Nondestructive inspection system and nondestructive inspection method of object

Abstract

A nondestructive inspection system and a method for nondestructive inspection of an object are provided. A nondestructive inspection ("NDI") system includes an unmanned aerial vehicle ("UAV") including a main structure and at least one support arm. The support arm includes a first arm portion having a first end coupled to the main structure and a second end coupled to a second arm portion. The second arm portion includes a first end coupled to the second end of the first arm portion and a second end coupled to an NDI scanning device. The support arm also includes a compliant member disposed between the first arm portion and the second arm portion. The NDI scanning device includes one or more NDI sensors.

Description

Technical Field

[0001] The present disclosure relates generally to inspection activities, and more particularly to remote inspection of structures of objects by unmanned aerial vehicles. Background Art

[0002] Nondestructive inspection ("NDI") of structures involves a thorough inspection of a structure without damaging it or requiring extensive disassembly of the structure. NDI is commonly used in the aircraft industry to inspect aircraft structures for any type of internal or external structural damage, such as cracks, voids or pores, which could adversely affect the performance of the aircraft.

[0003] Human-based in-person inspections of structures and various types of objects can be time-consuming, expensive, difficult, and often dangerous for individuals to perform. Typically, unmanned aerial vehicles ("UAVs") can be used to deliver devices for visual inspections of large remote structures and some simple infrared thermal imaging. However, current UAV delivery systems do not provide non-standoff NDI capabilities or simple maintenance assistance. Summary of the invention

[0004] The subject matter of the present application has been developed in response to the current state of the art, and in particular in response to the shortcomings of conventional nondestructive inspection techniques that have not been fully addressed by currently available techniques. Therefore, the subject matter of the present application has been developed to provide an apparatus, system, and related methods that overcome at least some of the above-mentioned shortcomings of the prior art.

[0005] An apparatus for a support arm for a nondestructive inspection ("NDI") sensor is disclosed herein. The support arm includes a first arm portion having a first end coupled to a main structure of an unmanned aerial vehicle (UAV) and a second end coupled to a second arm portion. The second arm portion has a first end coupled to an NDI scanning device and a second end coupled to the second end of the first arm portion, and a compliant member disposed between the first arm portion and the second arm portion.

[0006] In some embodiments, the first arm portion is pivotally coupled to the second arm portion via a swivel joint that allows the second arm portion to compliantly move relative to the first arm portion. In other embodiments, the second arm portion is slidably coupled to the first arm portion and telescopes into the first arm portion using a compliant element therebetween.

[0007] Further disclosed is an NDI system using a UAV and an NDI scanning device coupled to the UAV via the above-mentioned support arm. In some embodiments, the system includes an annular base surrounding the main structure of the UAV and coupled thereto. In this example, at least one support arm is rigidly coupled to the annular base at a first end of the first arm portion. The system may also include a second support arm coupled to the main structure and having a weight to balance the NDI scanning device.

[0008] The NDI scanning device may include a mounting mechanism that couples the NDI scanning device to the surface of the structure, wherein the mounting mechanism is a magnetic-based, vacuum-based, electrostatic-based, clamp-based, or adhesive-based mounting mechanism. In certain embodiments, the UAV is operable to move using a predetermined flight path that uses position and orientation data obtained from a tracking system or controlled using a remote control system. One or more NDI sensors of the NDI scanning device include, but are not limited to, eddy current sensors, ultrasonic sensors, acoustic sensors, mechanical impedance sensors, optical sensors, x-ray backscatter sensors, computed tomography sensors, surface roughness sensors, infrared thermal imaging, microwave sensors, and terahertz sensors. In some embodiments, one or more NDI sensors move relative to the structure to be inspected.

[0009] In some embodiments, the system further comprises one or more maintenance tools, including but not limited to: a grinder, a drill, a brush, a paint sprayer, a marker, an ink stamp, a laser, or a target applicator. The system may also include a movement mechanism for moving the NDI scanning device around the surface to be inspected.

[0010] A method for non-destructive inspection of a surface using an unmanned aerial vehicle utilizing the system is also provided.

[0011] The described features, structures, advantages and / or characteristics of the subject matter of the present disclosure can be combined in any suitable manner in one or more examples and / or embodiments. In the following description, many specific details are provided to give a thorough understanding of the examples of the subject matter of the present disclosure. Those skilled in the relevant art will recognize that the subject matter of the present disclosure can be implemented in the absence of one or more of the specific features, details, parts, materials and / or methods of a particular example or embodiment. In other examples, additional features and advantages that are not present in all examples or embodiments may be recognized in certain examples and / or embodiments. In addition, in some cases, well-known structures, materials or operations are not shown or described in detail to avoid blurring the various aspects of the subject matter of the present disclosure. According to the following description and the attached technical proposal book, the features and advantages of the subject matter of the present disclosure will become more completely obvious, or can be known by the practice of the subject matter described below. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] In order that the advantages of the subject matter may be more readily understood, a more particular description of the subject matter briefly described above will be provided by reference to specific examples shown in the accompanying drawings. Understanding that these drawings depict only typical examples of the subject matter and are therefore not to be considered limiting of its scope, the subject matter will be described and explained with additional specificity and detail through the use of the accompanying drawings, in which:

