Automated Optical Inspection for Reduced Cost of EOTS Sapphire Panel Assemblies

A2620 — Optical Evaluation of Sapphire Panels

Objective

This Electro-Optics Center (EOC) project is developing an automated optical inspection (AOI) system to use in pilot production for the inspection of the F-35 Electro-Optical Targeting System (EOTS) sapphire window assembly. The automated system will be able to inspect roughly 86 percent of an EOTS interior and exterior window assembly (the remaining approximately~14 percent requires manual inspection due to installation constraints and system mechanical limitations), and analyze the data to produce results based on Mil-Spec standard criteria. This project is focusing on the inspection of gridded / coated sapphire panels assembled in frames and factory-produced aircraft structural panels; however, the technology developed here is applicable to a variety of scratch / inspection scenarios.

Payoff

Automating the optical inspection task will greatly improve the process by producing objective and repeatable results while also providing a quality characterization more relatable to system performance over the operational life cycle. Automated inspection of panels will reduce labor, lower costs, decrease variability, and increase throughput.

This technology may be extended to other optical panels with Mil-Spec scratch and dig criteria. Therefore, large potential return on investment exists to develop a flexible system that can be tailored to different optical inspection criteria for multiple applications and programs. The projected acquisition affordability savings will be over $4M for the F-35 Program alone.

Implementation

The development of an AOI test station is a pilot project to prove out automated inspection technology on military sensor windows. The initial (prototype) system will be validated for EOTS window production by verification of successful detection algorithms and demonstration of production cost savings. The system will be used by Lockheed Martin Missiles and Fire Control for acceptance of the EOTS sapphire window assembly beginning in 2020. EOTS production builds for airframe low-rate initial production (LRIP) 13 are delivered in 2020, one year ahead of LRIP 13 aircraft delivery in 2021. The prototype test station throughput supports all future F-35 factory production rates up to 24 units per month. The Technology Transition Plan describes how the AOI system may be replicated and adapted as necessary for additional F-35 depot and/or field support uses within three to five years.