System and method for repairing equipment

Abstract

A robotic assembly configured to repair an engine, wherein the robotic assembly includes: an environment capture device configured to provide information associated with an environment in which the engine is disposed to one or more computing devices, and wherein the one or more computing devices are configured to use the information to inspect the engine before and after a repair operation associated with the repair to verify repair equipment or portions thereof remaining in the engine after the repair.

Description

Technical Field

[0001] The present subject matter relates generally to systems and methods for servicing equipment and, more particularly, to systems and methods for servicing gas turbine engines. Background Art

[0002] At least some gas turbine engines include in a serial flow arrangement: a compressor section, which includes a low-pressure compressor and a high-pressure compressor, for compressing air flowing through the engine; a combustor, which is used to mix fuel with the compressed air so that the mixture can be ignited; and a turbine section, which includes a high-pressure turbine and a low-pressure turbine, for providing power to the compressor section.

[0003] Throughout the life of a gas turbine engine, it is often necessary to inspect and / or repair one or more components of the gas turbine engine. Traditionally, the gas turbine engine must be unloaded and / or disassembled from the wing of the aircraft in which the gas turbine engine is used to expose the parts that need to be inspected and / or repaired. However, this process can be relatively expensive and time consuming.

[0004] Therefore, improved systems and methods for servicing equipment would be useful. Summary of the invention

[0005] Aspects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.

[0006] In one exemplary aspect of the present disclosure, a robotic assembly is configured to repair an engine. The robotic assembly includes an environment capture device configured to provide information associated with an environment in which the engine is disposed to one or more computing devices. The one or more computing devices are configured to use the information to inspect the engine before and after a repair operation associated with the repair to verify repair equipment or portions thereof remaining in the engine after the repair.

[0007] In another exemplary aspect of the present disclosure, a method for servicing an engine, the method comprising: capturing information associated with the engine using an environmental capture device; performing a repair operation on the engine; and comparing one or more portions of the information captured before performing the repair operation with one or more portions of the information captured after performing the repair operation to verify repair equipment or portions thereof remaining in the engine after the repair operation.

[0008] In another exemplary aspect of the present disclosure, an at least partially autonomous robotic assembly is configured to navigate relative to an engine and service the engine. The at least partially autonomous robotic assembly includes an environment capture device, a memory storing processor-executable instructions, and a processor that executes the processor-executable instructions so that the at least partially autonomous robotic assembly services the engine. Service includes determining completed service tasks and uncompleted service tasks; maintaining an activity log representing a current step in servicing the engine; moving relative to the engine during the service; and inspecting the engine after the service.

[0009] These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims.The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the present invention and, together with the description, serve to explain the principles of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] A full and enabling disclosure of the invention, including the best mode thereof for one of ordinary skill in the art, is set forth in the specification, which refers to the accompanying drawings, in which:

[0011] Figure 1 is a cross-sectional schematic diagram of a high bypass turbofan jet engine according to an exemplary embodiment of the present disclosure.

[0012] Figure 2 is a flow chart of a method of servicing equipment according to an exemplary embodiment of the present disclosure.

[0013] Figure 3 is a schematic cross-sectional view of a robot assembly according to an exemplary embodiment of the present disclosure.

[0014] Figure 4 is a schematic side view of a robot assembly docked with a mating station according to an exemplary embodiment of the present disclosure.

[0015] Figure 5 is a flow chart of an exemplary method of kitting as part of a maintenance operation of equipment according to an exemplary embodiment of the present disclosure.

[0016] Figure 6 is a flow chart of another exemplary method of kitting as part of a maintenance operation of equipment according to an exemplary embodiment of the present disclosure.

[0017] Figure 7 is a schematic top view of an environment in which a robotic assembly may be configured to operate according to an exemplary embodiment of the present disclosure.

[0018] Figure 8is a flow chart illustrating an exemplary method of looking for unexpected changes in equipment according to an exemplary embodiment of the present disclosure.

[0019] Fig. 9 is a flow chart of an exemplary method of creating an operating range for servicing an engine according to an exemplary embodiment of the present disclosure.

[0020] Fig.10 is a flow chart of an exemplary method of inspecting damage to equipment according to an exemplary embodiment of the present disclosure.

[0021] Fig.11 is a flow chart of an exemplary method for generating an alert when an updated condition associated with a maintenance operation deviates from an original condition determined prior to the maintenance operation by more than a preset threshold according to an exemplary embodiment of the present disclosure.

[0022] Fig.12 is a flow chart of an exemplary method for an operator to perform maintenance according to an exemplary embodiment of the present disclosure.

[0023] Fig.13 is a close-up perspective view of an inspection and repair tool according to an exemplary embodiment of the present disclosure.

[0024] Fig.14 is a close-up schematic diagram of an inspection and repair tool according to an exemplary embodiment of the present disclosure.

[0025] Fig.15 is a schematic diagram of a path taken by a robotic arm during a maintenance operation according to an exemplary embodiment of the present disclosure.

[0026] Fig.16 is a flow chart of an exemplary method of marking a stopping point identifying a current operating position according to an exemplary embodiment of the present disclosure.

[0027] Fig.17 is a perspective view of an augmented reality device for performing maintenance operations on equipment according to an exemplary embodiment of the present disclosure.

[0028] Fig.18 is a flow chart of an exemplary method of using an augmented reality device as part of maintenance equipment according to an exemplary embodiment of the present disclosure.

[0029] Fig.19 is a flow chart of an exemplary method for servicing an engine using a re-anchored analysis profile based on a previous maintenance operation according to an exemplary embodiment of the present disclosure.

[0030] Fig. 20 is an exemplary implementation of a machine learning model according to an exemplary embodiment of the present disclosure.

[0031] Fig.21 is an isometric side view of a combustor section of a gas turbine engine as viewed in a captured image to illustrate a damaged area of ​​the combustor section according to an exemplary embodiment of the present disclosure.

[0032] Fig. 22 is a schematic diagram of a dispensing head of a robotic assembly configured to dispense lubrication according to an exemplary embodiment of the present disclosure.

[0033] Fig.23 is a graphical view of a re-anchoring protocol associated with parameters of a gas turbine engine according to an exemplary embodiment of the present disclosure. DETAILED DESCRIPTION

[0034] Reference will now be made in detail to embodiments of the present invention, one or more examples of which are shown in the accompanying drawings. The specific embodiments use numbers and letters to refer to features in the drawings. The same or similar reference numerals have been used in the drawings and description to refer to the same or similar parts of the present invention.

[0035] As used herein, the terms “first,” “second,” and “third” may be used interchangeably to distinguish one component from another, and are not intended to indicate the position or importance of the individual components.

[0036] The terms "front" and "rear" refer to relative positions within a gas turbine engine or vehicle and refer to the normal operating attitude of the gas turbine engine or vehicle. For example, for a gas turbine engine, front refers to a position closer to the engine inlet and rear refers to a position closer to the engine nozzle or exhaust.

[0037] The terms "upstream" and "downstream" refer to relative directions relative to the flow of fluid in a fluid channel. For example, "upstream" refers to the direction from which the fluid flows, and "downstream" refers to the direction to which the fluid flows.

[0038] Unless otherwise indicated herein, the terms "coupled," "fixed," "attached to," and the like refer to both direct coupling, affixing, or attachment as well as indirect coupling, affixing, or attachment through one or more intermediate components or features.

[0039] The singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise.

[0040] Approximate language, as used throughout the specification and claims, is used to modify any quantitative representation that may permissibly vary without resulting in a change in the basic function to which it is related. Thus, values ​​modified by one or more terms, such as "about," "approximately," and "substantially," are not limited to the precise values ​​specified. In at least some cases, approximate language may correspond to the precision of an instrument used to measure a value, or the precision of a method or machine used to construct or manufacture a component and / or system. For example, approximate language may refer to within a margin of 10 percent.

[0041] Throughout the specification and claims, range limitations are combined and interchanged, such ranges are identified and include all sub-ranges contained therein unless context or language indicates otherwise. For example, all ranges disclosed herein include the endpoints, and the endpoints are independently combinable with each other.

[0042] According to one or more embodiments described herein, a robotic assembly can provide autonomous or semi-autonomous maintenance operations (including inspection and / or repair) on equipment such as a gas turbine engine. The robotic assembly can include a visual capture device configured to capture one or more images of the environment in which the equipment is disposed, the equipment itself, or both. The visual capture device can be configured to observe components removed from the equipment during maintenance operations, components introduced into the equipment during maintenance operations, and the like. In conjunction with one or more computing devices, the visual capture device can detect when a component is not properly sized to fit within the equipment, when it is not properly shaped, or when it is not properly positioned to perform an intended function, and the like. The visual capture device using one or more computing devices can further detect when a component or part thereof is inappropriately left in or on the engine during maintenance (e.g., based on a comparison of images captured when the component is introduced into the equipment and when the component is removed from the equipment).

[0043] The systems and methods described herein are not necessarily limited to visual capture devices and associated methods of robotic assemblies. The present disclosure is not intended to be limiting. It should be understood that one or more embodiments described herein may be configured to operate independently or in combination with other embodiments described herein or not explicitly described herein.

[0044] Now referring to the accompanying drawings, Figure 1 A high bypass turbofan jet engine, referred to herein as a "gas turbine engine," is shown in accordance with an embodiment. Figure 1 As shown, the turbofan engine 10 defines an axial direction A (extending parallel to the longitudinal centerline 12 for reference) and a radial direction R. Generally, the turbofan engine 10 includes a fan section 14 and a turbine 16 disposed downstream of the fan section 14 .

[0045] The exemplary turbine 16 shown generally includes a casing 18 defining an annular inlet 20. Within the casing 18 may be considered an interior 19 of the turbine 16, and more specifically, of the turbofan engine 10. The casing 18 encloses, in serial flow relationship: a compressor section including a supercharger or low pressure (LP) compressor 22 and a high pressure (HP) compressor 24; a combustion section 26; a turbine section including a high pressure (HP) turbine 28 and a low pressure (LP) turbine 30; and an ejection exhaust nozzle section 32. The compressor section, combustion section 26, turbine section, and exhaust nozzle section 32 together at least partially define a core air flow path 37 through the turbine 16. A high pressure (HP) shaft or spool 34 (or more specifically a high pressure spool assembly, as described below) drivingly connects the HP turbine 28 to the HP compressor 24. A low pressure (LP) shaft or spool 36 drivingly connects the LP turbine 30 to the LP compressor 22.

