Automated Integration of NDT Data into Digital Twins for Aircraft Structure Inspection: Results from the AIRPASS Project
Abstract
This abstract presents the outcomes of the AIRPASS project, a collaborative effort between Royal Netherlands Aerospace Centre (NLR) (an applied research organisation in the aerospace domain) and Bundeswehr Research Institute for Materials, Fuels and Lubricants (WIWeB) (an independent Bundeswehr research center which is responsible for the safety, technology and chemistry of materials and petroleum, oils and lubricants), which aimed to develop a novel inspection concept for aircraft structures by leveraging automation and digitalization. The project's core idea revolves around the central role of the digital twin, fed by non-destructive testing (NDT) data. Within AIRPASS, we successfully demonstrated an automated approach to link inspection data to the digital twin. Notably, NLR and WIWeB employed distinct methods to achieve this goal: NLR utilized visual properties of the inspected object to register the position of its contactless NDT sensor with respect to the digital twin, whereas WIWeB employed positioning devices that recognized reference points in 3D space, suitable for probe-like sensors. The method employed by NLR combines the simplicity of a Structure from Motion (SfM) system for camera positioning and orientation, with the geometric accuracy of high fidelity 3D scanning or CAD geometry for the projection of NDT measurements. The WIWeB’s system makes use of an optical tracking system, which enables precise locating of the sample, probe and Mixed Reality glasses. It features real-time feedback for the user by drawing the NDT results as a color-coded map into the texture of the 3D model and displaying it in the users field of view. A comparative analysis of the results from both approaches was also conducted, providing valuable insights into the effectiveness of each method. The AIRPASS project's findings pave the way for enhanced automation and digitalization in aircraft inspection processes.