Case Study: Honeycomb

AFI 5000P is the first system that enables fast and accurate inspection of ultra-fine details at large fields of view. Ever since scanning was developed, manufacturers have been trying to apply the many advantages. However, scanners have been unable to resolve the actual surface properties due to heavy interpolation of data or limited information available with each scan. The AFI 5000P is the first measurement system capable of resolving small details, even at large fields of view.

Problem

Up to this point in time, there has been no effective means of measuring components with high details. The "work around" has entailed switching to higher-resolution cameras or changing lenses to create smaller fields of view. However, these measures are, in most cases, a "band-aid" for inherent underlying technology weaknesses. The AFI 5000P is the first scanner capable of measuring fine details with large fields of view. An example of a high-detail, yet large surface is the top surface of honeycomb panels, which has been problematic to both CMMs and optical approaches due to:

• CMM probes fell into the honeycomb cells instead of touching the top face
• ball offset on CMMs
• CMMs slow, programming-intensive process
• thin surface of the honeycomb too narrow for optical systems
• light penetration by optical systems, hence unable to resolve the correct surface
• honeycomb material color posed a challenge for optical systems
• ridges, bumps, and sharply changing contours not resolvable by optical systems
• large surface area relative to small detail surfaces impossible for optical systems to measure at a large field of view

The scanning industry has been well-tested by honeycomb and other high-detail component manufacturers, but the technologies have been proven to be inaccurate and unsuitable for actual inspection purposes. Hence, manufacturers of honeycomb and high-detail materials have been attempting inspection processes with slower, more manual CMMs which deliver far less data, meanwhile banging their heads to try to apply optical approaches.

Solution

The AFI 5000P was employed to measure a machined honeycomb surface.

Test parameters were:

• no coatings or sprays allowed
• no photogrammetry/targets allowed
• full data coverage on honeycomb machined (top) surfaces and corresponding datums
• accurately collect and inspect data within the required tolerances
• large field of view
• NIST traceable
• no loss of performance in manufacturing environments

The unsprayed, uncoated honeycomb was placed in the AFI 5000P's field of view. The AFI 5000P measured the entire honeycomb face, and multiple views of the honeycomb face were accurately merged. All data was inspected and statistically analyzed.

Conclusion

The AFI 5000P addressed all requirements of a total honeycomb inspection system capable of quickly verifying dimensions in a manufacturing environment. Because the AFI 5000P can measure the small faces between the honeycomb cells, it addressed the "total solution" that honeycomb manufacturers require.

The AFI 5000P met all customer requirements by delivering:

• accurate data
• uncorrupted data, regardless of surface properties
• fast acquisition
• total inspection
• scaleable systems for large and small components
• no coatings or sprays required
• full data coverage on thin-cell machined surfaces and datums
• no targeting methods required
• suitable for demanding manufacturing environments
• NIST traceable