[0046] For the illustrated embodiment, the fan section 14 includes a variable pitch fan 38 having a plurality of fan blades 40 coupled to a disk 42 in a spaced apart manner. As shown, the fan blades 40 generally extend outwardly from the disk 42 in a radial direction R. Each fan blade 40 is rotatable about the pitch axis P relative to the disk 42 because the fan blades 40 are operably coupled to an appropriate actuation member 44 that is configured to collectively and uniformly change the pitch of the fan blades 40. The fan blades 40, disk 42, and actuation members 44 together are rotatable about the longitudinal centerline 12 via the LP shaft 36 passing through a power gearbox 46. The power gearbox 46 includes a plurality of gears for stepping down the rotational speed of the LP shaft 36 to a more efficient rotational fan speed.

[0047] Still reference Figure 1 In the exemplary embodiment of the present invention, the disk 42 is covered by a rotatable forward hub 48 that is aerodynamically shaped to facilitate airflow through the plurality of fan blades 40. In addition, the exemplary fan section 14 includes an annular fan casing or outer nacelle 50 that circumferentially surrounds the fan 38 and / or at least a portion of the turbine 16. The nacelle 50 is supported relative to the turbine 16 by a plurality of circumferentially spaced outlet guide vanes 52. In addition, the nacelle 50 extends over the exterior of the turbine 16 to define a bypass airflow passage 56 therebetween.

[0048] During operation of the turbofan engine 10, a quantity of air 58 enters the turbofan engine 10 through the nacelle 50 and / or the associated inlet 60 of the fan section 14. As the quantity of air 58 passes through the fan blades 40, a first portion of the air 58, as indicated by arrow 62, is directed or delivered to the bypass airflow passage 56, while a second portion of the air 58, as indicated by arrow 64, is directed or delivered to the LP compressor 22 and exits the tail 54 of the turbofan engine 10. The ratio between the first portion of air 62 and the second portion of air 64 is generally referred to as the bypass ratio. The pressure of the second portion of air 64 is then increased as it is delivered through the high pressure (HP) compressor 24 and enters the combustion section 26, where the second portion of air 64 is mixed with fuel and combusted to provide combustion gases 66. The combustion gases 66 are then delivered through the HP turbine 28 and the LP turbine 30, where a portion of the heat and / or kinetic energy is extracted from the combustion gases 66.

[0049] The combustion gases 66 are then routed through the jet exhaust nozzle section 32 of the turbine 16 to provide propulsive thrust. At the same time, the pressure of the first portion of air 62 is significantly increased as it is routed through the bypass airflow passage 56 before it is exhausted from the fan nozzle exhaust section 68 of the turbofan engine 10, also providing propulsive thrust.

[0050] Furthermore, it should be appreciated that the exemplary turbofan engine 10 defines a plurality of openings. For example, the exemplary turbofan engine 10, and more specifically the turbine 16, defines a plurality of aperture mirror openings 70, the inlet 20, the exhaust nozzle 32, etc., arranged along the axial direction A. Additionally, although not shown, the turbofan engine 10, or more specifically the turbine 16, may define one or more igniter openings, fuel-air mixer openings, fuel nozzle openings, etc.

[0051] However, it should be understood that Figure 1 The exemplary turbofan engine 10 shown in FIG. 1 is provided by way of example only. In other exemplary embodiments of the present disclosure, the turbofan engine 10 may have any other suitable configuration, such as any other suitable number of compressors or turbines, or any geared or direct drive system, variable pitch or fixed pitch fan, etc. In addition, although in FIG. Figure 1 In the embodiment described as a turbofan engine, however, in other embodiments, any other suitable turbine engine may be provided. For example, in other embodiments, the turbine engine may be a turbojet engine, a turboprop engine, etc. In addition, in other exemplary embodiments of the present disclosure, the turbine engine may not be an aviation gas turbine engine, such as Figure 1The engine shown, instead, may be, for example, a land turbine engine used, for example, for power generation, or a marine turbine engine. Furthermore, in other embodiments, any other suitable type of engine may be provided, such as a rotary engine, such as an internal combustion engine. In yet other embodiments, the engine may be any device or machine that experiences changes in condition due to wear or environmental factors and is periodically subjected to maintenance operations (e.g., maintenance and / or repair).

[0052] Equipment such as gas turbine engines often require maintenance on a routine or semi-routine basis. Figure 2 is a flow chart illustrating an exemplary method 200 for servicing equipment according to one or more embodiments described herein. Exemplary maintenance operations may include inspection and repair of equipment. For aircraft gas turbine engines, maintenance operations may be performed on-wing, near-wing, or at a separate location, such as at one or more dedicated or specialized repair shops. On-wing maintenance may include maintenance operations performed while the gas turbine engine is installed on the wing of the aircraft. Near-wing maintenance may include maintenance operations performed while the gas turbine engine is removed from the aircraft but still located nearby (e.g., on a lift or cart disposed in a maintenance location within the aircraft or near the aircraft). Maintenance operations at a separate location may include operations at one or more maintenance shops, for example, in which the gas turbine engine is transported from the aircraft to a separate location for maintenance.

[0053] The maintenance operation can be derived from a work scope that defines the steps (also referred to as tasks) associated with the maintenance operation. The work scope may include, for example, information related to the individual tasks to be performed, the order in which the tasks are to be performed, the tools required to complete the tasks, the parts required to complete the tasks, safety factors associated with the tasks, metrics for evaluating the success or failure of properly completing the tasks (e.g., after performing a maintenance operation such as applying a thermal barrier coating, verifying whether the operation was successful within the specified operating tolerances), etc. In an embodiment, at least some of the work scopes may be created and / or maintained by a human operator. In another embodiment, at least some of the work scopes may be created and / or maintained by one or more computing devices, as described below. For example, one or more computing devices may use machine learning to create, maintain, modify, or otherwise manage the work scope. Each work scope may be for a specific type of equipment, a specific model of equipment, a specific manufacturing date or year of equipment, a specific use of equipment, or any combination thereof.

[0054] The work scope may include a preliminary work scope determined based at least in part on one or more last known conditions of the equipment. These last known conditions may include, for example, one or more operator blockage lists associated with the equipment, possible diagnostic analysis based on historical data and / or analysis, previous equipment maintenance data including information associated with previous maintenance operations, fleet-wide derived data, etc. The preliminary work scope may also be determined based on a standard equipment work scope (e.g., a regular maintenance schedule).

[0055] The preliminary work scope may also be determined based on the maintenance scenario, e.g., on-wing, near-wing, and at a separate location. As an example, while on-wing maintenance may facilitate faster turnaround times due to fewer operational steps, access to one or more components of an on-wing gas turbine engine may be limited or require special tools to reach. The need for such special tools may be considered to form part of the preliminary work scope.

[0056] When a preliminary scope of work is received at step 202 of method 200, the repair operation may include a kitting operation at step 204. In an embodiment, the preliminary scope of work may describe the parts and / or tools required to perform the repair. As described in more detail below, the kitting operation 204 may include compiling kit components, such as any parts and / or tools described in the preliminary scope of work. After completing the kitting operation, method 200 may also include step 206, in which the kit components are navigated to the equipment to be repaired. Upon reaching the equipment, method 200 may also include inspecting the equipment at step 208. Preliminary repair operations, such as steps involved in preparing for future repair operations, may also be performed at this time. In response to the inspection performed at step 208, method 200 may include the steps of performing repairs 210 or further inspections 212 based on the results from the inspection 208. The repair operation may include routine general maintenance, repairing damage to the equipment, updating one or more components of the equipment, etc. As described in more detail below, in the event that the inspection does not reveal unexpected problems, repairs 210 may be performed, while further inspections 212 may be required when unexpected problems occur or other conditions that require further analysis are found. In the event that further inspections 212 are required, a step 214 of performing repairs may be completed after the further inspection of step 212. In some cases, the step 214 of performing repairs may be different from the repairs performed in step 210. This difference may be the result of an updated scope of work formed at least in part in response to the further inspection 212. After the repair is completed in one of steps 210 and 214, the method 200 may include a step 216 of re-inspecting the equipment. In the event that the equipment is re-inspected and the repair is completed, the equipment may be ready to return to normal use. Otherwise, one or more additional inspection and / or repair steps may be required. In addition, as described in more detail below, information associated with one or more steps of the method 200, such as inspection results, repair data, test information, etc., may be saved to create or modify a condition profile of the equipment and / or inform future scope of work or fleet-wide analysis.

[0057] Figure 33 is a schematic diagram of an exemplary robotic assembly 300 for servicing equipment, such as the gas turbine engine described above. The robotic assembly 300 may generally include a support assembly 302, a robotic arm 304, and a utility member 306. The support assembly 302 generally includes one or more motors 308 and a controller 310. The controller 310 is operably coupled to the one or more motors 308 for controlling the operation of the robotic assembly 300. In addition, the controller 310 is operably coupled to the utility member 306 and / or one or more sensors (not shown) that are attached to or embedded in the robotic arm 304 and / or the utility member 306. In addition, the robotic arm 304 generally extends between a root end 312 and a distal end 314. The robotic arm 304 is coupled to the support assembly 302 at the root end 312 and includes the utility member 306 at the distal end 314.

[0058] It should be understood that the robotic arm 304 can define certain parameters to further enable it to reach relatively remote locations, such as within the interior of a gas turbine engine or other remote locations of the environment. More specifically, for the illustrated embodiment, the robotic arm 304 defines a length of at least about 12 inches, such as at least about 36 inches, such as at least about 48 inches, such as at least about 60 inches, such as up to about 500 inches in length between the root end 312 and the distal end 314. Similarly, the robotic arm 304 defines a maximum diameter between the root end 312 and the distal end 314, which, for the illustrated embodiment, is the maximum diameter of each of the various segments 318 of the robotic arm 304, less than about 5 inches. For example, the maximum diameter of the robotic arm 304 can be less than about 3 inches, such as less than about 2.5 inches, such as less than about 1 inch. This can further allow the robotic arm 304 to reach a desired relatively remote location. In an embodiment, the robotic assembly 300 may include a system (not shown) configured to monitor the robotic arm 304 or one or more positions thereof, for example, the distal end 314 of the robotic arm 304, or a component held or housed by or at the distal end 314. The system may also compensate for relative motion between the robotic arm 304, or one or more positions thereof, and the equipment.

