Some thoughts on measurement technologies in the aerospace industry

Some thoughts on measurement technologies in the aerospace industry November 2016 Copyright 2016 Boeing. All rights reserved. Antonini Puppin-Macedo, Ph.D. Managing Director Boeing Research & Technology, Brazil

Materials and Manufacturing Technology Acknowledgement Dr. Philip Freeman, Senior Technical Fellow Boeing Research & Technology Materials and Manufacturing Technology For the support in preparing this material and giving a vision of our metrology needs 2

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History of innovation The Boeing B-47 Stratojet is the world s first large swept wing jet, it sets the pattern, still followed today, for the optimal design of the subsonic jet. The McDonnell Mercury capsule takes Alan Sheppard into space making him the first American in Space and following that John Glenn becomes the first American to orbit the Earth. Boeing introduces the first successful ground to air radio communication The Boeing 707 becomes the world s first successful commercial jet. Boeing flies the 747 - The world s first widebody jet 1929 1949 1957 1962 1969 1936 1953 1960 1968 Boeing Model 307 Stratoliner World s first pressurized commercial airplane. North American pioneers the first high thrust rocket engines that will evolve into the engines that powered the Saturn V and the Space Shuttle. The Douglas D-558-2 becomes the first aircraft to exceed Mach 2 Boeing, McDonnell Douglas and North American Rockwell team to build the Saturn Apollo space vehicle that takes the first humans to the surface of the moon and returns them safely to Earth. BR&T Story 5

Boeing introduces the modern computerized glass cockpit to commercial air travel on the 757 and 767. The 767 also introduces ETOPS allowing a twin jet to fly across the Atlantic Boeing, Virgin Atlantic and GE Aviation conduct the first commercial aviation flight using a sustainable biofuel mixed with conventional kerosenebased jetfuel. The Boeing Lunar Rover transports astronauts on the lunar surface. International Space Station First permanent home in space 1971 1981 1993 2008 Demonstrating a company commitment to pioneering research, the Boeing X-51A WaveRider in its first flight attains Mach 5 and completes the longest hypersonic scramjetpowered flight in history. 2010 1976 1987 1994 2009 North American Rockwell introduces the world s first reusable spacecraft the Space Shuttle The 777 is the world s first commercial jet to be entirely digitally designed and digitally pre-manufactured The first Hughes 601 satellite achieves orbit. The Boeing 787 Dreamliner takes flight. Marking a dramatic leap forward in aviation, this transformative jetliner pushes the boundaries of technology with structural, propulsion, aerodynamic and systems innovations. BR&T Story 6

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Boeing s Future and Innovation Boeing Commercial Airplanes Product Development Boeing Research & Technology Boeing Defense, Space & Security Phantom Works R&D organization 12

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BR&T-Brazil Snapshot Focus Area 1: Aero Technologies Integrated Simulation & Testing Airspace & Operations Efficiency Flight Sciences (Aerosciences + MDAO) Focus Area 2: High-Value Natural Resources Biofuels Joint Research Center with Embraer High-Temperature Metals & Sustainable Materials BCA Support EcoDemonstrator with Embraer Cabin Comfort Tool Testing

Measurements in the aerospace industry Some paradigms Large products, yet very precise Complex manufacturing Multiple materials metals, composites High production rate (e.g. B737 42 a/c per month) Our measuments Quality Guiding automation Significant reliance on measurements to build the airplane Performance drag, lift, speed; flow of fluids; electric measurements 16

Air Data Examples air data EcoDemonstrator 2016 As a potential replacement for today s Air Data Systems, Light Detection and Ranging (LIDAR) technology is installed to measure aircraft speed, angle of attack, temperature and pressure using small lasers. This technology has potential application to improve safety, reduce airplane weight, drag and fuel use 17

Aerodynamics Example Examples particle image velocimetry Engineers at NASA Langley used lasers inside the 14-by 22-Foot Subsonic Tunnel map how air flows over a Boeing BWB model Image credit: NASA/David C. Bowman A Laser-Sharp View of Blended Wing Body Plane Design NASA (source: http://www.nasa.gov/image-feature/langley/a-laser-sharp-view-of-blended-wing-body-plane-design 18

Aerodynamics Example Video http://www.nasa.gov/image-feature/langley/at-hangar-raptors-find-shelter-from-the-storm 19

Future new paradigms Laser is the now! Accuracy in 3D is limited by the mechanics of steering the beam. UK s National Physical Laboratory (NPL) developed very accurate 3D distance in any direction - but no angle measurement How can we get around the mechanical limitations which are orders of magnitude larger than the laser s wave length. Optimal + imaging measurements Photogrametry based systems with high accuracy targets Need to move to precision tracking of natural features get rid of targets. Lots of research, but few products at metrology grade SLAM (simutaneous localization and mapping) and sensor fusion It is similar to our experience as human beings getting in a place navigating and mapping at the same time. 6-DOF getting to metrology grade... Opportunity here as well!! Computational cost... It is a revolution to come 20

Shapping the future working with NIST Important initiatives and trends Help buiding the standards to certify sensors and measuments techniques Boeing is involved in helping this process, showing our requirements and needs Most metrology systems are end user systems how can we move into a network based automated system? Integratable into automated systems. No communication standards? Protocols? How a metrology system becomes part of a factory system? Becoming a part of the factory ecosystem, with less participation of the human in the loop less end user approaches Take away points: Systems are more and more integrated Integration requires common architecture and protocols, etc. Internet of measuring things All integrated into a factory imagine building very large Boeing airplanes this way... 21

Shapping the Future in measurement now! ecodemonstrator 2016 Systems: As a potential replacement for today s Air Data Systems, Light Detection and Ranging (LIDAR) technology is installed to measure aircraft speed, angle of attack, temperature and pressure using small lasers. This technology has potential application to improve safety, reduce airplane weight, drag and fuel use Airplane Noise: Developing noise improvements for slat design, located on the wing leading edge, that has the potential to reduce airplane noise on takeoff and approach Aerodynamics: Airflow near the wing surface will be examined using autonomous sensors and air visualization techniques to better understand inflight aerodynamics. This analysis could lead to further innovations to reduce fuel consumption and carbon emissions Ice Phobic Paint: The aircraft is painted with ice phobic paint that reduces icing and drag. Additionally, due to its adhesion reducing properties, the special paint can help operators save water by reducing the need for frequent aircraft washing Biofuels: All test flights will use biofuel blend produced in Brazil: 50 to 80 percent lower carbon emissions through its life cycle than fossil jet fuel 22

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Closing Remarks Video: SUGAR Volt 25

GRACIAS! 26