System Integration

Twin Coast Metrology can use its optical metrology and 3D projection capabilities to deliver completed turnkey systems tailored for your environment.

Our Capabilities

• Fully-automated production solutions including integration with robots and custom designed motion-control systems.
• High-throughput measurements systems, 5x to 10x faster than a CMM.
• Large field-of-view measurement systems, 12 meters by 3 meters (40’x20′ ).
• Optical 3D surface scanning using structured light, commercially known as white light scanning.
• Optical 3D surface scanning of uncoated composites and shiny metals
• Optical 3D measurements of hot (2000° F) metal parts.
• Optical 3D feature measurements of holes.
• Optical 3D feature measurements of edges.
• Optical 3D feature measurements of honeycomb and flex cells.
• Photogrammetry, 3D feature measurements of sticker targets.
• 3D Video Projection
• Statistical machine learning (neural networks, support vector machines, etc.) for Metrology
• Thermal paint analysis
• Composite repair

Thermochromic Paint

Thermochromic Paint, is paint that changes color with temperature. The paint is used to assist in the engineering of jet engine combustors. The paint is applied to the combustor, the combustor is installed into an engine, the engine is run through a test cycle, then the combustor is removed, and the paint color is interpreted to read the temperature of the fuel burn. However reading the temperature by interpreting the paint color by eye is imprecise and not repeatable.

System Overview

Twin Coast Metrology developed a system to directly read the temperature of thermochromic paint. The system observes the part in multiple color wavelengths, then uses a neural network to convert paint color to an accurate temperature measurement. The system then maps the calculated temperature to the 3D surface of the combustor, outputting a 3D temperature map that can be directly imported into the computational fluid dynamics (CFD) package.

The system final system included a rotary table, engineered LED ambient lighting, a light tent, a custom camera head with optical filters, and a custom software application.

Yield Improvement

High-accuracy, optically-guided center drilling increases material yields on superalloy powdered metal processes (PMP).

3-Axis Drill

3-axis drill integrated into the Center Drilling system provides high-accuracy positional drilling.  This maximizes material yield by allowing minimum removal of the outer casing.  Therefore, the largest diameter is yielded from the Powdered Metal billet.

Cradle accommodates billets up to 48″ (after band-saw cut)

Billets from 6″ thick up to 48″ long are accommodated on the part holding cradle.  The cradle contains hold-down straps that keep the billet in place during drilling.

Software-Controlled Feed Rate

The feed rate is adjusted in the software to allow for different material alloy types.

3D Cameras Image the Billet

After the billet is placed into the part holding cradle, 3D cameras image the billet under ideal lighting conditions.  The edges of the superalloy are visible as edge boundaries.  The highest-yield diameter is then extracted under operator control for maximum control of the yield.

Logging of Diameters In A Database

For each part number, the diameter is logged and fed downstream to the lathe operation.

Improved Drill Rates

The drill rate results in a cycle time comparable to or faster than traditional methods, while improving accuracy.  Constant-feed (as opposed to constant force) rates minimize work hardening of the material during drilling.

Rugged Design

Solid-steel and powder coated exterior construction can withstand bumps from the work area.

Software Integration With Factory Processes

The software outputs a report to scheduling personnel to feedback into an efficient process for inventory control.

NIST-Traceable

NIST-Traceable calibration artifacts ensure compliance with ISO/ANSI/MIL standards, and ensures consistent measurements.

Streamlined User Interface

The software User Interface was designed specifically for this process and requires minimal training while providing all functionality that operators request.

User-Serviceable

System maintenance can take place by in-house maintenance personnel.

Tough

Powdered metal superalloys are some of the toughest metals on the planet, and require special considerations regarding drilling forces, work-hardening, and feed/speed rates.  The Center-Drilling system was designed from the ground up to perform on these materials, providing peace of mind to customers for this critical process.