[0059] The robot assembly 300 described according to one or more embodiments can operate autonomously, that is, without human interaction. Autonomous operation can be performed by programming robot instructions, which can be executed by the robot assembly. Autonomous operation can include making decisions at least in part without further support from a human operator, such as the selection of sensor inputs, internal parameters, etc. The actions performed and the results depend at least in part on these autonomous decisions made by the robot assembly 300. The robot assembly 300 described according to other embodiments can operate at least in part autonomously, that is, with minimal human operation. For example, in addition to local autonomous decisions made by the robot assembly, further human input and decisions can be used to execute the initial instructions. The robot assembly 300 described according to yet another embodiment can be operated under manual control. For example, the robot assembly 300 can be operated by a human operator located in a public environment or a remote environment (e.g., at least 0.25 miles away, at least 1 mile away, at least 5 miles away, at least 10 miles away, at least 25 miles away, at least 100 miles away, at least 1000 miles away). The references to autonomous, semi-autonomous and manually operated robot assemblies herein can be used interchangeably. However, in certain embodiments, the robotic assembly 300 is at least partially autonomous, such as fully autonomous.

[0060] The robot assembly 300 may also include an environment capture device 320. It should be understood that the environment capture device 320 may provide one or more functions to the robot assembly 300. As an example, the environment capture device 320 may be configured to capture information of the gas turbine engine while maintaining, such as visual supply. The environment capture device 320 may also be configured to capture information of the environment in which the gas turbine engine is located. For example, the environment capture device 320 may be configured to capture information associated with the movement of the robot assembly 300 between two or more points within the environment (e.g., between a supporting station and a gas turbine engine). In an embodiment, the information may be processed by one or more computing devices 328 and / or 330 (described below) for performing maintenance operations (i.e., maintenance and / or repair) and / or during maintenance operations, the robot assembly 300, for example, navigates through the environment from a remote location or relative to the gas turbine engine to the gas turbine engine.

[0061] In an embodiment, the environment capture device 320 may include one or more cameras 322 and mounts 324. The camera 322 and the mount 324 may be dynamically coupled together, such as rotatably coupled, pivotably coupled, telescopically coupled, retractably coupled, etc. In an embodiment, the camera 322 and the mount 324 may be repositionable by activation of one or more motors (not shown). One or more motors may be configured to operate autonomously or semi-autonomously to maintain information in a desired direction relative to the robot assembly and / or relative to the environment and / or the gas turbine engine. In an embodiment, the information may capture a wide angle view of the environment, a narrow field of view, or may be adjustable between a wide and narrow field of view. In an exemplary embodiment, the information may be configured to capture all or substantially all of 360 degrees in at least one side of the robot assembly 300.

[0062] In an embodiment, the environment capture device 320 may include a thermal imaging device. In another embodiment, the environment capture device 320 may include one or more passive and / or active scanners, digital cameras, charge coupled devices (CCDs), infrared sensors, complementary metal oxide semiconductors, ultrasound imaging devices, photoacoustic devices, magnetic resonance imaging devices, sound navigation ranging (sonar), radio detection ranging (radar), light detection ranging (lidar), inductive and / or capacitive proximity sensing, touch sensors (e.g., micro switches, sensor whiskers or buffers, physical displacement sensors (e.g., potentiometers), linear variable differential transformers (LVDTs, etc. In some cases, the environment capture device 320 may include multiple devices, each having the same, similar, or different functions or spatial alignments. The environment capture device 320 may be in electronic communication with one or more computing devices 328 and / or 330, and may be configured to send information or one or more output signals having information associated with the maintenance operation to the one or more computing devices 328 and / or 330.

[0063] In many embodiments, the robot assembly 300 also includes a moving device, a drive assembly 326, which is configured to move the robot assembly 300 relative to the environment. The drive assembly 326 may include one or more of an all-wheel, a giant wheel, a wheel, a caster, a track, a pedal, a skid, a movable arm, a movable leg, etc., coupled to one or more generators (e.g., motors, engines, etc.). The drive assembly 326 can be in electronic communication with one or more computing devices 328 and / or 330. By way of an exemplary embodiment, the one or more computing devices 328 and / or 330 can be configured to send information corresponding to a repositioning instruction or a coordinate grid to the drive assembly 326 to navigate the robot assembly 300. In another exemplary embodiment, the one or more computing devices 328 and / or 330 can provide a repositioning task description rather than linear programming instructions. For example, the one or more computing devices 328 and / or 330 can instruct the drive assembly 326 to reposition the robot assembly 300 to a specific location without describing the environment. As an example, one or more computing devices 328 and / or 330 may instruct the robotic assembly 300 to position itself at a specified distance from a particular portion of a particular piece of equipment being serviced (e.g., "1.5 meters aft of engine number two on an aircraft having tail number N123AB"). The drive assembly 326 may be configured to move the robotic assembly 300 in accordance with the received information. As described in more detail below, the repositioning instructions may include initial positioning instructions, i.e., for initially moving the robotic assembly 300 to the gas turbine engine, and / or repositioning instructions, i.e., for repositioning the robotic assembly 300 relative to the gas turbine engine during a maintenance operation.

[0064] In some embodiments, the one or more computing devices include one or more local computing devices 328. The local computing device 328 can be locally set on the robot assembly 300 or included in the environment of the equipment. In other embodiments, the one or more computing devices include one or more remote devices 330. For example, the remote device 330 may include one or more nodes (e.g., virtual nodes), maintainers, or other off-site computing devices configured to communicate with the robot assembly 300 or other nodes in the maintenance environment. For example, the node may include, for example, an information link point along a wireless transmission path, a wired transmission path, etc. Exemplary nodes include user device interfaces, maintainer interfaces, equipment interfaces, etc. The remote computing device 330 may communicate with the robot assembly 300 via one or more wireless protocol standards. In yet other embodiments, the one or more computing devices may be split between one or more local computing devices 328 and one or more remote computing devices 330. That is, the one or more computing devices may include a combination of local and remote computing devices. The local and remote computing devices may work together or perform different processing operations described herein, such as autonomous or semi-autonomous processing.

[0065] One or more computing devices 328 and / or 330 may include instructions stored on a computer-readable storage device 332. The instructions may be read and executed by at least one processing element 334. The processing element 334 may be any suitable processing device (e.g., a processor core, a microprocessor, an ASIC, an FPGA, a controller, a microcontroller, etc.), and may be one or more processors that are operably connected. For example, the computer-readable storage device 332 may include one or more non-transitory computer-readable storage media, such as RAM, ROM, EEPROM, EPROM, one or more memory devices, flash memory devices, etc. and combinations thereof. The computer-readable storage device 332 may store information accessible by the processing element 334. The instructions may be software written in any appropriate programming language, or may be implemented in hardware. In addition, or alternatively, the instructions may be executed logically and / or virtually in separate threads on the processing element 334. According to aspects of the present disclosure, one or more computing devices 328 and / or 330 may store or include one or more models 2004 ( Fig. 20). As an example, model 2004 may include various machine learning models, such as models using enhanced random forest techniques, support vector machines, neural networks (e.g., deep neural networks), or other multi-layer nonlinear models. Exemplary neural networks include feedforward neural networks, recurrent neural networks (e.g., long short-term memory recurrent neural networks), convolutional neural networks, or other forms of neural networks. In an embodiment, model 2004 may implement multiple parallel instances of a single model (e.g., parallel action determination across multiple instances for a single determination).

[0066] In an embodiment, the robot assembly 300 may also include one or more wireless communication elements 336. The wireless communication element 336 may include circuits and one or more transceivers for sending and receiving signals. The wireless communication element 336 may also include an antenna, processing circuits, and memory to perform the wireless communication operations described herein.

[0067] In an embodiment, the robot assembly 300 can communicate peer to peer with other robot assemblies 300, for example, within a shared environment, between two or more remote locations, or between a shared assembly that houses multiple independent robot assemblies 300. In this way, the robot assemblies 300 can operate relative to each other. As an example, through peer-to-peer communication, multiple robot assemblies 300 can communicate and collaboratively navigate a path wide enough for only one robot assembly to pass through at a time. Peer-to-peer communication can also allow for simultaneous maintenance with real-time information sharing and / or transmission of delayed maintenance information between robot assemblies 300 performing maintenance. The use of peer-to-peer communication can further facilitate easier matching operations, mobile inter-assembly arrangements, etc. As another example, the robot assembly 300 can communicate with a second robot that is coupled to the robot assembly 300, such as mounted to the robot assembly 300. In some cases, the second robot can operate independently of the robot assembly 300, or at least partially independently of the robot assembly 300.

[0068] In some cases, the robot assembly 300 may be configured to operate in a human-inhabited environment. As an example, an aircraft hangar typically includes human operators who repair aircraft and their components. Using the robot assembly 300 in such an environment may create a dangerous working environment. Therefore, in an embodiment, the robot assembly 300 may be configured to detect the presence and / or proximity of a person by using an environment capture device 320 or another element of the robot assembly 300, for example, within a specified proximity of the robot assembly 300, thereby safely operating within the environment. When the robot assembly 300 detects a person within a specified proximity, one or more operations of the robot assembly 300 may be autonomously adjusted to create a safer environment. For example, when navigating through an environment within a specified proximity to a person, such as within ten feet of a worker, the drive assembly 326 may operate at a slower (safe) speed. If the typical operating speed through the environment is 1 meter / second, the safe speed (for example, when within a specified proximity of a person) may be less than 0.1 meters / second. In an embodiment, the safe speed may be less than 90% of a typical speed, such as less than 80% of a typical speed, such as less than 70% of a typical speed, such as less than 60% of a typical speed, such as less than 50% of a typical speed, such as less than 40% of a typical speed. Similarly, the speed of the robotic arm 304 may be different when operating within a specified proximity of a person. In the event of a condition such as a person no longer being within a specified proximity of the robotic assembly 300, the robotic assembly 300 may return to a normal operating condition, such as a normal (typical) speed.

