Optimisation of the collection of geometrical data in shipbuilding. Julian Niebylski Technical University of Szczecin, Ship Research Institute, Poland
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1 Optimisation of the collection of geometrical data in shipbuilding Julian Niebylski Technical University of Szczecin, Ship Research Institute, Poland Abstract At the present stage of ship design a strong tendency can be seen towards construction of highly specialised ship with very high requirements concerning tolerances. A condition that the ship fulfils its function is to build her at a required accuracy. Fulfilment of the mentioned tendency requires to introduce new technologies for shipbuilding metrology. This can be achieved applying electronic tachymeters. Possibility of application of the integrated PCMS+ system for measurements during assembly of spatial ship structures is presented in the paper. Configuration of the presented system is based on the electronic tachymeter TC 2002 produced by Leica company. 1. Introduction During building of a ship many of geometrical measurements are performed. They are meant for verification of the actual state of the structure against the design. Main stages of construction process are the following laying off, treatment, prefabrication assembly on the slipway launching Two of the above processes are the stages when the geometry of the ship hull is formed. Depending on the size and type of the ship and the manufacturing system the hull can be composed at the assembly stand of tens or even a few hundreds assembly units of various structures.
2 62 Marine Technology The main idea of the manufacturing process is to create structural elements which are assembled in sequential stages yielding larger and larger manufacturing units. For correct assemblage of such large number of elements to produce sections and than blocks and ultimately the ship hull, it is necessary to ensure retaining design sizes and shapes of the elements and their mutual positioning. To keep the dimensions of the assembled sections within specified tolerances, inter-operational and final measurements are performed at each production stage. Assembly base is the reference points which is marked at the material treatment stage and fulfilled in the next stages of building. Each element after treatment has its own base points which enable determination of its position in the ship co-ordinate system OXYZ. Keeping the dimensions of the ship hull structural elements at a required level is a complex problem. This is why the inspection and measurement works form an important part at each stage of ship construction process. An efficient inspection and measurement system plays an important role which makes it possible to estimate real geometry of the structural elements. Estimation of geometry of sections and blocks should be performed on the basis of direct verification against the design, especially on the basis of comparison of spatial measured co-ordinates with the theoretical co-ordinated determined using the mathematical model of the ship. Application of integrated measurement systems based on the electronic measurement devices is a new quality thus creating entirely new possibilities for ship metrology. It should be pointed that the advantages of the electronics devices can be fully appreciated when used in the integrated systems. The systems automate many stages in collecting the geometrical data, especially: methods of measurement and recording measurement data, data transfer from measuring device to the computer, calculation and recalculation of co-ordinates, graphical presentation, visualisation of measurement results and data exchange with CAD computer codes, storing geometrical data in the data bank, exchange of information on geometrical form of units between the shipyard divisions. 2. Integrated measurement systems Connection of the electronic measurement devices (electronic theodolites, electronic tachymeters) to an efficient portable PC-class computer allows setting up on-line or off-line integrated inspection and measurement systems. Using such a system it is possible to take advantage of the up-to-date electronic measurement devices.
3 Marine Technology 63 Open architecture of the systems and exchangeable data format allow for composition of the electronic geodesic devices to form one- and multi-stand systems whose functionality can be easily adapted to actual needs. The largest advantage of the integrated measurement systems is a possibility of automatisation of the process of recording the results of observation and performing basic computations in the field. Even if the simplest electronic devices have the option of displaying the measurement result, the more advanced devices can display the results of computation done by the instrument and store the results in the memory or magnetic devices. All the stored information can be then transferred to the desk computer. Communication can be done in two directions. Apart from presented off-line communication, also on-line communication can be established by connecting one or a few electronic instruments directly to the main computer. In the on-line measurement it is possible to perform calculations and analyses in the course of measurement in the place where it takes place. Calculations are thus done in real time. Due to this fact the on-line measurement supplies with many interesting geometrical data in the area. Most often these are co-ordinates of the observed points, measured in the defined coordinate system. Performance of more sophisticated analyses on the basis of the measured points is also possible. The on-line measurement is controlled by the computer code. Possibility of the bi-directional on-line communication between the instrument and the portable computer allows to create configurations adjusted to the analysed problem. 3. Precise electronic theodolites Electronic theodolite is a geodesic instrument if the traditional definition is to be applied, however, its essential function exact measurement of horizontal angle (or direction) and vertical angle as well as registering and processing of the measurement results (e.g. including corrections) is performed in the electronic systems integrated with the mechanical-optical part of the device. In fact the same configuration of theodolite main axes is retained (vertical axis "i", horizontal axis of rotation of its telescope HH V, sight axis "1" CC). Similarly the configuration of planes of code discs or impulse discs H and V is also retained as in traditional optical theodolites. Since electronic theodolites are produced to be combined with electro-optical range-finders to form modular systems called electronic tachymeters, they have appropriate mechanical construction. In the presently produced electronic theodolites impulse or dynamic system of angle measurement is applied, and the measurement process is controlled by an inner microprocessor and is performed automatically, including result recording.
4 64 Marine Technology The most universal are electronic tachymeters which are a combination of electronic theodolite, electro-optical range-finder and automated data recorder or computer in a measurement system. In this way a possibility appears of simultaneous collection of measurement data - angles and distances - and offor on-line processing these data to obtain X,Y,Z co-ordinates of the points observed using the pole method. The most precise is electronic tachymeter TC 2002 produced by Leica (Fig. 1). In this model a co-axial optical system of range-finder and electronic theodolite has been applied, forming an integrated system. Depending on the computer hardware, appropriate software is selected. Most often these are applications for PC-class portable computers working under DOS. Figure 1. Integrated electronic tachymeter TC 2002 produced by Leica.