[0013] Figure 1 A perspective view showing one example of a target structure on which nondestructive testing is performed using an unmanned aerial vehicle ("UAV") and an articulated arm in accordance with an embodiment of the present disclosure;

[0014] Figure 2 A side view showing another embodiment of a target structure for performing non-destructive testing on it using a UAV according to an embodiment of the present disclosure;

[0015] Figure 3 A side view showing an embodiment of a scanning pattern of an NDI scanning device according to an embodiment of the present disclosure;

[0016] Figure 4 A side view showing another embodiment of a target structure according to an embodiment of the present disclosure, wherein non-destructive testing is performed on the target structure using a UAV and a wheeled device including an NDI scanner;

[0017] Figure 5 A side view showing another embodiment of a UAV with a compliant telescopic arm according to an embodiment of the present disclosure;

[0018] Figure 6a 2 is a side view showing another embodiment of a UAV having a ring-based mount according to an embodiment of the present disclosure;

[0019] Figure 6b A top view showing another embodiment of a UAV according to an embodiment of the present disclosure;

[0020] Figure 7 A schematic block diagram showing an embodiment of a controller for NDI scanning according to an embodiment of the present disclosure;

[0021] Figure 8 A schematic flow chart showing an embodiment of a nondestructive inspection method according to an embodiment of the present disclosure; and

[0022] Fig. 9 A side view showing another embodiment of a base of a UAV according to an embodiment of the present disclosure. DETAILED DESCRIPTION

[0023] Throughout the specification, reference to "one example," "example," or similar language means that a particular feature, structure, or characteristic described in conjunction with the example is included in at least one example of the present disclosure. Throughout the specification, the appearance of the phrases "in one example," "in an example," and similar language may, but need not, all refer to the same example. Similarly, the use of the term "embodiment" means an embodiment having a particular feature, structure, or characteristic described in conjunction with one or more examples of the present disclosure, however, an embodiment may be associated with one or more examples if no explicit association is indicated. Throughout the description of the figures, the same reference numerals represent the same elements.

[0024] Figure 1 A perspective view of an example of a target structure 100 on which nondestructive testing is performed using an unmanned aerial vehicle ("UAV") 102 according to an embodiment of the present disclosure is shown. In the depicted embodiment, the target structure 100 is an aircraft. However, the target structure is any suitable manufacturing device or structure, such as an aircraft, an airplane, a turbine, an engine, a structure, a bridge, or a device that can operate in a space-like environment (e.g., a satellite, a rocket, a missile, a space station component, a space vehicle, a space simulator). In general, examples of the present disclosure describe methods and systems that enable remote NDI of a structure to be performed using a UAV 102 (also referred to as a drone) in addition to simple visual inspection using a visual or IR camera. As will be described in more detail below, the UAV 102 includes one or more support structures that are attached or integrated to the UAV 102 at one end (i.e., the proximal end) and support one or more NDI scanning devices 104 or attached or integrated to other end effectors at the other end (i.e., the distal end).

[0025] The UAV 102 can also enable maintenance activities such as painting, sanding, and location marking for periodic remote inspections. Adhesive labels, paints, etc. can also be retained for future reference, or to enable 3D visualization. Various systems and methods can be used to keep the NDI device on the surface of the target structure 100 to be inspected, including but not limited to magnetic-based, vacuum-based, electrostatic-based, adhesive-based, or clamp-based systems and methods. In some examples, more than one of these attachment mechanisms can be used in combination. In a magnetic-based method, an electropermanent ("EP") magnet can be enabled by an electric pulse and can be powered on without the use of a power source. In a vacuum-based method, the UAV may include one or more electric duct fans or other suction universal devices that are configured to generate corresponding suction forces at corresponding suction areas. In an electrostatic-based method, an electrostatic force is used between a substrate (e.g., the surface of the structure to be inspected) and an electroadhesive surface on a support structure or NDI device. In this method, an electroadhesive device (e.g., a pad, a wheel, a track, etc.) is composed of conductive electrodes deposited on a polymer surface. In a gripper-based approach, one or more support structures may include an end with one or more gripping portions that, when actuated, may open or close to physically hold onto a portion of the structure being inspected.

[0026] In one example operation, a support structure (see Figure 2 A UAV 102 with one or more NDI scanning devices 104 supported by a compliant support arm (such as a support arm) is flown to a target area of ​​a target structure 100. The UAV operator instructs the UAV 102 to position the NDI scanning device 104 (such as by extending the support arm) over the target area of ​​the target structure 100. The NDI scanning device 104 is movably secured to the target structure 100 (e.g., secured by a mechanism implementing an EP magnet, a vacuum device, an electrostatic device, an adhesive device, or a clamp device). In other embodiments, the UAV 102 movably secures the NDI scanning device 104 to a surface by applying pressure to the NDI scanning device 104 via a compliant support arm. The EP magnet can be enabled by an electrical pulse and then remain powered without the use of a power source. The NDI scanning device 104 can then be activated to extract inspection readings. The 3D position of the NDI scanning device 104 relative to the target structure 100 can be measured by an off-board tracking system such as a local positioning system ("LPS"). The NDI scanning device 104 maintains a history of the positions that have been scanned. Once the NDI check is complete, the process can be repeated, or in certain embodiments or use cases, the immobilization mechanism can be deactivated and the UAV can fly away.