[0069] With the preliminary scope of work formed, the robotic assembly 300 may be equipped with a kit including parts and / or tools as described in the preliminary scope of work to perform maintenance operations associated with the preliminary scope of work. Parts may include items other than tools configured for maintenance operations, such as lubricants, fasteners, clips, belts, seals, etc. Parts may include replacement parts for equipment 706. Additionally or alternatively, parts may include sprayable coating materials, cleaners, conditioners, welding materials, brazing materials, etc. Tools may include one or more single-use and / or reusable tools that can be used to perform maintenance operations. Exemplary tools include wrenches, drills, blowers, lights, scanners, blades, saws, brushes, dryers, measuring devices, pumps, sandblasters, polishers, ablative devices, welders, applicators and dispensers, robotic sensors, robotic tools, etc.

[0070] Figure 4is a schematic diagram of a robotic assembly 300 docked with a kitting station 400. The kitting station 400 includes a storage area 402 configured to temporarily store kit components including one or more parts and / or tools 404 that can be used by the robotic assembly 300 when servicing equipment (e.g., the gas turbine engine described above). As shown, the storage area 402 can include any number of racks, boxes, trays, shelves, stations, etc. configured to store tools and / or parts 404. The storage area 402 can be maintained and organized autonomously, or can be maintained and / or organized with the help of a manual interface.

[0071] In an embodiment, the robot assembly 300 and the kitting station 400 can communicate with each other. For example, the robot assembly 300 and the kitting station 400 can wirelessly communicate with each other (directly or indirectly) so that the kitting station 400 provides (kits) one or more parts and / or tools 404 to the robot assembly 300. Such a kitting operation can correspond to one or more preliminary or non-preliminary (update) work scopes associated with a maintenance operation of a gas turbine engine. For example, as a non-limiting example, repairing a valve of a gas turbine engine may require special tools to access and inspect the valve and special components, as well as parts, such as consumables, such as fluids, wipes, sprays, cleaning materials, etc., and / or replacement parts to repair the valve. The work scope associated with the valve maintenance operation may include a description of the parts and / or tools 404 required to complete the maintenance operation. Therefore, the kitting operation may include the steps of providing at least some parts and / or tools 404 to the robot assembly 300 to complete the maintenance operation.

[0072] The working scope may be communicated from the robotic assembly 300 to the mating station 400, from one or more computing devices 328 and / or 330 to the mating station 400, another remote or local component or instrument, or any combination thereof. In an embodiment, the preliminary or updated working scope may include loading instructions associated with a loading configuration of one or more parts and / or tools 404 within the mating area 406 of the robotic assembly 300. As an example, the loading instructions may be determined based on a sequence of operations to be performed during maintenance, such that highly important equipment is placed closest to the robotic arm 304 according to special operating instructions, etc., or any combination thereof.

[0073] The supporting area 406 may include a receiving area of ​​the robot assembly 300, which is configured to receive one or more parts and / or tools 404, for example, from the supporting station 400. In an embodiment, the supporting area 406 may include a single receiving area. In another embodiment, the supporting area 406 may include a plurality of discrete receiving areas. For example, the supporting area 406 may include a discrete first supporting area and a second supporting area, each supporting area having a predetermined function or storage capacity. For example, the first supporting area may be a general receiving area for basic tools, while the second supporting area is configured to keep one or more parts and / or tools under or within a specified condition, such as at a specified temperature. In an embodiment, at least one of the robot assembly 300 and the supporting area 406 may include one or more sensors, cameras, detectors, etc. (not shown) for monitoring the supporting area 406 and / or one or more parts and / or tools 404 contained therein.

[0074] In some cases, the loading instructions associated with the loading configuration in the kitting area 406 may include a prescribed spatial arrangement of the parts and / or tools 404, a loading order, or both. As an example, certain tools may be oriented at prescribed angles at predetermined locations within the kitting area 406 so that the robotic assembly 300 may access and utilize the tools.

[0075] In an embodiment, the robotic assembly 300 may be configured to determine the position of the part and / or tool 404 relative to the mating area 406. For example, the robotic assembly 300 may include sensors or detectors configured to locate the desired part and / or tool 404 within the mating area 406 and autonomously approach and remove the desired part and / or tool 404 from the mating area 406. In another embodiment, this step may be performed at least in part with the assistance of the environment capture device 320. The determination of the position may also include the identification of the angular orientation of the part and / or tool 404 within the mating area 406, or the identification of an appropriate interface location along the part and / or tool 404 (e.g., identifying a tool handle or graspable portion of a component).

[0076] Determining the location of the part and / or tool 404 may also require the use of the environment capture device 320. By using the environment capture device 320 to capture an image of the part and / or tool 404 as it enters the assembly area 406, the part and / or tool 404 may be mapped relative to the assembly area 406. The mapped location of the part and / or tool 404 may then be used to locate the part and / or tool 404 when needed during the maintenance operation.

[0077] exist Figure 4In the illustrated embodiment, the mating station 400 includes a plurality of storage areas, each of which holds tools and / or parts 404 associated with one or more work ranges. The plurality of storage areas are shown in a stacked configuration. In other embodiments, the mating station 400 may include a plurality of different stacked or non-stacked configurations disposed at one or more locations accessible to the robot assembly 300.

[0078] The individual storage areas may be categorized, for example, by object type, size, shape, frequency of use, etc. In an embodiment, each individual storage area may be configured to store the precise parts and / or tools required for a specific range of work. In this regard, the robot assembly 300 may be completely assembled from a single storage area. In another embodiment, the individual storage areas may hold assembled components in another specified arrangement.

[0079] In an embodiment, the kit station 400 can be set in the same environment as the equipment to be repaired, for example, in the same hangar as the gas turbine engine to be repaired. Alternatively, at least a portion of the kit station 400, such as the entire kit station 400, can be set in a discrete location separate from the environment housing the equipment. For example, the equipment can be set in a first building, and the kit station 400 can be set in a second building different from the first building. The robotic assembly 300 can be configured to navigate between the first building and the second building to approach the kit station 400 and return to the equipment for maintenance operations.

[0080] In some embodiments, the matching stations 400 may be distributed in two or more different locations. In this case, the robot assembly 300 may travel between multiple matching stations 400 to fully match the matching area 406 in preparation for maintenance operations. Alternatively, one or more auxiliary equipment may be configured to partially match parts and / or tools 404 associated with the working range at one or more handover locations and meet the robot assembly 300, where multiple parts and / or tools 404 from multiple matching stations 400 may be simultaneously transferred to the matching area 406. In an embodiment, the operation of matching the robot assembly 300 may be performed autonomously or semi-autonomously.

[0081] In an embodiment, the robotic assembly 300 may utilize the environment capture device 320 during or in response to a mating operation. For example, the robotic assembly 300 may track the parts and / or tools 404 as they are transferred from the mating station 400 (or one or more intermediate equipment) to the mating area 406. The robotic assembly 300 may map the parts and / or tools 404 based on the tracked data and locate the parts and / or tools 404 in response to their mapped locations. The environment capture device may further compare the information to determine whether the parts and / or tools 404 have been displaced, altered, damaged, or otherwise changed at any time before, during, or after the maintenance operation.

[0082] The transfer of parts and / or tools 404 between the mating station 400 and the robotic assembly 300 may be performed by the robotic assembly 300, such as by the robotic arm 304. Alternatively, the transfer of parts and / or tools 404 may be performed by the mating station 400 itself. Alternatively, the transfer of parts and / or tools 404 may be performed by one or more intermediate devices or by one or more human operators.

[0083] In some cases, the matching operation may include the step of providing one or more redundant tools or components to the robot assembly 300. Without wishing to be bound by any particular theory, redundancy may be particularly useful in cases where there is a high probability of a maintenance problem and where parts may need to be added in situ. In an embodiment, the robot assembly 300 may be configured to remove unused redundant tools and / or components from the matching area 406 after the maintenance is completed. The removal of redundant parts and / or tools 404 may be performed by returning the redundant parts to the original matching station 400 or another matching station 400 (e.g., a drop-down matching station). The removal of redundant parts may also include discarding redundant parts. In an embodiment, some redundant parts may be recycled and reused, while other redundant parts may be discarded (if not used). One or more of the robot assembly 300, matching station 400, one or more computing devices 328 and / or 330, etc. may be configured to determine the arrangement of redundant parts after completing the maintenance operation.

[0084] Figure 55 is a flow chart of a method 500 of outfitting a robotic assembly as part of a maintenance operation of equipment according to an exemplary embodiment of the present disclosure. As described above, the method 500 may include an initial step 502 of determining a current working range associated with the equipment. The current working range may include a preliminary working range based on an expected maintenance operation to be performed. The method 500 may also include a step 504 of determining parts and tools associated with the current working range. The method 500 may also include a step 506 of outfitting the robotic assembly with parts and tools for performing the maintenance operation. The method 500 may also include a step 508 of navigating the robotic assembly within an environment with the equipment, and a step 510 of performing at least one of an inspection and a repair of the equipment using the outfitted parts and tools.

[0085] Figure 6 is a flowchart of another method 600 for performing kitting, including step 602, determining, by one or more computing devices, a current (e.g., preliminary) working range associated with equipment, step 604, determining, by one or more computing devices, parts and tools associated with the current working range, step 606, causing, by one or more computing devices, at least some of the parts and tools to be equipped on a robotic assembly, step 608, determining, by one or more computing devices, a path for navigating the robotic assembly within an environment having the equipment, and step 610, causing, by one or more computing devices, the robotic assembly to perform at least one of an inspection and a repair of the equipment using the equipped parts and tools.

[0086] Figure 7 A schematic diagram of an exemplary environment 700 is shown in which the robotic assembly 300 may be configured to operate. The environment 700 includes a building 702, such as an aircraft hangar or maintenance location, having one or more maintenance areas 704 in which equipment 706 is maintained. The robotic assembly 300 is shown in a kit room 708, which includes one or more kit stations 400 configured to kit the robotic assembly 300 for a working range associated with the equipment 706. Although the kit room 708 is shown as a receiving space within the building 702, in other embodiments, the kit room 708 may include an open space within the building 702 (e.g., a common space shared with one or more maintenance areas 704). The kit room 708 may also be located within another building (not shown) or in an external environment relative to the building 702.

