTARS Photogrammetric equipment from the North American company , together with PowerINSPECT from CADCAM software developer Delcam. The initial improvements in productivity have come at a critical time for the company as currently the demand for its world-beating range of aircraft is at an all-time high.

Although Photogrammetric principles are well recognised, it is a relatively new measurement technique, where precision measurement with repeatability is paramount, especially with the direct link to the engineering geometry, specifically CATIA. The technique uses reflective datum points and targets on the product or tool, which are highlighted by a flash unit and recorded as a digital image. It is the ability of the new generation of digital cameras, computer systems and software that has enabled Photogrammetry to be exploited for industrial precision measurement. The technique can be used in one of two ways. In the first procedure, the equipment uses two cameras to photograph each point being measured. A triangulation algorithm is then used to calculate the position of the point from the two pictures. In this mode, the results produced are equivalent to those generated by a conventional co-ordinate measuring machine. This mode, known as 'on-line', achieves 'real time' measurement. 

The second method uses a single camera to take a series of pictures of the object. The points to be measured are identified again by reflective targets attached onto the part. Typically, about twelve pictures will be taken. These can generate several thousand points, depending on the size of the part and the range of reflective targets used. With this mode, referred to as 'off-line', data can be collected quickly and analysed later. With both approaches, the digital images are loaded into PowerINSPECT, which is used to perform detailed analysis and provide reports of the product compared to the CATIA model. The software generates both pictorial and graphical summaries of the results, plus an Excel spreadsheet containing all the numerical data.

Dave Wakely, Central Tooling Manager within GKN Westland Helicopters, identified a range of valuable benefits from the innovative measurement technique. "Firstly, the Photogrammetric equipment is much more portable than our traditional approach. That would take many hours to set up, whereas it is now possible to complete a measurement task in less than an hour," he said. "In fact, the system is so easy to transport that we are now looking into using it on our suppliers' sites. This will be more efficient than shipping parts and tools, particularly large fixed jigs, back and forth for measurement."

"A further bonus is that work can continue on another section of the aircraft while a measurement is taking place. Previously, everything had to stop as any movement of the part affected the results. This meant either a delay in production or waiting for the shift to end before we could start the measurement task."

"The information we get from PowerINSPECT is laid out extremely clearly. The graphs and pictures meant that the results are meaningful to everyone, not just to the specialist. The system is also very fast - it can analyse thousands of points in under a minute. Being able to see, and understand, the results so quickly allows us to start work on fixing the problem that much sooner. All this has been achieved without any sacrifices in accuracy. Before we installed the system, we tested it extensively on a range of standard measurements and found that the results were equivalent to those we had recorded previously. This is essential for us because, in the aerospace industry, compliance to standards needs to be demonstrated at every stage in the manufacturing process."

"PowerINSPECT has integrated well with Westland's corporate CADCAM system, CATIA. We regularly take files from CATIA into PowerINSPECT and have not experienced any data translation problems. Also the sophisticated surface fit software programme has provide invaluable in determining minimum product deformation. Additionally we have now also loaded PowerINSPECT on to our Co-ordinate Measuring Machine to exploit the benefit of a common software package supporting two systems."

"The training and use of software is an important feature. The Tooling Metrology Section was instrumental in the selection process and has been pleased with the short integration and learning time-scales. A final consideration has been the back-up we have received from Delcam. The training package was excellent and quickly gave our Metrologists confidence in using the software. The support has also been very strong. Furthermore, we have regular contact with the development staff, who are keen to use our ideas to make the software even better."

The installation of Photogrammetry typifies two of the key factors in GKN Westland's record order levels - a clear emphasis on customer service and a willingness to experiment with innovative technology. "Our customers have high expectations of our products," concluded Mr Wakely. "With this new approach, we can quickly and easily demonstrate that we can meet those expectations."

http://www.delcam.com

 

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