[0027] Figure 2A side view of another embodiment of a target structure 202 for performing nondestructive testing on it using a UAV 102 according to an embodiment of the present disclosure is shown. As described above, the target structure 202 can be a part of an aircraft. As shown here, the UAV 102 is used to inspect an aircraft wing, and a cross-section of the aircraft wing is identified by the reference numeral 202. In some embodiments, the UAV 102 includes a main structure 204, and one or more support arms 206 are arranged on the main structure 204. The one or more support arms 206 are attached to the main structure 204 at a first (proximal) end. Each of the one or more support arms 206 is connected to the NDI scanning device 104 at a second (distal) end. In some embodiments, the articulated support arm 206 is configured with a passive or active end effector mechanism at the distal end for manipulating one or more maintenance tools, including but not limited to a gripper, a sander, a drill, a brush, a paint sprayer, a marker, an ink stamp, etc.

[0028] In some embodiments, the support arm 206 is implemented as an articulated arm having one or more pivot joints 208. The one or more pivot joints 208 allow the UAV 102 to apply a predetermined and substantially constant pressure to the target structure 202 via the NDI scanning device 104, regardless of the distance d between the UAV 102 and the target structure 202 during contact between the NDI scanning device 104 and the target structure 202. This can be accomplished by one or more compression springs 210 across the pivot joints 208. Alternatively, other compliance mechanisms can be implemented to apply a biasing force to the NDI scanning device 104. The articulated support arm 206 can extend and rotate to position and orient the NDI scanning device 104 near the target structure 202. The UAV 102 is configured to use proximity sensors and / or visual cameras to determine when the UAV 102 is at an appropriate distance to automatically deploy or extend the support arm 206. Alternatively, the articulated support arm 206 may be constantly in the deployed configuration in preparation for coupling the NDI scanning device 104 to a target structure.

[0029] In one example, the compression spring 210 is provided with a long stroke length and a preloaded rest position such that the compression spring 210 applies an approximately proportional force along the compression stroke of the spring. Alternatively, the UAV 102 can be configured to measure the pressure applied to the NDI scanning device 104 and modify the distance between the UAV 102 and the target structure 202 to maintain a desired pressure. For example, the desired pressure is selected to maintain contact between the NDI scanning device 104 and the target structure 202 while allowing the NDI scanning device 104 to slide on the surface of the target structure 202. As described above, the NDI scanning device 104 is configured with an attachment mechanism (e.g., EP magnets, electric glue, etc.), so that the NDI scanning device 104 supports its own weight and can reduce the burden on the UAV 102 in some cases and subsequently extend the operating time of the UAV 102.

[0030] Each NDI scanning device 104 is composed of a housing that houses one or more sensors, including but not limited to eddy current sensors, ultrasonic sensors, acoustic sensors, mechanical impedance sensors, optical sensors, x-ray backscatter sensors, computed tomography sensors, surface roughness sensors, infrared thermal imaging, microwave sensors, and terahertz sensors. The UAV 102 moves the NDI scanning device 104 across the surface of the target structure 202 to allow one or more sensors to scan damage to the target structure 202. As will be described in more detail below, in other embodiments, the NDI scanning device 104 is provided with a moving mechanism (e.g., a motor-driven wheel) for moving around on the surface of the target structure 202. Alternatively, the passive wheel is provided with a rotary encoder to measure distance. In this example, the UAV 102 can be configured to operate in a "follower" mode when the end effector passes through the surface of the target structure 202.

[0031] Figure 3 2 is a side view illustrating one embodiment of a scanning pattern of an NDI scanning device 104 according to an embodiment of the present disclosure. In the depicted embodiment, the UAV 102 directs the NDI scanning device 104 in a pattern across the surface of the target structure 202. The articulated support arm 206 of the UAV 102 is configured to extend above and below the UAV main structure 204 to allow the UAV 102 to position the NDI scanning device 104 in different areas of the target structure 202. In the depicted embodiment, this allows the UAV 102 to position the NDI scanning device 104 on the underside of an aircraft wing.

[0032] The UAV 102 is configured to follow a pattern using distance measurement feedback and / or positioning methods (e.g., omnidirectional wheels with rotary encoders on the surface or a ground-based high-resolution camera with tracking capabilities) so that the NDI scanning device 104 can fully scan the target structure 202 or maintain it by a sander, cleaner, painter, etc.

[0033] Any data collected is transmitted (e.g., wirelessly) to an electronic processing device for real-time and / or post-scan analysis. In addition, the data can be stored in a storage device in the NDI scanning device 104 and retrieved at a later time. The mode can be a predetermined mode defined by the operator and followed by the UAV 102 until completion. Alternatively, the UAV 102 can use visual data obtained from the camera to determine when the entire surface of the target structure 202 has been scanned. In another embodiment, the UAV 102 receives an instruction from the NDI scanning device 104 indicating that the entire surface of the target structure 202 has been scanned.