[0087] After receiving the kitting parts from the kitting operation station 400, the robotic assembly 300 may navigate through the environment 700. Navigation may include, for example, determining a path 710 within the environment, e.g., from the kitting station 400 to an appropriate maintenance area 704. The path 710 may be formulated to avoid obstacles 712 within the environment 700. These obstacles 712 may include building supports, walls, doors, other equipment and robotic assemblies, parts, human operators, animals, etc. In embodiments, the path 710 may be formed based on other robotic assemblies 300 also operating within the environment 700, e.g., taking into account the movements of the other robotic assemblies 300. In embodiments, the path 710 may be formulated by one or more computing devices 328 and / or 330 and communicated to the robotic assembly 300.

[0088] The path 710 may be saved as a series of coordinates, lines, or other recognizable data and used to navigate the robotic assembly 300 through the environment 700. Deviations in the path 710 may occur as a result of unknown obstacles 712, such as, for example, human operators moving through the building 702, dropped equipment or parts, etc. In an embodiment, the environment capture device 320 may be used during navigation to detect the unknown obstacles 712 and assist in navigating through the environment 700. In another embodiment, a separate environment capture device (not shown) may be used to detect the unknown obstacles 712. The detection of the unknown obstacles may be communicated to the one or more computing devices 328 and / or 330, and the path 710 may be updated in light of it. The updating of the path 710 may be performed autonomously.

[0089] Once the equipment 706 is reached, the robot assembly 300 can begin a maintenance operation on the equipment 706 according to the associated working range. In some embodiments, the working range may not have been fully downloaded to the robot assembly 300 before the previously described matching operation. In this case, the download can be completed during the navigation from the matching room 708 to the maintenance area 704, once at the maintenance area 704, or both. In other embodiments, the working range can be continuously received during the maintenance operation. In yet other embodiments, the working range or at least a portion of the working range can be determined by the robot assembly 300 itself. For example, the computing device 328 can be part of the robot assembly 300 and is configured to autonomously or partially autonomously determine the working range or a portion thereof. In a specific embodiment, the computing device 328 can determine a portion of the working range, such as appropriate alignment relative to the equipment, capturing and / or associating the manufacture and model of the equipment to determine the working range, comparing the working range with the full fleet data, etc. At this point, a large number of maintenance operations-that is, from forming the working range to executing the working range, can be performed locally by the robot assembly 300. The present disclosure is not intended to be limited to the above-described methods of information transmission and transfer between two or more nodes, and may include other methods of information transmission and transfer between two or more nodes.

[0090] For certain working ranges, precise alignment may be required between the robotic assembly 300 and the equipment 706. Precise alignment may result in a higher degree of variable control between the positions of the equipment 706 and the robotic assembly 300. As an example, precise alignment may occur when the alignment deviation relative to the intended alignment between the equipment 706 and the robotic assembly 300 is less than 10 mm, such as less than 8 mm, such as less than 6 mm, such as less than 4 mm, such as less than 2 mm, such as less than 1 mm, such as less than 0.5 mm. In a particular embodiment, precise alignment occurs when the alignment deviation is less than 0.25 mm. In yet another embodiment, precise alignment occurs when the alignment deviation is less than 0.1 mm, such as less than 0.01 mm, such as less than 0.001 mm.

[0091] In an embodiment, the environment capture device 320 may be used to establish a precise alignment of the robotic assembly 300 relative to the equipment 706. In another embodiment, the robotic assembly 300 may also include a precise alignment detector 338 ( Figure 3 ), which is configured to establish precise data or position information of the robotic assembly 300 relative to the equipment 706. An exemplary precise alignment detector 338 may utilize stereo vision, three-dimensional triangulation techniques, etc. Automatic collision avoidance may be used to ensure that situational collision risks, e.g., collision risks relative to the equipment 706 are understood and avoided.

[0092] In some embodiments, one or more steps associated with the maintenance operation may require the use of additional, discrete maintenance components, such as additional robotic components or discrete sensors and detectors. The robotic assembly 300 can be configured to deploy one or more sensors or detectors along, near and / or within the equipment 706 at any time relative to the maintenance operation. The one or more sensors or detectors can be precisely or imprecisely placed relative to the equipment 706. The one or more sensors or detectors can be used before, during and / or after the maintenance operation to collect information related to the equipment 706, the maintenance operation, the robotic assembly 300, etc., or any combination thereof. In some cases, the one or more sensors or detectors can communicate with the robotic assembly 300 and / or one or more computing devices 328 and / or 330, such as wirelessly or wired communication, to transmit sensed / detected information thereto.

[0093] Once properly positioned relative to the equipment 706 (e.g., either precisely aligned or ready for maintenance operations), the robotic assembly 300 can be configured to perform an initial inspection. The initial inspection can include comparing the equipment 706 to the last known condition of the equipment 706 and, optionally, other additional information associated with the equipment 706. In some cases, the environmental capture device 320 can be used to perform an initial inspection of the current condition. As an example, the step of determining the current condition can be performed, for example, by one or more of the following: visual inspection, thermal inspection, fatigue indicator, strength testing, coating inspection (e.g., thickness, color, peeling, adhesion of contaminants, etc.), damage and degradation inspection, shrinkage and expansion determination, electronic verification, hose inspection, rotor inspection, and the like.

[0094] The current status can be compared to a last known status (i.e., reference information such as reference data) on which the preliminary scope of work is based at least in part. The comparison can be on a rolling (i.e., ongoing), hierarchical, or completion-based protocol. In an embodiment, the current status can be compared to computer-aided design (CAD) reference data including a CAD engine design. The comparison of the last known status and the current status can look for unexpected changes and analyze any unexpected changes based on the preliminary scope of work. As an example, the CAD reference data can include a tool envelope that defines the necessary dimensions of a tool in order to properly fit within the equipment 706 to perform the repair. Unexpected changes to the equipment 706 may cause the tool envelope to fail, i.e., the specified tool cannot fit within the equipment 706 to perform the scope of work associated with the repair operation. Figure 88 is a flow chart illustrating a method 800 for finding unexpected changes, including a step 802 of inspecting equipment and a step 804 of comparing the inspected equipment to reference data associated with the inspected equipment. In an embodiment, the step 802 of inspecting equipment and the step 804 of comparing the inspected equipment may be performed simultaneously or substantially simultaneously. For example, the inspecting and comparing may occur substantially simultaneously when, while further inspecting, already inspected aspects of the maintenance operation are compared. Alternatively, substantially simultaneous performance may occur when the duration between the inspecting and comparing is negligible (e.g., less than 10 minutes or less than 1 minute).

[0095] At step 806, information associated with the comparison performed at step 804 may be used to determine whether the tools and / or parts 404 to be used when performing the repair are appropriately sized and / or shaped to fit relative to the equipment (i.e., to prevent a tool envelope failure). The preliminary working scope may be updated in light of such unexpected changes (e.g., a tool envelope failure), and in some embodiments, a modified working scope may be created. In an embodiment, the creation of the modified working scope may be performed by one or more computing devices 328 and / or 330. In another embodiment, the creation of the modified working scope may be performed by a human operator. In another embodiment, the creation of the modified working scope may include the use of autonomous logic and one or more human operators. The comparison performed at step 804 may also be used to inspect for damage to the inspected equipment at step 808.

[0096] The modified working range may be communicated between two or more nodes, e.g., between two or more robot assemblies 300, between a kitting station 400 and a robot assembly 300, between one or more computing devices 328 and / or 330 and any other nodes, between two or more other nodes, or any combination thereof. In some cases, the modified working range may require that the robot assembly 300 be re-kitted in order to perform the modified working range. For example, in the event that a tool envelope failure has occurred, re-kitting may require the use of a smaller tool. In other cases, the modified working range may generate an alert seeking human intervention (e.g., involving an expert as described in more detail below). In other cases, the modified working range may be performed using some other combination of kitted components already on the robot assembly 300 (e.g., one or more redundant components on the robot assembly 300).

[0097] The robotic assembly 300 according to the embodiments described herein can be configured to operate autonomously or semi-autonomously. That is, the robotic assembly 300 can be configured to operate without or with minimal active human involvement. The robotic assembly 300 can also be configured to operate in or near high temperature environments, such as near a gas turbine engine that is cooled from operating temperature. In this way, the robotic assembly 300 is able to repair equipment, such as a gas turbine engine, when human interaction is too dangerous. In view of such capabilities, it may be advantageous to prioritize certain tasks within the scope of work.

[0098] In an embodiment, the work scope may define a queue of tasks, including multiple ordered maintenance steps. For example, the work scope may indicate an initial maintenance operation according to an initial environment or equipment condition, and indicate a continuous maintenance operation according to a continuous environment or equipment condition. As an example, a gas turbine engine that is repaired on the wing immediately after use may have an initial high temperature close to the operating temperature, which may decrease when cooled. The high temperature of the gas turbine engine may refer to an ambient engine temperature average of at least 300°F, such as at least 350°F, such as at least 400°F, such as at least 500°F, such as at least 750°F, such as at least 2000°F, or higher. In some embodiments, the ambient engine temperature average may be less than 10000°F, such as less than 5000°F. In some embodiments, the term "ambient engine temperature" may refer to the temperature of a surface component of an engine, a specific component of an engine being repaired, a surface component of an engine being repaired, or an area around a specific component, etc. Therefore, if an operator or a tool or a robotic assembly repairs a specific component, the ambient engine temperature may be an indicator of the temperature to which the operator or the tool or the robotic assembly will be exposed. The operating envelope can take this high temperature and cooling gradient into account when determining the sequence of maintenance operations.

[0099] Reference Fig. 9, a method 900 for repairing an engine according to an embodiment may include a step 902 of determining a work scope associated with the engine, the work scope including a plurality of tasks associated with at least one of inspection and repair of the engine. The method 900 also includes a step 904 of determining risk factors for at least two tasks of the work scope. The method 900 also includes a step 906 of creating a queue of tasks according to the risk factors determined in step 904, and prioritizing tasks determined to have high risk factors. In this way, in some embodiments, at least two tasks of the tasks of the work scope may be evaluated for the risk factors associated therewith, and a resulting queue of tasks associated with the work scope may be formed according to the risk factors. Tasks with higher risk factors may be prioritized in the queue. Risk factors may include, for example, the likelihood of task failure, the criticality of the task, the likelihood that performing the task may cause the work scope to be escalated to a more serious or more time-consuming operation, and the like. In an embodiment, the queue may be passive. For example, a passive queue may contain a specific order of tasks to be completed without an option for adjusting the order or scope of the tasks. In another embodiment, the queue may be dynamic. For example, in response to one or more unexpected changes associated with maintenance, a dynamic queue may be adjusted during a maintenance operation. In an embodiment, the dynamic queue may be managed using, optionally, machine learning, by one or more computing devices 328 and / or 330. The dynamic queue may provide maintenance flexibility.

