Robotic Automated Coating Removal System (RACRS) Ben Thompson New Technology Insertion, Fleet Readiness Center – East ben.h.thompson@navy.mil, 252-464-9985 Ted Reutzel, PhD Applied Research Laboratory, Pennsylvania State University ewr101@psu.edu, 814-863-9891

RACRS Background New Weapon System Challenges Technical approach Intro / (2) parts Background / technical approach

V-22 Osprey New Weapon System FRC East designated as the OH fac for the V22 Started with mods New Weapon System

New Weapons Systems System Acquisition for Operations Maintenance /Sustainment Back seat numerous problems to solve or purchase from OEM.

Challenges Copper Mesh Geometry Facilities Unknowns

Challenges Copper Mesh- brown material on fuselage Factory view as being built Copper Mesh- brown material on fuselage

Close-up of copper mesh Use for lightning strike, if damaged is a costly and timely repair. Depends on the damage.

Geometry Refueling Probe Don’t Think this configuration is continuing but have to be prepared for older models. Refueling Probe

Geometry Pitot tubes , other pertrusions Obstacles

Geometry Engine Housing Without the rotor blades, can be rotated to the horizontal position. Engine Housing

Geometry Vertical / Horizontal

Geometry Need know the position of A/C moving parts Wing ailerons

Facilities Open Hanger Safety, re-useable 2-3 a year now ramping to 14-20. Open Hanger

Facilities Jacking / Underneath/Height Higher we jack, still need to get to the top. Jacking / Underneath/Height

Unknowns Special paint Air Force needs, Bottom line to meet those as efficiently as possible. One constant the problem. Variable is how we solve it and we believe have a proven solution. Special paint

Images courtesy FRC East Problem Statement 5,000 helicopters in DoD ~1,770 blades refurbished each year Depainting is critical step in the process Hand sanding is labor intensive, can result in damage, and generates secondary hazardous waste 450 V-22 tiltrotors are planned Initially 5 refurbs annually, but ramping up 2,457 ft2 surface area requires depaint 372 hours/aircraft by hand sanding Images courtesy FRC East

Technical Approach Raster pulsed laser beam to stripping paint Pulsed laser ablates materials & limits thermal impact Closed-loop sensor feedback control to protect substrate Already Stripped Area Area to Strip Video courtesy of General Lasertronics Corporation (Mitch Wool, 408-947-1181) and Pacific Northwest National Laboratory (Norm Olson, 509-372-4810)

Q-switched Nd:YAG Laser Technical Approach Topcoat Removed with Q-switched Nd:YAG Laser Hand Sanding Damage

Images courtesy FRC East and NUWC Keyport Technical Approach Background Extensive testing laser to approval for laser stripping for H53E Blades in April 2009 Automated Rotor Blade Stripping System (ARBSS) installed in June 2009 Numerous production blades have been processed  8-12 hrs vs 22 hrs hand sanding Approved for Set & Forget operation Upgrade the Automated Rotor Blade Stripping System (ARBSS) Integrate ARBSS technology with sophisticated robotics to strip full V-22 aircraft Images courtesy FRC East and NUWC Keyport

Technical Approach

Images courtesy FRC East and NUWC Keyport Technical Approach ARBSS Upgrades Upgrade the three (3) lasers: Older/Used 150 W laser systems  new 400 W laser systems Improve Laser Stripping Head Maintainability Modularity Laser Workhead cleaning station Strip other blades H-60 Miscellaneous improvements to User Interface Images courtesy FRC East and NUWC Keyport

Technical Approach Robotic Automated Coating Removal System - RACRS Transition the advanced laser stripping head and sensing technology to a semi-automated robot for stripping V-22 off-aircraft components and full aircraft. Integrate into Flexible Work Cell for stripping other rotor blades and off-aircraft components. Integrate with mobile robots for V-22 full aircraft. Images courtesy Battelle Sophisticated robot path planning to prevent collision is critical to cost effective implementation.

Technical Approach Images courtesy Battelle The operator positions the RACRS near the V-22 Aircraft in preparation for laser processing. The operator then commands the RACRS to perform a 3D overview scan that defines the work space.

Technical Approach Images courtesy Battelle The 3D scan is saved within the operator control system as a 3D surface model. Using the 3D model, the operator will click and drag a window to represent the area on the aircraft that the RACRS will be requested to process.

Technical Approach Images courtesy Battelle The RACRS control software will define a collision-free coverage trajectory for the defined process area. The operator will be able to check the planned trajectory to assure that the algorithm has defined a viable coverage area before commanding the RACRS to laser strip the defined area.

Technical Approach Images courtesy Battelle When the stripping is complete, and to the satisfaction of the operator, the RACRS is repositioned to address the next area to process. One or more RACRS may be employed simultaneously to reduce the amount of time required to completely strip the V-22 aircraft.

Overall Benefits ARBSS Upgrades Worker and Environmental Benefits Production Cost Benefits At full FRC East workload of 450 rotor blades/year, estimated that costs recovered in 10.5 months RACRS V-22 Full Aircraft Reduce coating removal hours 372 hrs hand sanding  50 hrs RACRS Ability to use system for other blades, off-aircraft components, and other aircraft!

Technology Deployment Who’s using the technology? Laser stripping technology with closed-loop control is approved by the U.S. Navy and Sikorsky Aircraft for certain thin composite rotor blades. Approved by FAA for use on commercial aircraft. FRC East is currently using the ARBSS system to strip H53E rotor blades. What are some challenges? Funding uncertainty and delays. Integrating the (i) environment mapping and (ii) robot path planning to prevent collision with the aircraft. Ease-of-use to ensure buy-in from managers and operators. Demonstrating cost benefit to ensure buy-in from decision makers. Ensuring adequate support during and after installation.

Strong Commercial Team In Place For Effective Deployment