Step/Gap Meter for Composite Panel Assembly

The goal of the proposed effort is the development of a real-time step and gap sensor to be used for the assembly of fighter aircraft. This sensor will use time domain THz technology to generate a spatial image of the gap between the panels while simultaneously determining the ground plane step mismatch through a time-of-flight type measurement. This time-of-flight measurement will also determine the coating thickness, and step measurement will be corrected for coating thickness variations. In the Phase I effort, an existing real-time wet paint thickness sensor design will be modified for step and gap measurements and the utility of the proposed technology will be demonstrated at Lockheed-Martin, thereby achieving Technology Readiness Level (TRL) 5 before the completion of the Phase I effort. A second goal of the Phase I effort will be further advancement of the technical and manufacturing readiness levels of the sensor. A preliminary design of the Phase II prototype will be completed, and vendors for critical OEM components and assemblies will be identified. In the Phase II effort, PSI will team with Comau, Inc., a systems integrator. Comau will integrate the sensor into the ultimate tool used in the aircraft assembly facility.