Irkutsk Aviation Industrial Association (IAIA) found that the introduction of CAD/CAM methods in its plant caused problems in its inspection procedures. The company found it difficult to handle the increased number of requests for part inspection, since its traditional coordinate measuring machines required a special environment and trained staff. In addition, IAIA needed to inspect parts, assemblies and tooling during intermediate manufacturing stages.

List of requirements

A comprehensive list of requirements was drawn up for a new inspection system. It would require full inspection functionality but would also have to be mobile and flexible so that it could be used in workshop conditions. It would need to have a short learning curve as well as being able to be integrated with the company's CAD/CAM software. Finally, it needed to be cost-effective. After research into a variety of measurement tools, IAIA specialists selected Romer inspection arms combined with Delcam's PowerINSPECT software.

The first test for the new system was the inspection of an assembly jig, approximately 5 x 3 m, with sets of clamps on each side. The positions of the main features and the clamps were measured and deviations from the computer model were calculated.

By utilising the Romer arm, calculations were soon confirmed, there was no need to move bulky jigs into the traditional measurement areas, which reduced inspection time and difficulty. Further tests showed that it was also possible to inspect jigs at all stages - during their own manufacture, while they were being used in production or after any alterations.

The PowerINSPECT software allowed easy alignment to standard geometry and, most importantly, to any surface. It was possible to align the jig with the computer model, make the inspection and immediately see all the deviations. The accuracy of the individual jig parts and their relative positions in assembly could be checked at the same time.

Subsequently, the PowerINSPECT/Romer combination was used in the inspection of press tools, moulds and other tooling. The main advantage here was the mobility. It was even possible to move the system to make an inspection on the machine tool while machining and immediately produce a report. Inspection time, including the installation time, was reduced to between 20 and 30 minutes. Similar results were obtained in the inspection of parts from the mechanical workshops.

The final test was the inspection of the central part of an aircraft hull in the assembly workshop, to measure the position of landing gear attachment points. Again, the ability to attach the arm to virtually any part of the assembly allowed measurements to be made in difficult-to-access areas, where inspection had been very complicated, if not impossible.

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