Development of a system for automatically generating the mechanical interface of aircraft electrical connectors
Customer name :
Ziota Technology
Completion date : Since 2022
In brief
In an NSERC-funded project with Ziota Technology, we have developed a system for automatically generating the mechanical interface of aircraft electrical connectors. From a photo, an algorithm detects contacts and keys, converts the dimensions into millimeters and then into a 3D model, printable in SLA. The resulting connectors comply with Ziota Technology's electrical standards, and can be produced in less than 5 h at a cost of less than $5. A second project aims to replace the template by the use of videos taken with a cell phone.
Project summary
In the project entitled "Recognition and automatic generation of the mechanical interface of electrical connectors", funded by the Natural Sciences and Engineering Research Council of Canada (NSERC), we designed a template for Ziota Technology, which enables a connector (socket or plug) to be photographed on an aircraft undergoing maintenance. The photo is then processed by a specially developed image recognition algorithm. The algorithm detects contact surfaces, the positions of male and female contacts, and the positions and shapes of keying system. The dimensions obtained in pixels are then converted into millimeters using the characteristics of the self-centering system and the distance between the camera and the connector.
A second algorithm, also developed during the project, then converts the parameters obtained into a 3D file. The mechanical interface can then be printed using a stereolithography 3D printer (solidification of an ultraviolet-sensitive resin using a laser (photopolymerization), layer by layer), commonly known as an SLA printer. The printed connector features a system, developed during the project, for inserting and holding the contacts. Electrical resistivity and dielectric absorption ratio tests were carried out and showed that the printed connectors met the most stringent standards to which Ziota Technology must adhere.
Printed connectors are intended to be used for maintenance purposes. The time required, from taking a photo to completing the printing of a connector interface, is 5h, including 4h of printing. The cost of printing a connector is estimated at less than $5.
A second project is currently underway with Ziota Technology, with the aim of eliminating the need for a template to take images, and instead using video from a cell phone.
Gallery
CTA's role
CTA carried out R&D for Ziota Technology.
Results
- Physical template used to take a photo of an electrical connector on an aircraft.
- Algorithms for creating an SLA-printable 3D model of a mechanical interface with a contact retention system.
- The mechanical interface created meets Ziota Technology standards.
- The total time required to create the interface is 5h (including 4h for printing), for a cost of less than $5.