[0100] Reference again Figure 3 In an embodiment, the robotic assembly 300 may include a medium dispenser 340 (e.g., a lubricant dispenser) configured to dispense one or more mediums, such as lubricants, relative to, for example, at least a portion of the equipment 706 (e.g., on one or more adjustable components of an engine, a surface component surrounding an adjustable component, or an area surrounding an adjustable component or a surface component). Dispensing lubricant on the equipment 706 is an exemplary task that may be prioritized in a queue of work ranges because it may be an initial step required for subsequent steps to be performed (e.g., loosening of a fastener). The lubricant may include, for example, a boundary lubricant, a mixed lubricant, and / or a full film lubricant including a hydrodynamic or elastohydrodynamic lubricant. The lubricant may include a liquid lubricant, a solid lubricant, a gas lubricant, or a semi-solid lubricant. As non-limiting examples, the lubricant may include fatty alcohols, esters, EVA waxes, PE waxes, paraffin waxes, soaps, amides, fatty acids, and the like, and combinations thereof. In an embodiment, at least a portion of the lubricant dispenser 340 may be disposed on the robotic arm 304. Referring to Fig. 22, the lubricant dispenser 340 may include a dispenser head 2200, such as a dispenser tip, and one or more lubricant containers (not shown). One or more biasing elements, such as one or more pumps, pistons, etc., may bias lubricant from the one or more lubricant containers to the dispenser head 2200. The robotic arm 304 may be configured to move the dispenser head 2200 of the lubricant dispenser 340 relative to the equipment 706 to a position to lubricate one or more parts 2202 or a block thereof. The one or more parts 2202 may include, for example, threaded or non-threaded fasteners, hole mirror plugs, hinges, clips, etc. In an embodiment, as an initial or near initial operation step of the work range, the work range may dispense lubricant 2204 on one or more parts 2202 of the equipment 706. The penetrating lubricant 2204 may then have an opportunity to penetrate the one or more parts 2202 to allow easier operation thereon in a later step of the work range. In addition, without wishing to be bound by any particular theory, it is believed that at least some lubricants may perform better when applied to heated parts and surfaces.

[0101] In some embodiments, lubricant 2204 may be given a predetermined amount of time to penetrate. At the end of the predetermined amount of time, the robotic assembly may then proceed to a further task of the work range associated with component 2202 downstream of the lubrication step (e.g., removing the component). In other embodiments, the robotic assembly may attempt to operate on the component until the component becomes operable. That is, for example, if the component is not yet operable, the robotic assembly may return to other tasks and resume attempting to operate on the component at a later time after further penetration of the lubrication has occurred.

[0102] In some embodiments, the robot assembly 300 may also include a cooling component 342, which is configured to expose the equipment 706 or a portion thereof to a relatively low temperature coolant. The cooling component 342 may be disposed on the robot arm 304 or another portion of the robot assembly 300. In an embodiment, the cooling component 342 may include a sprayer configured to distribute a cooling spray on the equipment 706. The cooling spray may include, for example, a liquid coolant (e.g., liquid nitrogen) and / or a solid coolant (e.g., carbon dioxide). The cooling spray may be biased to contact a specified position of the equipment 706. When the equipment 706 or a portion thereof cools in response to contact with the cooling spray, it may be easier to provide maintenance for it. In another embodiment, the cooling component 342 may include a closed loop coolant, such as a refrigerant circulating through at least a portion of the cooling component 342. A conductive interface may be formed between the closed loop coolant and the equipment 706 to expose the desired portion of the equipment 706 to low temperatures. The closed loop coolant may allow the equipment 706 to cool without being wetted. As another example, cooling component 342 may also include a Peltier effect thermo-electric cooler. As another example, component 342 may include a non-cyclic phase change material, such as paraffin or other material having a relatively low temperature melting point compared to equipment 706.

[0103] The localized cooling facilitated by the cooling member 342 can allow, for example, a male fastener to cool at a relatively faster rate than a female fastener or the threads in which the male fastener is disposed. Thus, by virtue of the cooling and thermal gradient, the male fastener can be caused to contract relative to the female threads and the torque required to loosen the male fastener from the female threads can be reduced. In this way, the risk of stripping threads or damaging equipment can be minimized without compromising the amount of time required to perform a repair operation.

[0104] The cooling operation may be performed based on a cooling scheme, which is established based on, for example, environmental conditions, component design, component material, etc. In this regard, the unique characteristics of different equipment and components may be taken into account in determining the amount and location of cooling to be applied to the equipment and / or component. For example, a short set screw may be locally cooled without temperature gradient issues, while a long shank bolt may require a prescribed cooling and / or heating scheme, i.e., a temperature control scheme, to affect removal of the long shank bolt without risk of damaging the equipment and / or the long shank bolt. Similarly, the optimal cooling scheme for the screw may vary depending on the specific material properties of the screw, such as absolute temperature, desired cooling location, cooling duration, temperature profile, etc.

[0105] Necessary temperature control solutions, such as cooling solutions, may be included in the operating range based on reference values, fleet-wide data, maintenance history information, etc. In an embodiment, one or more computing devices 328 and / or 330 may determine the appropriate temperature control solution for each component on the equipment. This determination may be autonomous or semi-autonomous (i.e., including, for example, manual confirmation).

[0106] In an embodiment, the cooling component 342 can be part of a temperature control component (not shown). The temperature control component 342 can be configured with a heating component that is configured to apply local heat to the equipment. In a specific embodiment, the cooling component and the heating component can be part of the same structure. As a non-limiting example, a compressed air vortex tube can supply hot air to a first portion of the equipment and cold air to a second portion of the equipment. In some cases, the application of hot air and cold air can be performed simultaneously.

[0107] The robotic assembly 300 may also include an operating tool, such as a wrenching device 344, configured to operate one or more components, such as one or more threaded or non-threaded fasteners of the equipment 706. The wrenching device 344 may be disposed on the robotic arm 304 or another portion of the robotic assembly 300. For example, the wrenching device 344 may allow the threaded fastener to be loosened when the threaded fastener is at or above a threshold operating temperature above which a person may not come into contact with it. In this regard, the robotic assembly 300 may operate on the equipment 706 while the equipment is above a threshold of manual operation, such as above 200°F, such as above 500°F, such as above 1000°F. In an embodiment including a cooling system 342 and a wrenching device 344, the cooling system 342 may first be applied to the fastener for a specified duration, after which the wrenching device 344 may be used to remove the fastener. For a rapid cooling system 342, a successive fastener, i.e., the next fastener, may be cooled by the cooling system 342 while the previous fastener is being removed by the wrenching device 344. In another embodiment, the robotic assembly 300 may include an operating tool, such as a wrench device equipped with a pulse loading device to propagate shock waves through the threaded fastener, such pulse loading enabling friction between the male and female threads of the fastener to be overcome without the use of excessive torque or impact torque devices.

[0108] The robotic assembly 300 may include a receiving area (not shown) in which fasteners or other removed parts removed from the equipment 706 may be stored. In an embodiment, the receiving area may be configured to hold removed fasteners and / or parts at elevated temperatures without causing danger to the fasteners or parts, the equipment 706, the robotic assembly 300, nearby personnel, or other sensitive equipment. In an exemplary operating range, the process of cooling, removing, and storing fasteners and / or parts may occur during one or more initial steps of the operating range, i.e., when the gas turbine engine is too hot for a human operator to approach.

[0109] The environment capture device 320 can be used to observe the fasteners and other parts of the equipment 706 when the fasteners and other parts of the equipment 706 are removed from the equipment 706 or the receiving area of ​​the robot assembly 300. The environment capture device 320 can detect the conditions of at least some (e.g., all) of the parts that are removed (and later reinstalled) to perform inbound (and outbound) verification of the parts. This verification can check for component damage and ensure that the reinstalled parts match the previously removed parts. This verification can further check that the parts are returned within the same range of the initial state of the parts or within a safe range. In an embodiment, the parts removed from the equipment 706 can be recorded on the recorded parts list, for example, through visual capture of the environment capture device 320 and autonomous analysis performed at least in part by one or more computing devices 328 and / or 330. During the reassembly or reinstallation of the parts on the equipment 706, the recorded parts list can be adjusted to remove each part when reinstalled or when the reinstallation is completed. After the reassembly of the equipment 706 is finally completed, the recorded parts list should be empty as an indication that all parts are reinstalled relative to the equipment. When one or more parts remain on the parts list of record after completing reassembly of equipment 706, diagnostics may be performed to determine where remaining parts need to be installed and / or to analyze service issues that resulted in omitting remaining parts from the reinstallation.

[0110] In an embodiment, the environment capture device 320 can be used to check for appropriate equipment failures to prepare for maintenance operations. That is, for example, the environment capture device 320 can identify one or more plugs, ports, and other components that need to be removed from the equipment 706 to perform / complete maintenance. For example, in an embodiment, the robot assembly 300 includes a lighting device 346, such as a light pointer (e.g., a laser), a light bulb, etc., to shine light into cracks, gaps, openings, and other spaces of the equipment. The reflected light or penetrating light detected by the environment capture device 320 in the opening can represent, for example, a plug opening, where the plug is removed in advance. On the contrary, in the case where reflected light or penetrating light is expected but not detected, it may be that the plug or fastener has not been removed, or debris or other materials are still retained in the opening. In response to detecting an object in an opening where no object is expected, the working range can be adjusted to remove the detected object. In some cases, this adjustment of the working range can be performed on the fly, that is, at the time of detection. In other cases, this adjustment can be queued as a later task to be completed after one or more intermediate tasks are completed. This may be particularly appropriate, for example, during a process in which the robotic arm 304 is actively performing a task that is not suitable for abrupt termination.

