status of 3d ice shape measurement effort
TRANSCRIPT
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National Aeronautics and Space Administration
www.nasa.gov
Status of 3D Ice Shape Measurement Effort
Sam Lee
ASRC Aerospace, Inc.
2011 Annual Technical Meeting
May 10–12, 2011
St. Louis, MO
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National Aeronautics and Space Administration
www.nasa.gov 2
Outline
• Introduction
• Research Plan
• Project Status
• Future Plans
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National Aeronautics and Space Administration
www.nasa.gov 3
Introduction• Main goal of the Airframe Icing Technical Challenge is to
achieve acceptance of experimental and computational icing simulation tools– Supercooled Large Droplet Icing (SLD) conditions
– 3D airframe components including swept wings.
• It is necessary to develop suitable means of recording and archiving fully 3D descriptions of experimental ice accretion geometry.
• Past research has shown that commercial laser scanners have the potential to be adapted to this task.
• A research plan has been developed to implement and validate the use of this technology for experimental ice accretions.
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National Aeronautics and Space Administration
www.nasa.gov 4
Introduction (cont’d)• Phase 1 – Identify most suitable scanning system
– Focus specifically upon measuring ice accreted in the NASA Icing Research Tunnel (IRT).
– Built on recent demonstration tests of portable scanners in IRT.
– Follow-on IRT testing and demonstrations conducted to complete a down-selection process to the most promising and suitable technology.
• Phase 2 – Validation exercises to define scanning capability.– Calibration block
– 2D geometric and aerodynamic comparisons
– Swept-wing geometric comparisons
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National Aeronautics and Space Administration
www.nasa.gov 5
NASA Milestones
• Level 3 milestone– “Select Candidate Laser Scanning System”
– Q1 FY2012
• Level 1 milestone– “Declare 3D Ice Accretion Measurement Capability”
– Q4 FY2013
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National Aeronautics and Space Administration
www.nasa.gov 6
Research Plan – 1st Phase• Evaluate candidate laser scanning system in IRT.
– Demonstrate capability to operate in the IRT environment.
– Evaluated on the basis of criteria having to do with operations, scanning capability/accuracy and cost.
• Evaluate candidate software used to post-process the scanner data .– Demonstrate ability to create “water-tight” surface.
– Evaluated on the basis of criteria having to do with operations, efficiency, ease of use, and cost.
• Assessment of rapid-prototyping capability. – Scan data of ice accretion will be processed to water-tight surface.
– Various RPM (rapid-prototype model) vendors will be contacted to ascertain the current state of capability to manufacture artificial ice shapes.
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National Aeronautics and Space Administration
www.nasa.gov 7
Research Plan – 1st Phase (cont’d)
• The outcome of Phase I will be a selection of both laser scanning hardware system and post-processing software.– This will satisfy the AEST level 3 milestone.
Define
Scanner
Selection
Criteria
Evaluate
Scanners
in IRT
Define
Software
Selection
Criteria
Down-
Select &
Purchase
Scanner
Evaluate
Software
Down-
Select &
Purchase
Software
RPM
Assessment
Phase I Roadmap
Evaluate
Scan
Data
Le
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Mile
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National Aeronautics and Space Administration
www.nasa.gov 8
1st Phase Research Task
• Define evaluation/selection criteria for scanner hardware and software.
• Define specific laser scanner systems (hardware) and post-processing software to be evaluated.
• Develop test and evaluation plans.
• Evaluate candidate current laser-scanning systems in IRT.
• Evaluate candidate software systems.
• Conduct assessment of Rapid Prototype Method (RPM) capability.
• Down-select one hardware system and one software system for Phase II.
• Purchase hardware and software.
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National Aeronautics and Space Administration
www.nasa.gov 9
Selection Criteria - Hardware
• IRT test section capability– Environment - operate in a wide range of IRT test section
environment.
– Usability
• Portability
• Ease of use.
• Convenience of measurement procedure
• Scanning capability– Scan resolution
– Scan speed
– Ability to scan gaps and holes.
– Accuracy
• Cost vs. capability
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National Aeronautics and Space Administration
www.nasa.gov 10
Selection Criteria - Software
• Scanner compatibility
• Water-tight modeling ability
• Noise filtering
• Efficiency– Ease of use
– Speed
– Processing time
– Large file capability
• Cost vs. capability
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National Aeronautics and Space Administration
www.nasa.gov 11
Research Plan – 2nd Phase• Implementation and validation of the selected system.
• Validation exercise with known geometry to define the measurement capability. – Benchmark measurements performed on the metal calibration blocks.
– These data can be used as a type of check standard to ensure uniform capability over time.
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National Aeronautics and Space Administration
www.nasa.gov 12
Research Plan – 2nd Phase (cont’d)• “Circular” validation along with aerodynamic assessment
based upon a 2D airfoil geometry.– Perform laser scans and pour molds of selected ice accretion.
– Use scan data to create high-fidelity (RPM) artificial ice shapes along with castings from molds.
– Compare scanned and cast geometries
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National Aeronautics and Space Administration
www.nasa.gov 13
Research Plan – 2nd Phase (cont’d)• A closely related 2D aerodynamic evaluation will also be
conducted– RPM artificial shapes made from ice scans will be tested against
castings.