[0034] Figure 4 1 is a side view of another embodiment of a target structure 202 on which nondestructive testing is performed using a UAV 102 according to an embodiment of the present disclosure. As described above, the NDI scanning device 104 is a passive scanning device that slides on the surface of the target structure 202. In some embodiments, the NDI scanning device 104 includes a mechanism for facilitating movement of the NDI scanning device 104 on the surface of the target structure 202. For example, the NDI scanning device 104 includes wheels 402. In some embodiments, the wheels are undriven and allow the UAV 102 to guide the movement of the NDI scanning device 104.

[0035] Alternatively, the NDI scanning device 104 can be operated to move along or around the surface of the target structure 202 using one or more movement mechanisms, such as using tracks, wheels (e.g., full wheels), articulated arms, etc. Movement can be used in conjunction with a fixing mechanism, such as by opening and closing the fixing mechanism in a controlled manner. In some embodiments, the NDI scanning device 104 includes a body capable of supporting multiple wheels (e.g., 4 wheels). In some embodiments, at least two wheels are independently controllable to guide the NDI scanning device 104 to move on the surface of the target structure 202.

[0036] In certain embodiments, the articulated support arm 206 includes a counterweight 404 to counteract the effect of the weight of the NDI scanning device 104 on the UAV 102. The counterweight 404 may extend beyond the pivot point 406 and include a counterweight selected to provide a counterweight torque to the torque of the NDI scanning device 104. The counterweight of the arm 404 may be integral to the support arm 206. The position of the articulated support arm 206 relative to the pivot point 406 may be adjusted according to the payload carried by the UAV 102 (e.g., the NDI scanning device 102, a sanding device, a paint brush, etc.). For example, the articulated support arm 206 may be provided with a plurality of locating openings through which a rod may pass that secures the articulated support arm 206 to the UAV 102. An increase in the distance between the pivot point 406 and the counterweight of the counterweight 404 results in an increase in the counterweight torque.

[0037] Figure 5 1 is a side view of another embodiment of a UAV 102 according to an embodiment of the present disclosure. In the depicted embodiment, the support arm includes a telescoping arm 502. In some embodiments, the telescoping arm 502 is formed to have at least two slidable nesting portions. A first portion 506 of the arm 502 is rotatably coupled to the main structure 204 at a first (proximal) end. A second (distal) end of the first portion 506 of the support arm 502 is configured to slidably engage a proximal end of a second portion 504 of the support arm 502, which is rotatably coupled to the NDI scanning device 104 at its distal end.

[0038] A compliant element (e.g., a spring) may be disposed within the cavity of the second portion to bias the first portion 504 relative to the second portion 506. Thus, when the NDI scanning device 104 is in contact with the surface, the UAV 102 is configured to apply an approximately constant pressure to the surface of the target structure regardless of the distance between the UAV 102 and the surface. In this way, slight deviations in the flight path of the UAV 102 do not affect the operation of the NDI scanning device 104. In other words, if the distance between the UAV 102 and the surface of the target structure changes, then the above reference to the NDI scanning device 104 will not affect the operation of the NDI scanning device 104. Figure 1-5 The described support arm is constructed to absorb such variations without affecting the analysis of the surface.

[0039] Figure 6a 1 is a side view of another embodiment of a UAV 102 according to an embodiment of the present disclosure. In certain embodiments, the UAV 102 includes an NDI scanning device base structure ("base") 602 that surrounds the main structure 204 of the UAV 102. The base arm 604 couples the base 602 to the main structure 204 of the UAV 102. In some embodiments, the base 602 is substantially centered on the rotor blade 610 of the UAV 102 (see Figure 6bOther configurations are contemplated that substantially balance the base 602 in the lateral and longitudinal directions relative to the main structure 204 of the UAV 102.

[0040] In certain embodiments, the telescopic arm 502 is coupled to the NDI scanning device 104 at a first (proximal) end and to a base 602 at a second end, which can be annular or circular. The telescopic arm 502 can be rigidly coupled to the base 602 to allow the control system of the UAV 102 to control the orientation of the NDI scanning device 104. The telescopic arm 502 can also have a compliant element or compliant member between the sliding sections of the arm. Although depicted in an approximately 7 o'clock position, the UAV 102 can orient the telescopic arm at other rotational angles (e.g., 3 or 9 o'clock) while the telescopic arm 502 extends outward from the base 602 in a generally vertical plane. This allows the UAV 102 to position the NDI scanning device 104 on a variety of surfaces while still allowing stable and controllable movement of the UAV 102. In alternative embodiments, the mounting ring can be configured in a horizontal plane.