[0111] In an embodiment, the environmental capture device 320 can be used to check for damage to the equipment 706 by observing the thermal response of the equipment over a period of time, such as during the duration of a thermal transition that occurs when the equipment changes between a high temperature (e.g., an operating or near-operating temperature) and a lower temperature. When objects undergo temperature changes, they typically exhibit reproducible thermal responses, resulting in thermal gradients, which can be observed repeatedly with little or no change. That is, for example, a gas turbine engine that is cooled from operating temperature will exhibit similar cooling patterns along the surface and on its components each time it is cooled. When the cooling pattern is different from that expected, damage to the gas turbine engine can be identified. Specific reference is made to cooling transitions below, however, in other embodiments, the same thermal response can be observed in a temperature increase transition (i.e., a transition from a lower temperature to a high temperature). In addition, the transition can occur naturally or through forced conditions (e.g., forced cooling and / or forced heating), and the forced conditions can occur in any number of possible combinations and arrangements.

[0112] Fig.10 A method 1000 for detecting damage within equipment during an exemplary cooling transition is shown, including step 1002, observing a thermal response from the equipment during the cooling transition as the equipment transitions from a high temperature to a lower temperature. In the case of an engine, the high and lower temperatures may differ by at least 10°C, such as at least 20°C, such as at least 50°C, or more. The exact cooling gradient required to observe damage may vary depending on the material of the equipment, the type of equipment, the location along the equipment, the schematic arrangement of the equipment, etc.

[0113] In an embodiment, cooling may occur naturally, for example, as a result of ambient conditions, such as those encountered in a maintenance area. The step 1002 of observing a thermal response may occur during and / or after cooling is completed. In another embodiment, cooling may include forced cooling, in which the component is cooled locally or in its entirety, and the step 1002 of observing a thermal response is performed in response to the forced cooling operation. The specific type of cooling, i.e., natural or forced, and the location of the cooling, e.g., which parts of the component are locally or in their entirety are cooled, may be information included as part of the work envelope associated with the maintenance operation. The step 1002 of observing a thermal response may be performed autonomously or semi-autonomously by the robotic assembly 300 based at least in part on the work envelope.

[0114] The method 1000 may also include step 1004 of determining one or more cooling gradients in the equipment using the observed thermal response. This may include determining potential damage to the equipment based on the observed thermal response of the equipment. In an embodiment, step 1004 may be performed at least in part by one or more computing devices 328 and / or 330. Such determination may utilize finite element analysis, mapped thermal gradients, etc.

[0115] At step 1006, method 1000 may include comparing the determined cooling gradient to one or more predetermined cooling gradient margins. In embodiments, the predetermined cooling gradient margins may be formed based on past maintenance operations, computer simulation modeling, machine learning, fleet-wide analysis (e.g., created at least in part from information from other similar equipment), etc.

[0116] Method 1000 may also include step 1008, generating an alarm (or action) when the determined cooling gradient is different from one or more predetermined cooling gradient margins. This can be performed in response to the determined potential damage to the equipment. In an embodiment, the alarm can be an alarm detectable by a human operator. Exemplary alarm schemes include audible, visual and tactile alarm notifications. In another embodiment, the alarm can be detected by a robotic component. For example, the alarm can be an information message to the robotic component to take action based on the potential damage. As an example, the task of the robotic component can be to re-inspect an area determined to have potential damage. In another embodiment, the alarm can include multiple aspects, such as a first alarm for a human operator and a second alarm for a robotic component.

[0117] The determined cooling gradients may then be compared to one or more predetermined cooling gradient margins (i.e., expected cooling gradients), which may be stored, for example, in a data lake, such as the data lake described in more detail below. The predetermined cooling gradient margins may be determined, for example, based on historical information related to past maintenance events for the direct equipment or fleet-wide information, such as known and / or suspected defects found in other equipment in the fleet. An alarm may be generated when it is determined that one or more determined cooling gradients deviate from the predetermined cooling gradient margin by more than a threshold value (e.g., a predetermined percentage or absolute value). An alarm may indicate an unexpected condition of the equipment observed by an unexpected thermal gradient. An unexpected condition encountered during thermal gradient analysis may indicate damage to the equipment 706. The alarm may signal one or more human operators (i.e., remote or local) about the problem, or notify future aspects of the scope of work, for example, causing the robotic assembly 300 to complete further tasks around the alarm condition, such as confirmation, analysis, etc.

[0118] Fig.21 An isolated isometric side view of a combustor section 2100 of a gas turbine engine as observed from a captured image (stationary or moving) of an environmental capture device such as the aforementioned environmental capture device 320 is shown. The combustor section 2100 generally includes a body in which at least one combustion stage within the gas turbine engine can occur. As shown, the combustor section 2100 includes a damaged area 2102, such as a crack. For ease of viewing, the damaged area 2102 is shown enlarged along the surface of the combustor section 2100. It should be understood that, as shown, the damaged area 2102 may not be visible or not easily visible to be detected. For example, the damaged area 2102 may include stress points at which the accumulated stress has weakened the material of the combustor section 2100, one or more microscopic cracks have been formed, etc., which are not easily discernible by unassisted manual visual inspection. Furthermore, while the damaged region 2102 is illustrated as a single discrete region along the combustor section 2100, it should be understood that the damaged region 2102 may span one or more regions spaced apart over a larger section of the combustor section 2100. Additionally, the damaged region 2102 may be generally located along a liner of the combustor that forms an interior of the combustor section 2100.

[0119] like Fig.21As shown, the image from the environment capture device 320 can display the thermal gradient of the combustor section 2100. The thermal gradient can refer to the relative or absolute temperature of the combustor section 2100 on a local or aggregated basis. As a non-limiting example, the thermal gradient can include multiple lines 2104, each indicating a temperature. The same line can extend along the surface of the combustor section 2100, where the temperature is at a specific temperature. For example, line 2106 can indicate a first temperature, such as 1200 degrees Fahrenheit, and line 2108 can indicate a second temperature, such as 1300 degrees Fahrenheit. The positions along lines 2106 and 2108 correspond to the first temperature and the second temperature, respectively. The position between lines 2106 and 2108 is at a temperature between the first temperature and the second temperature. The accuracy of the thermal analysis, that is, the degree of thermal difference observed between adjacent lines 2104, can be as small as 0.001°F, such as 0.1°F. That is, adjacent lines 2104 can be narrowly spaced apart at relative temperatures.

[0120] A damaged region 2102 of the combustor section 2100 is depicted as being surrounded by additional lines 2110 and 2112. For example, line 2110 may indicate a third temperature, such as 1100 degrees Fahrenheit, and line 2112 may indicate a fourth temperature, such as 1000 degrees Fahrenheit. By comparing line 2104, or a similar thermal gradient analysis (e.g., finite element analysis, color gradient, etc.) to one or more predetermined cooling gradient margins expected for the combustor section 2100, the damaged region 2102 may be detected because the damaged region 2102 may affect the cooling profile of the combustor section 2100 when its temperature drops from a different elevated temperature (e.g., operating temperature) than expected. Without wishing to be bound by any particular theory, it is believed that the damaged region 2102 may exist as a localized temperature fluctuation, such as a localized cold spot and / or a localized hot spot along the surface of the equipment or component. Such localized temperature fluctuations may be caused by material thickness deviations, thereby changing the cooling characteristics of the component. Alternatively, one or more cracks or microcracks may allow air to penetrate deeper into the equipment or component at the damaged area 2102, thereby allowing the area to cool faster than the rest of the equipment or component. Such damaged areas 2102 may be detected by comparing the observed thermal gradient with the expected thermal gradient (i.e., the predetermined cooling gradient margin). As previously described, in some embodiments, cooling may be performed by forced cooling and / or natural cooling. In some embodiments, the cooling component 342 may perform a forced cooling operation. In other embodiments, the robot assembly 300 may also include additional cooling components configured to force cool the equipment or component.

[0121] After or during inspection of the equipment 706, the robotic assembly 300 can interact with the equipment 706 to perform maintenance on the equipment 706, such as in preparation for further inspection or repair. Such preparatory interactions can include, for example, the opening of latches and doors of the equipment 706 to reduce cooling time and / or provide access to internal components of the gas turbine engine. In a gas turbine engine, the scope of work may initially task the robotic assembly 300 with opening latches, holding thrust reverser doors closed, and closing fan cowling doors. In an embodiment, the robotic assembly 300 may support the opening and closing of latches and doors, respectively, if required as part of the scope of work. With the doors and latches open, the environmental capture device 320 may observe one or more internal components of the gas turbine engine. The observation may include inspecting the current condition of one or more internal components, such as thermal inspections, damage inspections, cooling behavior, etc.

[0122] In some cases, the robotic assembly 300 may perform preliminary steps on the equipment 706 while performing an inspection. That is, for example, the environment capture device 320 may inspect one piece of equipment 706 while another portion of the robotic assembly 300 opens latches and doors of another piece of equipment 706. In other cases, the preliminary steps may be completed before performing any portion of the inspection.

[0123] The inspection process may generally include inspecting the equipment 706 according to the working range. For example, certain working ranges or tasks of the working range may be related to the thickness of a protective coating on the equipment 706. The inspection may include observing and testing the current coating thickness at one or more areas along the equipment 706. This may be performed by a non-physical inspection, such as using a scanner, or by one or more physical inspections, such as using a push probe. In an embodiment, each task of the inspection may be performed separately, such as in series. That is, for example, the robotic assembly 300 may perform a second (later) inspection task only when the first (previous) inspection task is completed. In other embodiments, at least two of the tasks associated with the inspection process may be performed simultaneously (e.g., in parallel). This is particularly useful in situations where a large number of inspections on the equipment are highly intensive and / or time intensive.

[0124] The inspection may result in inspection information describing the inspected aspects of the equipment 706, such as the coating thickness tested, surface damage, temperature gradients, etc. The inspection information associated with the maintenance operation may be sent to one or more computing devices 328 and / or 330. The inspection information may be used to compare the current condition of the equipment 706 with the last known condition of the equipment 706 and other information. In the event that the inspection does not reveal unexpected inspection information, it may be appropriate to continue the maintenance, such as performing any necessary repairs. In the event that the inspection reveals unexpected inspection information, it may be more appropriate to update the preliminary (previous) scope of work accordingly. The update of the scope of work may be performed by one or more computing devices 328 and / or 330, by a human operator (e.g., by an expert described in more detail below), or both.

