Braking high for confident measurements

Citation

(2005), "Braking high for confident measurements", Aircraft Engineering and Aerospace Technology, Vol. 77 No. 2. https://doi.org/10.1108/aeat.2005.12777baf.007

Braking high for confident measurements

Braking high for confident measurements

Keywords: Aerospace industry, Braking systems

Dunlop Aerospace is a leading provider of high technology solutions to the aerospace industry, its products at the performance end of the sector where quality matters most. The company's recent acquisition by Meggitt PLC has married key technologies to form an integrated organisation of complementary technologies, aiming to provide the best products and after- market services for both civil and defence aerospace industries world- wide.

Based in Coventry, Dunlop Aerospace Braking Systems is at the forefront of materials innovation and precision manufacturing, using skills and experience gained over many decades to deliver new systems for emerging markets.

Continually improving and reappraising existing designs, the company is now developing braking systems for electric applications, meeting future demand for hydraulics- free aero structures. To be the best, the company looks to its quality control activities to ensure its reputation is maintained.

As factory sites go, Dunlop's Holbrook Lane site is large and traditional from the outside.

Within the factory walls, however, a clean and contemporary environment is complemented by some of the most advanced manufacturing and production equipment. Tiny components with incredible detail for hydraulics and activation systems are made side-by-side with huge parts for brake and wheel assemblies fitted on the largest aircraft.

The contrast is not lost on Manufacturing Team Leader, John Snell. “One of the hardest parts of my job is ensuring that our diverse manufacturing output is within specification,” he says, “With large carbon brake discs on one hand and miniature stainless steel or titanium components on the other, the quality of our quality control is paramount.”

Almost three years ago, Dunlop realised that existing coordinate measuring machines and profile projectors were just too slow and inefficient for developing production requirements in their machining shop. In addition, spark erosion techniques were providing features that traditional inspection methods could not handle. “We have to manufacture to difficult tolerances on both features and position. The only way we can check parts accurately, repeatedly and quickly is with image- based inspection.”

In particular, bores of just twelve- and-a-half thousandths in a nozzle, drilled at an angle on a spark erosion machine, had to be measured to size and position checked within three- tenths – after lapping. Plug gauges damaged the edges and were subject to differences between operators.

“We had to find a solution that we could be confident with,” adds John, “These parts are critical and it's no good having a report that tells us something is within specification. We have to know it is.”

Dunlop looked at a number of non- contact measuring systems and found the performance of the top brands to be similar. However, the operators were asked to evaluate the different choices and one came out a clear favourite – the OGP UK Smartscope.

“Operators told us the Smartscope was not only the most repeatable machine, it was also the easiest to use.” John Snell was himself impressed with OGP, “For ease of setup, the clear screen and instructions and the need for little training, Smartscope gave us exactly what we wanted. It did what it said on the box.”

Since commissioning and programming the Smartscope, Dunlop have found many more applications where the machine's versatility and speed have replaced other forms of measurement, including a number of components needing three-dimensional checking of alignment and spatial relationships.

Dunlop's Smartscope has taken new product introductions in its stride.

A rotary jig attachment allows operators to check shaft components for dimension and roundness as well as cylindricity and other features not originally envisaged.

After 2 years, the installation is as popular as ever. “Thanks to the robustness of the Smartscope the machine is as able as the day it was delivered. OGP provide a great service and keep us – and the system – completely up to date.” John goes on, “I really can't fault OGP on support, they are very supportive, provide excellent backup and even help with knowledge-based issues.

They are there for us whenever we need them.”