Sikorsky Senior Design Project

1
Sikorsky Senior Design Project

• Group Members
• Ali Awdi (ME/MEM)
• Jeff Euen (MEM)
• Donald Gwizdak (MEM)
• Shailan Lala (CMPE)
• Haley Meader (MEM)
• Alejandro Wille (CSE/EE)

• Advisors
• School of Engineering
• John Ayers
• Zbigniew Bzymek
• School of Business
• Manuel Nunez

2
Outline

• Problem Statement
• Initial Solutions
• Proposed Solutions
• Cost Analysis
• Solution Assessment
• Conclusion
• Acknowledgments

3
Problem Statement

• Develop a new paperless inspection method and
  procedure to eliminate the use of Mylar in the
  inspection process.
• Reduce time, reduce spending and eliminate manual
  verification of part geometry while increasing
  overall quality.

4
Preliminary Solutions

• Revamp Current System
• Molding
• Silhouette Projection
• Laser Scanning
• 3D Digitization

5
Proposed Solutions

• Laser Scanning - Mensi
• 70,000
• Photogrammetry - Eos Systems
• 1,000 - 5,000
• Vision System Cognex
• Equipment 2,000 - 5,000
• Integrated System 10,000 - 20,000

6
Photogrammetry vs. Vision System

• What is photogrammetry?
• Technique of measuring objects (2D or 3D) from
  digital photographs
• Multiple photographs taken from different angles
• Software recreates 3D image
• Produces data - dimensions, hole placements and
  part angles

7
Photogrammetry vs. Vision Systems

• What is a vision system?
• Works similar to an eye
• Camera views a part and captures an image
• Image is then compared to a master image
  existing on a database

8
Eos Systems Inc.

• Based in Vancouver, British Columbia
• Develops software for 3D modeling technology by
  using the technique of Photogrammetry
• Creators of the award winning software
  PhotoModeler

9
Eos Systems Inc.

• PhotoModeler Pro V.5
• What is PhotoModeler?
• Software allows a user to create accurate, high
  quality 3D models
• Measurements based on digital photographs

10
Eos Systems Inc.

• How does Photomodeler work?
• Software overlaps two or more photos taken from
  different angles
• User marks key reference points on the
  photographs
• Software recreates a 2D or 3D image using
  reference points
• Image used to measure dimensions, angles and
  other critical features

11
Eos Systems Analysis
12
Cognex

• Founded in 1981
• Headquarters in Natick, Massachusetts
• Figures from 2003
• 150 million in sales
• Growth 31 in sales
• Net Income 16 million
• Employs 634 people
• Current users include Ford Motor, Isuzu, Volvo,
  GM Canada
• Integrators include Ohlheiser, Palomar
  Technologies, and Inex Vision
• www.cognex.com

13
Cognex

• In-Sight Vision Sensors
• Low-cost, high-performance online inspection
  devices used to automatically identify and
  measure parts
• Vision sensors are effectively eyes
• Sensor looks at a part at a rate of 18 frames /
  sec
• Image compares pre-existing image via software
• Part is automatically accepted/rejected based on
  the software analysis

14
Cognex Specifications

• In-Vision 4001
• Hi-resolution camera
• Resolution 1024x768 pixels
• 18 Frames / Second
• Accuracy to 1 / 1000 of the parts size
• Power consumption 6.6W at 24VDC
• Memory
• 8MB non-volatile flash memory
• 16MB SDRAM
• Weight 275g (9.7 oz) Height 46.7mm (1.84in)
  Width 43.18mm (1.7in) Length 118.6mm (4.6in)
• Built-in Ethernet connector

15
Ohlheiser / Cincinnati Automation

• Integrate Vision Systems
• Utilizes Cognex as one of its suppliers
• Develops custom robotics used to inspect a part
• Custom software for specific applications
• Inspecting a part
• Cognex offers its integrators free software
  updates as well as training and 24/7 technical
  support
• www.ohlheiser.com
• www.cincinnatiautomation.com

16
Cost Analysis

• Cost benefits of each solution
• Sikorskys in-house and supplier costs
• Current System, 3D Digitization, Vision Systems
• Cost of bad parts
• Implementation of a new system
• Necessary Assumptions

17
Cost Analysis
18
Cost Analysis
19
Solution Assessment

• Advantages
• All proposed solutions are less expensive than
  Mylar
• Reduced cost of quality
• Increased accuracy
• Significantly reduced inspection time
• Disadvantages
• Adapting to a new system takes time and effort
• Implementation cost

20
Conclusion

• Photogrammetry (Eos Systems) and Vision System
  (Cognex)
• Inexpensive and cost-effective
• Minimal down time for implementation
• Meets design requirements
• Simplified system with customer support

21
Conclusion

• Option of in-house part verification
• Supplier networked with Sikorskys server
• Sikorsky has complete control over part
  specifications
• Suppliers need only a digital camera and a
  network computer

22
References

• Cincinnatiautomation.com
• Cognex.com
• Cyberware.com
• geomagic.com/advantage/quality/squared-index.php3
• hpcwire.com/hpcwire/hpcwireWWW/03/0725/105604.html
  
• inventors.about.com/library/inventors/blhelicoptor
  .htm
• machinevisiononline.org/public/
  articles/archivedetails.cfm?id909
• Mensi.com
• photogrammetry.ethz.ch/
• photomodeler.com
• renishaw.com
• Sikorsky.com
• Sikorskyarchives.com
• shapegrabber.com
• trimble.com/news/091703d.htm
• univie.ac.at/Luftbildarchiv/wgv/intro.htm

23
Acknowledgements

• Richard Allard (Tool Design Manager)
• Dr. John Ayers
• Dr. Zbigniew Bzymek
• Omar Dinar
• Gene Frohman (Tools and Test Facilities Design)
• Dr. Kathleen Maurer (Head of the Medical
  Department)
• Dr. Manuel Nunez