[0041] In some embodiments, the base 602 includes a counterweight 606 oriented opposite the telescopic arm 502 to offset the effect of the weight of the NDI scanning device 104. A rotation mechanism in operative communication with the UAV 102 rotates and positions the telescopic arm 502 and the counterweight 606 in response to a surface to be scanned by the NDI scanning device 104. The rotation mechanism can move the telescopic arm 502 together with the counterweight 606, or alternatively independently of the counterweight 606. The rotation mechanism may include a plurality of rings that are movable independently of one another. At least one of the rings is fixedly coupled to the base arm 604. A gear disposed between the fixed ring and the movable ring may be actuated to move the ring coupled to the telescopic arm 502 to move the NDI scanning device 104. Although depicted here with the telescopic arm 502, the base 602 may be used with reference to the above. Figure 2 The described articulated support arm 206 is implemented.

[0042] Figure 6b FIG. 1 is a top view of another embodiment of a UAV 102 according to an embodiment of the present disclosure. Figure 6a As discussed, the base 602 surrounds the main structure 204. In certain embodiments, the base 602 is disposed between the rotors 610 of the UAV 102 so as not to interfere with the flight capabilities of the UAV 102. Typically, the UAV 102 includes one or more rotors 610 that can be controlled to guide the UAV 102 to the target structure 100 and perform NDI using the NDI scanning device 104. The UAV 102 can be autonomous and capable of following a predetermined flight path, or can be controlled by a remote control 612.

[0043] Figure 7 1 is a schematic block diagram showing an embodiment of a controller for NDI scanning according to an embodiment of the present disclosure. The UAV 102 and the NDI scanning device 104 together form a system for capturing information corresponding to the target structure 100. The controller 700 operatively coupled to the UAV 102 or the NDI scanning device 104 includes a data processor 702 that processes the information captured by the system and directs the UAV 102 and the NDI scanning device 104 to perform a method for non-destructive inspection of the target structure 100. The data processor 702 can be any suitable information processing device capable of processing the captured information. In one example, the data processor 702 is a computer, a smart phone, a processing device, etc. In one example, the data processor 702 includes one or more processors for processing the captured information. The captured information can be sent to a display via a transceiver 704, which is used to display a mapping of the surface of the target structure 100 generated from the captured information. The data processor 702 receives the captured information (e.g., data) and generates an image corresponding to the data. In one example, the data processor 702 generates a two-dimensional map of a surface of an object and / or a three-dimensional map of a surface of an object.

[0044] As used herein, a target structure 100 (e.g., an object) has a potential defect if an anomaly is detected below the surface of the target structure 100, such as a deformation caused by air trapped below the surface of the target structure 100. In some cases, the air trapped below the surface of the target structure 100 is caused by debonded material (e.g., insufficient bonding between materials) below the surface of the target structure 100. The system is configured to detect defects in the target structure 100.

[0045] The controller 700 includes a sensor 706 that is operable to detect one or more contact-based, contactless-based, or both sensing modalities. The sensor 706 may include, but is not limited to, an eddy current sensor, an ultrasonic sensor (and other proximity sensors), an acoustic sensor, a mechanical impedance sensor, an optical sensor (e.g., an optical camera), an x-ray backscatter sensor, a computed tomography sensor, a surface roughness sensor, an infrared thermal imaging, a microwave sensor, and a terahertz sensor. The controller 700 may also optionally include a power supply 708, a fixing / detaching mechanism 710, and a moving mechanism 712, all of which are connected via a communication bus. In some embodiments, the power supply 708 may provide power to one or more subsystems (e.g., UAV 102, NDI scanning device 104, annular base 602, etc.). In some examples, additional power or total power may be provided by a tether connected to the UAV 102. The optional tether may also be used to send command or data signals to and receive command or data signals from one or more NDI sensors 706, as well as to provide a safety and retrieval mechanism for the system.

[0046] The attachment / detachment mechanism 710 may include one or more attachment mechanisms disclosed herein. The transceiver 704 may be configured to provide position and / or measurement data from one or more NDI sensors 706 to the wireless UAV controller 102 and / or a remote inspection station. The controller 700 is programmed with instructions to control one or more subsystems in the UAV 102 and the NDI scanning device 104 and / or communicate with the wireless UAV controller and / or the remote inspection station via the transceiver 704. The movement mechanism 712 is operable to move the NDI scanning device 104 along or around the surface of the target structure 100 disclosed herein.

[0047] In some embodiments, the sensor 706 includes a pressure sensor for detecting the amount of pressure applied by the UAV 102 to the surface of the target structure 100 via the NDI scanning device 104. The processor 702 is configured to receive the pressure information and adjust the distance between the target structure 100 and the UAV 102 to maintain slidable contact between the NDI scanning device 104 and the target structure 100. If the pressure is too great, the NDI scanning device 104 may not slide properly. If the pressure is close to zero, indicating no contact, the sensor 706 of the NDI scanning device 104 may not function properly. Alternatively, the controller 700 uses another sensor to maintain an appropriate distance between the UAV 102 and the target structure 100.

[0048] Figure 8800 is a schematic flow chart showing an embodiment of a method 800 for nondestructive inspection according to an embodiment of the present disclosure. Parts of the method 800 may be performed by processing logic, which may include hardware (e.g., circuits, dedicated logic, programmable logic, microcode, etc.), software (e.g., instructions running on a processing device), firmware, or a combination thereof. In one embodiment, the method 800 is performed by Figure 7 The controller 700 executes.

