Community Research and Development Information Service - CORDIS

FP7

REFLECTOCFP16 Report Summary

Project ID: 641067
Funded under: FP7-JTI
Country: Germany

Periodic Report Summary 3 - REFLECTOCFP16 (In-Flight Local Surface Deformation Measurement by Means of Reflectometry and Shadow Casting)

Project Context and Objectives:
To measure the minute disturbances of the designed wing shape in-flight, at high altitude and subsonic cruising speeds a measurement system has been pre-designed in Clean Sky call 7 and need to be matured and evaluated for the flight test campaign in this project call 16. Based on this preliminary ‘reflectometry measurement system’ design the complete system as sensor components (hardware) and the analyses-software have to be improved so that the complete reflectometry system will be appropriate for the current overall BLADE design. Robustness and reliability during the flight test campaign is the top target. As the measurement method shall not affect the behaviour of the wing profile structure the wing reflectometry methodology development need to be completed in such a way that the requirement to detect any local deformations of the laminar wing surface whilst airborne will be met
Design realization and deployment of a complete measuring system based on quasi tangential reflectometry (bumps and dents) and triangulation (filler shape measurement). The System is featuring following components.
In the wing tip pod of each wing:
• 2 camera modules (4 cameras each)
• 1 ADU (Area distribution unit)
• 2 LED illuminators
In the aircraft cabin:
• 2 cabin computers (1 for each wing)
On ground:
• 1 Ground computer
The cabin computers are running a special software to control the system and collect the data from all the cameras simultaneously.
The ground computer is running the post processing software for reflectometry, Filler shape measurement and data/result transfer to an archive system.
The main objectives of this system are:
In-flight synchronous collection of the images from 16 cameras.
Supply of the flight test engineer with a user interface to monitor and control the complete airborne system.
Collect the data of up to 4 hours per flight onto a set of mobile disks
Transfer the data to the ground computer immediately after landing
Analyse the data in short time to free the mobile disks for the next flight.

Project Results:
The development of the complete reflectomety measurement system has been finalized and delivered to Airbus for integration into aircraft and is ready for the test campaign consisting of hardware and software

Delivered Software
The software architecture has been revised, the algorithms improved and the user interfaces developed and all programming parts completed:
• reflectometry analysis software (the software is now tolerant to reflection flaws as well as to wing bending and torsion and able to analyze general wing deformation (bending and torsion) in the defined range.
• control software for data acquisition with user interface for the flight test engineer on a/c, the single computer concept, installed on the cabin computer
• Shadow Casting software
• Filler Shape measurement software (This work package replaces WP 17 (formerly assigned to troubleshooting during flight test)
• Single computer concept (new WP)
As the BLADE flight test campaign is shifted to 2017 and to assure that the reflectometry measurement software is reliable and robust simulation tests of the full system set up (hardware and software) have been performed in the laboratory (Saab Wing Mock Up) onsite Airbus in Toulouse. The system was successfully tested in laboratory environment measuring wing surface imperfections as bumps, steps, bending and torsion. Further tests of finalized pattern on the fairing and its compatibility of the reflectometry architecture have been performed, too.
The optimization of the algorithms to assure adequate calculation time and provision of results in time during flight test campaign has been tested during the Saab wing mock up tests.

Delivered hardware to be installed in the wing tip pod:
Redesign for all units completed, tested and manufactured.
• 4 Camera Modules (2 for each wing)
• 4 Illuminators (2 for each wing)
• 2 ADU
Delivered hardware for the aircraft cabin:
• 2 cabin computer (incl. the single computer concept) and 1 set of SSD
Delivered hardware on ground:
• 1 Ground Analysis Computer
• 1 Adjustment bench
• 3 LED remote display boxes (ref. ADU)
Status of supporting markers on the wing:
Pattern and markers have been completed in period 1 and 2.

Potential Impact:
The Reflectometry Measurement System:
To measure the minute disturbances of the designed wing shape in-flight, at high altitude and subsonic cruising speeds the measurement system needed to be matured and evaluated for the flight test campaign. Based on this preliminary ‘reflectometry measurement system’ design the complete system as sensor components (hardware) and the analyses-software have to be improved so that the complete reflectometry system will be appropriate for the current overall BLADE design. Robustness and reliability during the flight test campaign is the top target. As the measurement method shall not affect the behavior of the wing profile structure the wing reflectometry methodology development need to be completed in such a way that the requirement to detect any local deformations of the laminar wing surface whilst airborne will be met. The reflectometry wing surface measurement system supports the development results of the overall CleanSky SFWA project goal to improve the laminar flow and therefore the carbon foot print.
The main objectives of the reflectometry wing surface measurement system are:
In-flight synchronous collection of the images from 16 cameras. To meet the light conditions during flight a special illumination have been developed. The acquired images from the camera modules observing the wing surfaces are being transferred (by an arial distribution unit / ADU) to the cabin computers, operated during flight from the flight test engineer. The user interface for the flight test engineer was designed and programmed to monitor and control the complete airborne system.
The System has been developed and delivered as a complete stand-alone measurement system. It is featuring all hardware sensors in the wing tip pod as well as in the aircraft cabin and the reqquired equipment on ground. The cabin computers are running a special software to control the system and collect the data from all the cameras simultaneously meeting the requirements of the flight test engineer during flight. The ground computer is running the post processing software for reflectometry and shadow casting measurement and data/result transfer to an archive system.

List of Websites:
www.5micron.de

Reported by

5MICRON GMBH
Germany
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