– Use methods established during NASA/ONERA/UIUC Aerosim Project
– These validations (both geometric and aerodynamic) should be conducted for each of the four basic categories of ice accretion: roughness, horn, streamwise and spanwise ridge.
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National Aeronautics and Space Administration
www.nasa.gov 14
Research Plan – 2nd Phase (cont’d)
• Geometric validation test on a swept-wing model.– This exercise will consist of scanning an ice accretion, making a mold
and casting of that ice accretion.
– The scan data used to create an RPM artificial shape that can be scanned and compared to the original ice accretion.
– A scan of the casting can also be compared to the original ice accretion scan.
– Aerodynamic assessment not possible at this time due to lack of established method.
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National Aeronautics and Space Administration
www.nasa.gov 15
Research Plan – 2nd Phase (cont’d)• Develop procedures for using the scanner in the IRT as well as
for post-processing the data.– Document to serve as an internal reference guide for continued IRT
testing and use of the scanner and software system.
– Include all aspects of the measurement
• Preparation of the ice accretion (e.g., “painting”)
• Set-up of the scanning (e.g., any in-situ calibration or homing)
• Scanning of the ice (e.g., software settings, resolution vs. time and desired accuracy)
• Saving of the data (e.g., file types and sizes)
• Post-processing of the data (e.g., procedures for hole-filing, software settings, extracting tracings, etc.).
• The outcome of Phase II will be declaration of 3D ice accretion measurement capability.– This will satisfy the AEST level 1 milestone.
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National Aeronautics and Space Administration
www.nasa.gov 16
Research Plan – 2nd Phase (cont’d)
Benchmark
Measurements
Rqmts
Met?
Le
ve
l 1
Mile
sto
ne
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3D
Ic
e S
ha
pe
Me
as
ure
men
t C
ap
ab
ilit
y
Declare
Swept
Wing
Capability
Y
N
Phase II Roadmap
RPM of
Scan
Shapes
Mold/Cast
Ice Shapes
IRT Ice
Accretion
Test
Aero test/
Comparisons
Geometric
Comparisons
Geometric
Comparisons
RPM of
Scan
Shapes
Mold/Cast
Ice Shapes
2D Airfoil Validation
Swept Wing Validation
IRT Ice
Accretion
Test
Declare 2D
Capability
Ph
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National Aeronautics and Space Administration
www.nasa.gov 17
2nd Phase Research Tasks
• Benchmark scanner with calibration blocks
• 2D airfoil model evaluation– Geometry comparisons
– Aerodynamic comparisons
• Swept wing model evaluation– Geometry comparisons
• Standardize methods for laser scan data acquisition and post-processing.– Write process description with quantifiable standards
• Declare 3D ice accretion measurement capability.– Satisfy AEST Level 1 milestone.
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National Aeronautics and Space Administration
www.nasa.gov 18
Project Status
• Hardware/software selection criteria established
• Evaluated candidate scanners in IRT– Creaform – Oct 2009
– Faro Arm– Nov 2009, March and April 2011
– Romer – March 2011
– nVision – April 2011
• Tested ice shapes from identical model and icing conditions– Glaze, rime, roughness on straight NACA 0012
– Scallop ice shape on 45 deg swept NACA 0012
• Purchased software to evaluate scan data (Geomagic)
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National Aeronautics and Space Administration
www.nasa.gov 19
IRT Scanner Evaluation Procedure
1. Accrete ice on test article
2. Photograph ice
3. Spray paint accreted ice using airbrush
4. Install/set up laser scanner
5. Scan ice
6. Cut ice and make tracing
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National Aeronautics and Space Administration
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IRT Scanner Evaluation
Painting ice with air brush paint
Painted ice
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National Aeronautics and Space Administration
www.nasa.gov 21
IRT Scanner Evaluation
Scanning ice shape with 3D scanner.
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National Aeronautics and Space Administration
www.nasa.gov 22
IRT Scanner Evaluation
Hand tracing of ice shapes for
comparison to scanner.
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National Aeronautics and Space Administration
www.nasa.gov 23
Water Tight Scanned DataGlaze Ice
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National Aeronautics and Space Administration
www.nasa.gov 24
Water Tight Scanned DataRime ice
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National Aeronautics and Space Administration
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Scanned Data3D Scallop Ice
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National Aeronautics and Space Administration
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Comparison of 3D Scanned Data to Hand Tracing
x (in)
-1 0 1 2 3 4 5
y (
in)
-2
-1
0
1
2
Clean Model
Hand Traced
3D Scanner
Glaze ice
x (in)
-1 0 1 2 3 4 5
y (
in)
-2
-1
0
1
2
Clean Model
Hand Traced
3D Scanner
Rime ice
x (in)
-2 0 2 4 6
y (
in)
-3
-2
-1
0
1
2
3
Clean Model
Hand Traced
3D Scanner
3D scallop ice
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National Aeronautics and Space Administration
www.nasa.gov 27
Future Plans
• Evaluate data from candidate scanners
• Down-select and purchase scanner
– Q1 FY2012 (L3 milestone)
• Assess and validate scanning system and methods
– Straight and swept wing geometry
– Compare aero results with scanned and cast ice shapes
• Declare 3D ice shape scanning capability
– Q4 FY 2013 (L1 milestone)