Supervised Autonomous Robotic System for Complex Surface Inspection and Processing

Abstract

The invention disclosed herein describes a supervised autonomy system designed to precisely model, inspect and process the surfaces of complex three-dimensional objects. The current application context for this system is laser coating removal of aircraft, but this invention is suitable for use in a wide variety of applications that require close, precise positioning and maneuvering of an inspection or processing tool over the entire surface of a physical object. For example, this system, in addition to laser coating removal, could also apply new coatings, perform fine-grained or gross inspection tasks, deliver and / or use manufacturing process tools or instruments, and / or verify the results of other manufacturing processes such as but not limited to welding, riveting, or the placement of various surface markings or fixtures.

Description

RELATED APPLICATIONS[0001]This application is a continuation of U.S. Patent Application No. 14 / 774,731, filed Sep. 11, 2015, which was a filing under 37 C.F.R. §371 of international application PCT / US14 / 30242, filed Mar. 17, 2014, which claimed the benefit of U.S. Provisional Application No. 61 / 852,310, filed Mar. 15, 2013.GOVERNMENT INTEREST[0002]This invention was made partially with government support under the U.S. Air[0003]Force number FA5320-09-D-5601 & U.S. Army W91ZLK-10-D-0005 Task 0793. The government has certain rights in this invention.FIELD OF THE INVENTION[0004]This invention relates to the control of robotic manipulators to move a surface processing device over the surface of a three dimensional object. In particular, the present application has utility for removing paint from the surfaces of aircraft fuselage, wings and control surfaces.BACKGROUND OF THE INVENTION[0005]Scenarios which require a robot to process, visit, or in some way perform an action over the entire...

AI Technical Summary

Benefits of technology

[0008]The system disclosed herein precisely maneuvers one or more machine vision components and / or one or more surface processing devices over the surface of a three-dimensional object. The vision systems gather data about the surface that are used to inform the surface process. These data include both intrinsic properties of the surface, such as color, texture or abstract classification results, along with precise estimates of the distance and orientation of the surface relative to the processing point. These data are used to accurately plan for and modulate the surface process to efficiently generate high-quality results. In the preferred embodiment of the invention, the machine vision components are comprised of multi-spectral cameras with corresponding illumination sources that can discriminate between various layers of paint and underlying substrates, and the surface processing device is a high-power laser scanner, originally designed for laser welding, which is used to remove coatings from aeronautical surfaces.

Problems solved by technology

Some problems, such as exploratory mapping, operate on a dynamic environment with many unknowns.

Other problems, such as lawn mowing, operate on a quasi-static environment, allowing robot actions to be planned much farther in advance.

Environmental and robotic constraints also significantly affect the types of algorithms used.

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