Subproject C2 Fast Measurement of Complex Geometries

For aircraft engine maintenance, in particular the inspection of a blisk, the engines are partially disassembled and analyzed with flexible video endoscopes. This subjective visual inspection is conducted by specially trained employees. In order to enable a quantitative analysis, research is carried out a high-precision miniature 3D measuring system based on the fringe projection method. This sensor is implemented via a borescope, that is equipped with a chip-on-the-tip camera. The combination of high-precision actuators and a sensor with specially developed calibration and stitching procedures can achieve automated 3D measurements. This system will enable a precise quantitative quality control that increases the safety and efficiency of engine maintenance. 

In the third funding period, the research will focus on the prediction of measurement uncertainty of endoscopic fringe projection sensors. With the additional uncertainty information, a detailed planning of the measurement strategy can be prepared. In particular, the artifact formation caused by multi-reflections of the measuring light on the work piece should be avoided by a smart measuring pose planning. In the further progress of the third funding period, the fringe projection sensor will be integrated into a milling machine (as a tool). The high precision actuators and measuring systems enable the automated generation of a “digital twin” of the real work piece. A digital twin can map the machining process as well as the actual and the target geometry for each individual component. In the end of the project all research will be used to develop an even more.