5 Marine Technology A concept of PCMS+ measurement system based on precise tachymeter Wild TC General concept of the system PCMS+ system is a one-stand system for measurement of spatial polar coordinates. It is a versatile and complex measurement and computational system of simple structure. The system is basically composed of an electronic tachymeter connected with an interface to a portable PC AT computer. Due to its clear and simple structure the system works very well during measurements performed in prefabrication halls and in the places where the conditions enforce action in disadvantageous geometrical configurations, in narrow spaces. PCMS (Polar Coordinate Measurement System) integrated system is a versatile measurement system adapted for shipbuilding metrology. Connection of electronic tachymeter with a PC computer forms a mobile, one-stand measurement and computational system (Fig.2). Suitable software controls measurement, process, analyses and archives measurement data sent from the tachymeter. Functions are carried out in real time. Figure 2. Measurement of cross-section using one-stand measurementcomputational system.
6 66 Marine Technology A basic function of the system is to supply spatial ortho-carthesian coordinates in an arbitrary system OXYZ defined by a user. Based on the observed points a discrete model of the measured object is obtained. The model can be next a subject of profound analyses performed with the analytical software module of PCMS+. The complete PCMS+ system is composed of the following units a precise integrated electronic tachymeter (total station) Wild TC 2002 portable PC-class computer (laptop, notebook, palmtop), serial interface RS232 (communication cable), laser ocular, 4.2. Basic technical parameters of precise tachymeter Wild TC 2002 Obtaining high precision of polar coordinates measurement is possible applying PCMS+ system on the base of integrated electronic tachymeter Wild TC 2002, produced by the Swiss company Leica. The instrument is a self-sufficient measurement and computational device (total station) equipped with an internal control processor CPU. The device measures angles by the dynamic method with a mean error of 0.5", measures distances by the phase method with a mean error of 1 mm (up to 1000 m), and at small distances with an error of mm (up to 200 m), records the measured values in replaceable memory modules - REC (up to 200 measured points in each module), communication and data transfer (with the other devices or a computer) through serial interface RS232, preliminary data processing with a geometrical functions module stored in tachymeter ROM. Moreover, the device is equipped with a set of fluid compensators, correcting departures form the verticality of the device rotation axis in the range of ±3'. The compensator can be switched off for measurements in dynamical systems (ship in waves). 5. Mathematical model of measurement using the pole method A person operating the total station sights at observed point P, whose coordinates (Xp, Y?, Zp) are to be determined. The idea of the measurement is shown in Fig. 3.
7 Marine Technology 67 P{Xp,Yp,Zp) Figure 3. Idea of measurement by polar method. Tachymeter measurement determines three independent geometrical parameters: horizontal direction Hz zenith angle V - if the tachymeter disc compensator is active then one of the sight leafs is collinear with vertical axis (vector normal to the equipotential surface of the gravitational field), and the other leaf coincides with the sight axis to the observed point, skew spatial distance D to the point. The three quantities are polar coordinates of point P (Hz?, Vp, DP). Calculation of the ortho-carthesian coordinates (X?, Yp, Zp) from the polar coordinates is performed according to the following set of equations: Yp=Dsin(Hz)sin(V) (1) The coordinates are determined in the local coordinate system OXYZ. Observed point P can be signalised with a prismatic reflector (Fig. 4) or selfadhesive reflection foil (Fig. 5).
8 68 Marine Technology Figure 4. Signalisation of observed point using prismatic reflector. Figure 5. Sygnalisation of observed point using reflection foil marks. 6. Summary Methodology of inspection and measurement works presented in the paper applied in shipbuilding is in fact fully automated measurement-computational process. It is possible due to application of modern electronic measurement devices. These systems offer new quality in shipbuilding metrology. Numerical data processing enables data exchange between various applications; CAD and CAM software and databases. It provides with a possibility of connection metrological systems with ship manufacturing. PCMS+ integrated measurement system is implemented more and more often to metrological supervision of shipbuilding process in Szczecin Shipyard, Inc.
9 Marine Technology 69 References 1. Gocal, LI: Geodesic methods and instruments in precise measurements of machines and mechanical devices, Krakow, Leica AG: PCMSplus, Heerbrugg, Leica AG: Catalogues of company products, instructions of use, Heerbrugg. 4. Leica AG: Wild instruments on line, Heerbrugg, Niebylski, J.: Methods of geodesic measurements for assembly and investigation of ship deformations, PhD dissertation, AGH, IGGiP, Krakow. 6. Platek, A.: Electronic measurements technology in geodesy, Wydawnictwo AGH, Krakow Platek, A.: Geodesic electromagnetic range-finders and electronic tachymeters, part I and II, PPWK, Warszawa-Wroclaw, Ingenieurvermessung 88 - Beitrage zum X. Internationalen 9. KursfiirIngenieurvermessung, Technische Universitat Munchen, Witosiriski, T.: PCMS+ inspection and measurement system and possibility of its application for shipbuilding metrology, Budownictwo Okr^towe i Gospodarka Morska, February 1988.
1 Initial assumptions
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