Visual assistance system for manual composite scarf repair

Kurzfassung

Scarfed bonded joints are the preferred way to repair composite structures as they have many advantages regarding mechanical optical and aerodynamic characteristics. The scarfed repairs typical are produced manually by grinding. This leads to time-consuming preparation work, especially for more complex geometries, and requires well-trained personnel. In the past, several projects have already been carried out with a view to possible process automation. However, due to the very individual damage and component characteristics, this process will continue to require manual labor in the future. In order to support the manual repair process, a visual assistance system is being developed in the Genex project. The aim is to support the grinding process and ensure quality assurance at the same time. Therefore, a 3D scanning system scans the surface in a repetitive loop and calculates the deviation to the target geometry. The generation of the target scarf geometry is based on the digitally measured original structure with the parameters defined in a user interface. The difference is then projected onto the surface allowing the worker to identify all necessary deviations for further grinding. Furthermore, after the finished grinding process, the system provides support in the production and the positioning of the patch. Finally, further potential applications of rear projection in the field of digitally supported MRO activities are identified.