Sometimes "fake" is as good as real things.
While this may not be the case with a "Rolex" watch purchased for $20 on the streets of Manhattan, in the case of the United States
US Air Force jet fighter simulator
The functional replica of the ejection seat is as good as the real one.
It's actually better because the cost is much lower.
Bedford Fain Models Co. , Ltd. , Texas uses a handheld laser scanner from frovision, Inc.
South Lake, Texas, producing an accurate copy of jet fighter ejection seats for the flight simulation and training market at a cost of only a fraction of the original flightworthy seat.
Faintechnicians use scanners to capture 3D geometry of more than 100 components in the seat, and then use geometry to process these parts or models used to make molds for other seat parts.
"The scanner is ideal for this application because it can move objects to capture data from any angle with high resolution and accuracy," said Cris Runge, manager of scanning and reverse engineering.
Fain specializes in producing a small number of complex components.
"In our business, it's not a question of how many people can do it in an hour, it's a question of a work that can be done quickly and accurately," he said . ".
Engineers at the company use SolidWorks, SolidWorks and MasterCAM software to design and manufacture parts from 2D layouts, 3D surfaces, and 3D solid models.
Fain must measure customer accurately
Provide models and inspect the parts produced by the company's mechanics to ensure that they are accurate in size.
The company uses a portable CMM that uses laser changers, precision encoders and proprietary software to calculate, store and display three-
The size position of the target.
The beam steering system detects the movement of the target and directly tracks the servo motor of the target.
A limiting factor is that the device points to a point at a time, so the operator must manually move the steering system for each point measured.
The time involved in this process makes it impractical to reverse engineer anything outside of simple components and components.
Taking advanced measures, the company uses CMM to measure the dimensions of glass objects to be replicated inside the aircraft.
It took an operator about 12 hours to generate 650,000 points, which is enough to describe its geometry roughly but not completely.
Managers believe it is necessary to deal with more challenging reverse engineering tasks to meet the trend of more complex and unusual customer geometry. [
The Fain model wants to have a more advanced measurement method that not only captures enough data points to represent the profile surface, but also compares the two surfaces.
They looked at many other scanning options and chose vision's handheld laser scanner because it was able to move around the part, making it possible for parts of almost any size or shape to reverse engineer.
Handheld scanner is a portable scanning device that can capture 3D geometry.
The scanner is connected to the manipulator arm, which moves around the object, enabling the user to quickly capture data at high resolution.
The software allows complete model editing, Polygon simplification, and data output for standard 3D packages.
Due to the high cost and risk of actual aircraft training, a small part of the production cost, the army is training as many simulators as possible to replicate the flight experience with as real details as possible.
Companies that make flight simulators need high
The appearance, feel and function are similar to the original seat, but there is no fidelity ejection seat for ejection hardware and fireworks as well as other internal components. A fully-
Function aircraft ejection seat purchased in small quantities from original-
Equipment manufacturers cost up to $300,000.
Using the NVision scanning system, Fain Models developed a method to produce replicas of seats for $15,000 to $75,000 per seattenth to one-
The cost of the actual seat is fourth.
The company removed the real seat and placed the components on the granite base.
The technician then moves the hand-held scanner around the seat parts to capture its complete geometry.
One advantage of the scanner is that it is mounted on a mechanical alarm, so it is free to move any part.
It can also capture data sets to create a part frame for the coordinate system used to associate multiple parts to the same coordinate system.
Technicians disassemble the seat of their top-out mechanism on the granite base.
The first step is to measure personal points using a touch probe mounted on the laser scan manipulator arm.
These measurements serve as a coordinate system for the point cloud data collected by the laser scanner.
The next step is to scan the seat surface with a laser scanner.
The technician moves the scanner around the part with the same type of motion as the painted seat.
The scanner generates a point cloud for a single point.
The technician then converts the point cloud to a polygon mesh using the software that comes with the scanner.
They use reverse engineering software to convert polygon data into a surface model.
Technicians export the Surface model in IGES or STEP format and import it into CAD software.
The generated entity model is good-
Adjust to make sure it matches the geometry of the seat.
The geometry is exported to the CNC programming software, which is used to create tool paths for machining certain parts of the seat and to process the mold to cast other parts of the seat.
The seat body is made of aluminum.
Other parts such as seat cover and backrest are made of vacuum molds.
In order to make the simulator seat, about 100 components were produced and assembled.
This aspect of the "Simulation" success Fain business is so successful that it creates a new department called Fain Simulation Systems that produces analog hardware for commercial and military flight simulators at a far Cost
The department can develop, design and create almost any analog seat or cockpit hardware while ensuring that each design has the same look and feel as the real product. From low-fidelity, non-
Fully functional, high fidelity
Replica of the function, the design can be customized to meet the needs of customers.
"Our approach allows us to make a full seat faster than the traditional approach, depending on the Fidelity required," Runge said . ".
"This makes it possible for us to provide a lot of savings for companies that build simulators.
"The key to our success is the NVision handheld scanner's ability to capture the geometry needed for high-precision reverse engineering complex parts. " NVision [