1. Robotic Automated Coating Removal System (RACRS)
Ben Thompson
New Technology Insertion, Fleet Readiness Center – East
Ted Reutzel, PhD
Applied Research Laboratory, Pennsylvania State University

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

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

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

5. Challenges
Copper Mesh
Geometry
Facilities
Unknowns

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

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

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

9. Geometry
Pitot tubes , other pertrusions
Obstacles

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

11. Geometry
Vertical / Horizontal

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

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

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

15. 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

16. 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

17. 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, )
and Pacific Northwest National Laboratory (Norm Olson, )

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

19. 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

20. Technical Approach

21. 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

22. 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.

23. 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.

24. 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.

25. 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.

26. 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.

27. 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!

28. 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.

29. Strong Commercial Team In Place For Effective Deployment