[0049] Method 800 begins, and a UAV having a compliant and balanced support arm is provided. As described above, in some embodiments, the biased support arm includes a biasing mechanism, such as a spring, to provide a biasing force between a first portion and a second portion of the support arm. In alternative embodiments, the biasing force is provided by elasticity or compressed air. At box 804, processing logic guides the UAV to a target structure. For example, the UAV may include an onboard system that is capable of navigating the UAV according to a preprogrammed flight plan and is capable of obtaining inspection data for an inspected target structure and / or is capable of being flown along a flight path by an operator using a wireless UAV controller.

[0050] At block 806, processing logic places the NDI scanning device on the surface of the target structure and maintains contact between the NDI scanning device and the surface of the target structure. For example, processing logic analyzes the surface of the target structure to determine a distance from the surface and approaches the surface until contact is made between the NDI scanning device and the surface. Processing logic also instructs a fixing mechanism (e.g., EP magnet, electric glue, etc.) to couple the NDI scanning device to the surface. Processing logic then maintains an appropriate distance from the surface. The compliant support arm can compensate for deviations from the appropriate distance.

[0051] At block 808, processing logic performs a nondestructive inspection of the surface using one or more NDI sensors. At block 810, processing logic disengages the NDI scanning device from the surface of the target structure, and method 800 ends.

[0052] Fig. 9 602 according to an embodiment of the present disclosure. For clarity, some components of the UAV 102, such as the rotor blades 610, are not shown. In the depicted embodiment, the base 602 includes at least two rings 902, 904 that surround the main structure 204 of the UAV 102. The inner ring 902 is fixedly coupled to the main structure 204 via the mounting arms 604. In some embodiments, the outer ring 904 is configured to rotate relative to the inner ring 902. Ball bearings can be provided between the inner ring 902 and the outer ring 904 to facilitate sliding and rotational movement of the outer ring 904 relative to the inner ring 902.

[0053] In some embodiments, the motor 906 and battery 908 serve as a counterweight for the NDI scanning device 104 and may be fixedly coupled to the outer ring 904 opposite the support arm 502. The gear 910 driven by the motor 906 may engage the inner ring 902 and rotate the outer ring 904 in response to a command from the controller 700. This, therefore, allows the controller to cause the motor 906 to position the NDI scanning device 104 via the outer ring 904 at any angular position between 0 and 360 degrees.

[0054] In the above description, certain terms may be used, such as "upper", "lower", "upper", "lower", "horizontal", "vertical", "left", "right", "above", "below", etc. These terms are used to provide some clear description when dealing with relative relationships when applicable. However, these terms are not intended to imply absolute relationships, positions and / or orientations. For example, with respect to an object, a "upper" surface can become a "lower" surface by simply turning the object over. Nevertheless, it is still the same object. In addition, unless otherwise expressly stated, the terms "include", "comprise", "have" and their variations mean "including but not limited to". Unless otherwise expressly stated, the list of enumerated items does not mean that any or all items are mutually exclusive and / or mutually inclusive. Unless otherwise expressly stated, the terms "one", "an" and "the" also refer to "one or more". In addition, the term "multiple" may be defined as "at least two". In addition, unless otherwise stated, as defined herein, multiple specific features do not necessarily mean each specific feature in the entire set or category of specific features.

[0055] In addition, examples of an element being "coupled" to another element in this specification may include direct and indirect coupling. Direct coupling may be defined as an element being coupled to another element and forming some contact therewith. Indirect coupling may be defined as a coupling between two elements that are not in direct contact with each other but have one or more additional elements between the coupled members. In addition, as used herein, fixing an element to another element may include direct fixing and indirect fixing. In addition, as used herein, "immediately adjacent to" does not necessarily mean contact. For example, an element may be in close proximity to another element without being in contact with the element.

[0056] As used herein, the phrase "at least one" when used with a list of items means that different combinations of one or more of the listed items may be used, and only one of the items in the list may be required. The item may be a specific object, thing, or category. In other words, "at least one" means that any combination of items or multiple items may be used from the list, but not all items in the list may be required. For example, "at least one of item A, item B, and item C" may mean item A; item A and item B; item B; item A, item B, and item C; or item B and item C. In some cases, "at least one of item A, item B, and item C" may be, for example, but not limited to, two items in item A, one item in item B, and ten items in item C; four items in item B and seven items in item C; and other suitable combinations.

[0057] Unless otherwise indicated, the terms "first", "second", etc. are used herein merely as labels and are not intended to impose order, position, or hierarchy requirements on the items to which these terms refer. In addition, reference to an item such as "second" does not require or exclude the presence of an item such as "first" or lower numbered and / or an item such as "third" or higher numbered.

[0058] As used herein, a system, device, structure, article, element, component, or hardware that is "configured to" perform a specified function is actually capable of performing the specified function without any changes, rather than merely having the potential to perform the specified function after further modification. In other words, a system, device, structure, article, element, component, or hardware that is "configured to" perform a specified function is specifically selected, created, implemented, utilized, programmed, and / or designed for the purpose of performing the specified function. As used herein, "configured to" means an existing characteristic of a system, device, structure, article, element, component, or hardware that enables the system, device, structure, article, element, component, or hardware to perform the specified function without further modification. For the purposes of this disclosure, a system, device, structure, article, element, component, or hardware that is described as "configured to" perform a particular function may additionally or alternatively be described as "adapted to" and / or "operable to" perform that function.

[0059] The schematic flow charts included herein are generally described as logic flow charts. In this way, the depicted order and the steps of the mark indicate an example of the proposed method. Other steps and methods that are equivalent to one or more steps or parts thereof of the method shown in function, logic or effect can be envisioned. In addition, the format and symbols adopted are provided to explain the logical steps of the method, and are understood to not limit the scope of the method. Although various arrow types and line types can be adopted in the flow chart, they should be understood to not limit the scope of the corresponding method. In fact, some arrows or other connectors can be used to indicate only the logical flow of the method. For example, an arrow can indicate a waiting or monitoring period of unspecified duration between the enumerated steps of the depicted method. In addition, the order of occurrence of a particular method may strictly follow or may not strictly follow the order of the corresponding steps shown.

[0060] Furthermore, the present disclosure includes embodiments according to the following clauses:

[0061] Clause 1. A nondestructive inspection ("NDI") system, the system comprising:

[0062] An unmanned aerial vehicle comprising a main structure having at least one support arm, wherein the at least one support arm comprises:

[0063] a first arm portion having a first end coupled to the main structure and a second end coupled to the second arm portion;

[0064] a second arm portion having a first end coupled to the NDI scanning device and a second end coupled to the second end of the first arm portion; and

[0065] a compliant member disposed between the first arm portion and the second arm portion; and

[0066] Wherein, the NDI scanning device is formed with a housing including one or more NDI sensors.

[0067] Clause 2. The NDI system of clause 1, wherein the first arm portion is pivotally coupled to the second arm portion.

[0068] Clause 3. An NDI system as described in clause 2, wherein the biasing compliant member biases movement of the second arm portion relative to the first arm portion.

[0069] Clause 4. The NDI system of clause 1, wherein the second arm portion is slidably coupled to the first arm portion and telescopes into the first arm portion.

[0070] Clause 5. An NDI system as described in clause 1, wherein the compliant member biases movement of the second arm portion relative to the first arm portion.

[0071] Clause 6. The NDI system according to clause 1, further comprising an annular base surrounding the main structure and coupled thereto, the annular base comprising an inner ring element and an outer ring element rotating relative to the inner ring element.

[0072] Clause 7. The NDI system of clause 6, wherein the at least one support arm is rigidly coupled to an outer ring element of the annular base at a first end of the first arm portion.

[0073] Clause 8. An NDI system according to clause 1, wherein the at least one support arm includes a first support arm, and further includes a second support arm coupled to the main structure and having a weight balancing the at least one support arm and the NDI scanning device.

[0074] Clause 9. An NDI system according to clause 1, wherein the NDI scanning device further comprises a mounting mechanism for coupling the NDI scanning device to a surface of a structure, wherein the mounting mechanism is a magnetic-based, vacuum-based, electrostatic-based, clamp-based, or adhesive-based mounting mechanism.

[0075] Clause 10. An NDI system as described in clause 1, wherein the UAV is operable to move using a predetermined flight path that uses position and orientation data obtained from a tracking system or controlled using a remote control system.

[0076] Clause 11. An NDI system as described in clause 1, wherein the one or more NDI sensors include at least one of an eddy current sensor, an ultrasonic sensor, an acoustic sensor, a mechanical impedance sensor, an optical sensor, an x-ray backscatter sensor, a computed tomography sensor, a surface roughness sensor, an infrared thermal imaging, a microwave sensor, and a terahertz sensor.

[0077] Clause 12. The NDI system of clause 1, wherein the one or more NDI sensors move relative to the structure to be inspected.

[0078] Clause 13. An NDI system according to clause 1, wherein the at least one or more support arms are configured to support one or more maintenance tools, wherein the one or more maintenance tools include one of a grinder, a drill, a brush, a paint sprayer, a marker, an ink stamp, a laser, or a target applicator.

[0079] Clause 14. The NDI system of clause 1, wherein the NDI scanning device further comprises a movement mechanism for moving the NDI scanning device around a surface to be inspected.

[0080] Clause 15. A support arm for a nondestructive inspection ("NDI") system, the support arm comprising:

[0081] a first arm portion having a first end coupled to a main structure of an unmanned aerial vehicle ("UAV") and a second end coupled to a second arm portion;

[0082] a second arm portion having a first end coupled to the second end of the first arm portion and a second end coupled to the NDI scanning device; and

[0083] A compliant member is disposed between the first arm portion and the second arm portion.

[0084] Clause 16. The support arm of clause 15, wherein the first arm portion is pivotally coupled to the second arm portion.

[0085] Clause 17. The support arm of clause 16, wherein the compliant member biases movement of the second arm portion relative to the first arm portion.

[0086] Clause 18. The support arm of clause 15, wherein the second arm portion is slidably coupled to the first arm portion and telescopes into the first arm portion.

[0087] Clause 19. The support arm of clause 18, wherein the compliant member biases movement of the second arm portion relative to the first arm portion.

[0088] Clause 20. A method for nondestructive inspection ("NDI") of an object, comprising:

[0089] An unmanned aerial vehicle is provided that includes a main structure having at least one support arm, wherein the at least one support arm includes:

[0090] a first arm portion having a first end coupled to the main structure and a second end coupled to the second arm portion;

[0091] a second arm portion having a first end coupled to the second end of the first arm portion and a second end coupled to the NDI scanning device;

[0092] a compliant member disposed between the first arm portion and the second arm portion; and

[0093] Wherein, the NDI scanning device is formed with a housing including one or more NDI sensors;

[0094] guiding the UAV to a target location of a structure;

[0095] placing the NDI scanning device on a surface at a target location of the structure; and

[0096] NDI is performed on the surface using the one or more NDI sensors.

[0097] Without departing from the spirit or essential features of the present invention, the subject matter may be implemented in other specific forms. The described examples should be considered in all respects as illustrative and non-restrictive. All changes falling within the equivalent meaning and scope of the technical solution should be included within its scope.

Claims

1. A non-destructive inspection system (100), the non-destructive inspection system (100) comprising: An unmanned aerial vehicle (102) comprises a main structure (204) having at least one support arm (502), wherein the at least one support arm (502) comprises: a first arm portion (504), a first end of the first arm portion (504) coupled to the main structure (204), and a second end of the first arm portion (504) coupled to a second arm portion (506); a second arm portion (506), a first end of the second arm portion (506) coupled to the non-destructive inspection scanning device (104), and a second end of the second arm portion (506) coupled to the second end of the first arm portion (504); and a compliant member (210) disposed between the first arm portion (504) and the second arm portion (506), the compliant member (210) biasing movement of the second arm portion (506) relative to the first arm portion (504) to apply a biasing force to the non-destructive inspection scanning device (104); and The non-destructive inspection scanning device (104) is formed with a housing including one or more non-destructive inspection sensors, and the non-destructive inspection scanning device (104) is placed on the surface of a target position of a structure (202) to be inspected.

2. The non-destructive inspection system (100) according to claim 1, wherein: The first arm portion (504) is pivotally coupled to the second arm portion (506).

3. The non-destructive inspection system (100) according to claim 1, wherein: The second arm portion (506) is slidably coupled to the first arm portion (504) and telescopes into the first arm portion (504).

4. The nondestructive inspection system (100) according to claim 1, further comprising an annular base (602) surrounding the main structure (204) and coupled to the main structure (204), the annular base (602) comprising an inner ring element (902) and an outer ring element (904) rotating relative to the inner ring element (902).

5. The non-destructive inspection system (100) according to claim 4, wherein: The at least one support arm (502) is rigidly coupled to the outer ring element (904) of the annular base (602) at a first end of the first arm portion (504).

6. The non-destructive inspection system (100) according to claim 1, wherein: The at least one support arm (502) includes a first support arm, and further includes a second support arm (404) coupled to the main structure (204) and having a weight balancing the at least one support arm (502) and the non-destructive inspection scanning device (104).

7. The non-destructive inspection system (100) according to claim 1, wherein: The unmanned aerial vehicle (102) is operable to move using a predetermined flight path using position and orientation data obtained from a tracking system or controlled using a remote control system (612).

8. The non-destructive inspection system (100) according to claim 1, wherein: The one or more non-destructive inspection sensors are moved relative to the structure to be inspected (202).

9. The non-destructive inspection system (100) according to claim 1, wherein: The non-destructive inspection scanning device (104) further comprises a moving mechanism (402) for moving the non-destructive inspection scanning device (104) around the surface of the structure (202) to be inspected.

10. A method for nondestructive inspection of an object, comprising: An unmanned aerial vehicle (102) is provided, the unmanned aerial vehicle (102) comprising a main structure (204) having at least one support arm (502), wherein the at least one support arm (502) comprises: a first arm portion (504), a first end of the first arm portion (504) coupled to the main structure (204), and a second end of the first arm portion (504) coupled to a second arm portion (506); a second arm portion (506) having a first end coupled to the second end of the first arm portion (504) and a second end coupled to the non-destructive inspection scanning device (104); a compliant member (210) disposed between the first arm portion (504) and the second arm portion (506), the compliant member (210) biasing movement of the second arm portion (506) relative to the first arm portion (504) to apply a biasing force to the non-destructive inspection scanning device (104); and Wherein, the non-destructive inspection scanning device (104) is formed with a housing including one or more non-destructive inspection sensors; guiding the unmanned aerial vehicle (102) to a target location of a structure (202) to be inspected; placing the non-destructive inspection scanning device (104) on the surface of the target location of the structure (202) to be inspected; and The surface is non-destructively inspected using the one or more non-destructive inspection sensors.

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