[0125] In an embodiment, an alarm may be generated when an updated condition of the equipment 706 determined after the inspection operation deviates from an original condition of the equipment 706 determined before the maintenance operation by more than a preset threshold. Fig.11 A flow chart of a method 1100 for generating an alarm when an updated condition deviates from an original condition by more than a preset threshold is shown. The method 1100 includes a step 1102 of capturing and recording the original condition of the equipment before performing a task associated with repairing the equipment. The method 1100 also includes a step 1104 of capturing and recording the updated condition of the equipment after performing the task. The method 1100 also includes a step 1106 of comparing the updated condition of the equipment with the original condition of the equipment. The method 1100 also includes a step 1108 of generating an alarm when the updated condition deviates from the original condition by more than a preset threshold. For example, a gas turbine engine may include a hinged door that is held closed by n fasteners in an original condition, i.e., before maintenance. After maintenance, if the number of fasteners is different from n, the updated condition has deviated from the original condition by more than a preset threshold. Similarly, in an embodiment, an alarm may be generated when the inspection information exceeds an acceptable condition.

[0126] An inspection of equipment 706 may be performed to assess whether the condition of certain components of equipment 706 is within predetermined limits and ranges. For example, certain coatings may pass inspection when no portion of the coating is less than a threshold thickness. The inspection process may include steps of capturing information associated with the coating thickness and assessing whether the coating thickness is less than a threshold thickness. In the event that the thickness is less than the threshold thickness, an alarm may be generated and / or information associated with the thickness may be saved, such as uploaded to a node having a memory device (e.g., a data lake).

[0127] As used herein, the term "data lake" may refer to any one or more storage media that are constructed to store large amounts of information. In an embodiment, all or substantially all data captured by the robotic assembly 300 (or another assembly operating on the equipment 706) is stored on the data lake. Visual images and / or videos of the inspection and / or repair process may be saved in the data lake for future analysis and inspection. The visual images and / or videos of the inspection may be further analyzed in real time for possible damage, defects, and other problems. Any detected damage, defects, or problems may be tagged or marked in the data lake with metadata for easier access and classification in the future. In addition, any data or information generated by any one or more tests, analyses, models, etc. may be stored on the data lake.

[0128] Inspection and / or repair information may be saved to the data lake and used to prepare future work scopes, tasks within the work scope, kit lists, and the like. For example, the nth maintenance operation may result in maintenance information such as recorded information, which may be stored on one or more computing devices and / or the data lake. The recorded information may relate to any inspection data captured, such as material thickness, wear level, damage, and the like. The recorded information may include representative data, such as data determined by one or more measurement steps of the inspection, such as visual data from an environmental capture device, audible data, including audio recordings created during the inspection, and the like. Similarly, the n+1th maintenance operation may result in maintenance information such as recorded information, which may also be stored on one or more computing devices and / or the data lake. Information from the n+1th maintenance operation may be synchronized with information from the nth maintenance operation to provide a maintenance history for the equipment. The maintenance history may be used to autonomously inform aspects of future work scopes for the equipment 706. For example, in the event that the detected wear rate repeatedly exceeds an expected range, the future work scope may be adjusted to take into account more frequent inspections, thicker repair coatings, and the like. Additional maintenance operations, such as the n+2nd, n+3rd, etc., maintenance operations may result in further maintenance information, such as recorded information, which may also be stored on one or more computing devices and / or data lakes to further update the maintenance history of the equipment and further inform aspects of future working scopes. In an embodiment, the saved inspection and / or repair information may be used by one or more computing devices 328 and / or 330 to train processing elements to autonomously perform or upgrade inspections and repairs. That is, for example, as described above, in the event that the detected wear rate repeatedly exceeds the expected range, one or more computing devices 328 and / or 330 may autonomously adjust the future working scope associated with at least the equipment being operated so that subsequent inspections will display the wear rate as being within the expected range.

[0129] Information from the inspection may be analyzed after capture. The analysis may be performed by a person (remote and / or local) and / or one or more machine processors (e.g., one or more computing devices 328 and / or 330). In some cases, the analysis may be performed while the inspection is still ongoing. That is, for example, a component that has been inspected may be analyzed while a component that has not been inspected is still being inspected or is in a queue for inspection. In some embodiments, at least some analysis of the captured information from the inspection may occur prior to a repair operation. In this way, a repair operation may be delayed for a duration after the information was captured during the inspection. In some cases, it may be important to ensure that all inspections are clean, i.e., free of major flagging conditions, etc., before initiating a repair to prevent the possibility of only performing some repairs and then finding that further steps in the repair cannot be completed due to a flagging condition.

[0130] According to an embodiment, in order to reduce the likelihood of flagged conditions or other issues detected later that may cause a later increase in work scope (e.g., an inspection is initially performed on-wing, but maintenance later becomes increased due to problems encountered), the inspections can be sequenced so that the inspection aspects with the highest estimate or the most likely to cause an escalation in work scope are first inspected and / or analyzed. For example, if a particular component is known to fail more quickly than other components, the inspection and / or analysis of the inspection information associated with the particular component can be performed before the inspection and / or analysis of the inspection information associated with other components. In this way, the problems known to have the highest probability of causing long equipment downtime can be inspected and / or analyzed first. This can reduce the likelihood of investing a large amount of time in thorough inspections and / or repairs that become less valuable due to later decisions, such as removing the gas turbine engine from the aircraft wing (where the inspection was performed on-wing), or opening the gas turbine engine further than expected. In the case where the gas turbine engine can remain on-wing during the inspection, the prioritized analysis of the inspection information can reduce the maintenance time and provide the maximum time to obtain the tools and parts needed in the maintenance operation. As an example, where a component is routinely outside of a threshold expected range, inspection of the component may be performed earlier in the inspection process, such as during one of the initial tasks of the inspection process.

[0131] In an embodiment, for example, after an initial inspection finds an unexpected problem, an additional inspection may be guaranteed. That is, although some scopes of work may define tasks associated with additional follow-up inspections, in other cases, follow-up inspections may not be part of the original scope of work. In these instances, instructions associated with follow-up inspections may be executed at a task level or a subtask level with a certain degree of autonomy. For example, a follow-up inspection may be based on an initial inspection and autonomously updated according to one or more problems encountered during the initial inspection. In this way, delays that occur as a result of the generation of additional scopes of work may be minimized, and downtime may be shortened. However, such autonomous follow-up inspections may not be applicable to all situations. For example, there may be a maintenance operation that requires a manual interface to determine the necessary aspects of the maintenance that warrants a follow-up inspection. In this case, a remote operator may be able to provide a local simulation environment to simulate maintenance or a portion thereof without delay. The local simulation environment may be generated, for example, by one or more CAD programs, which may analyze equipment within the environment under normal load and operating conditions, etc. A remote operator may use a CAD program to effectively simulate an environment to perform tests that may require a local operator to perform. The remote operator may be able to generate new autonomous task-based or subtask-based scopes of work based, at least in part, on simulated machine intelligence observations or machine learning based on trial and error tested in simulations of the environment and system. The remote operator may also validate the generated new autonomous task-based or subtask-based scopes of work based on presenting simulated boundary error situations to the operator. If necessary, local operators, i.e., one or more operators located in the environment, may be deployed to assist in the operations performed locally. In some cases, local and remote operators may work collaboratively to influence the scope of work or one or more tasks associated therewith.

[0132] As previously mentioned, inspection information can be stored in a data lake. Information such as flagged conditions or components can be forwarded to a human operator, such as one or more experts in that particular component or engine section. Fig.12A method 1200 is shown that utilizes a human operator, such as a remote expert, to provide input. The method 1200 may include a step 1202 of recording information associated with equipment at a first location. The method 1200 may also include a step 1204 of sending the recorded information to an operator, such as via a node. In response to the information, the expert may create a deployment of the information and change the scope of work if necessary. The expert may further request additional autonomous inspections, perform remote inspections by controlling a machine (e.g., a field machine), or request a field manual inspection where appropriate. In some cases, the expert may use a model (e.g., a computer simulation) to analyze the recorded information. Running the model to analyze the recorded information may include performing a component analysis of a component of the equipment to determine data, such as indicating the likelihood of failure of the component. An exemplary component analysis includes running a component analysis of a turbine blade having a crack to determine whether the crack will cause the turbine blade to fail and after what duration the failure may occur.

[0133] The method 1200 may also include a step 1206 of receiving operator input. The method 1200 also includes a step 1208 of performing maintenance based on the received operator input. In some embodiments, a second opinion may be called in the event that the expert diagnosis differs or conflicts with the diagnosis generated by the processor. This may allow for a repeat review where the results from the initial review are inconsistent.

[0134] One or more human operators may access the information stored in the data lake through a user interface (not shown). In an embodiment, the one or more human operators may include experts with advanced knowledge of components or subcomponents of gas turbine engines. Experts may access the information stored in the data lake in order to inspect at least a portion of the equipment, modify the scope of work associated with the equipment, provide approval for continued scope of work, troubleshoot problems encountered, modify the CAD description of the equipment, and the like. In an embodiment, information to be reviewed by experts may be marked for their attention. For example, where a portion of the maintenance requires expert assistance, that portion of the information stored in the data lake may be marked for expert review. The marked information may include metadata, etc., which may describe the criticality of the problem, the areas of expertise required for review, the review schedule, and other relevant information that may allow for targeted professional reviews.

[0135] In some cases, the expert may be located in or near the environment where the equipment being repaired is located. In other cases, the expert may be remote. For example, the expert may be located in a different country or region of the world where the inspection is performed. In this way, an expert review may be performed when there is no local on-site operator. In an embodiment, the expert may review information associated with a flagged problem while the maintenance is stopped (e.g., during an overnight maintenance).

[0136] Upon completion of (or in some embodiments, during) the inspection (and any necessary re-inspection), the maintenance operation may include repairing the equipment 706 in accordance with the scope of work (i.e., the preliminary scope of work or one or more updated scopes of work). The term "repair" may generally refer to any repair or maintenance activity on the equipment, including any activity that adds material to the equipment, removes material from the equipment, or changes the material properties of all or part of the equipment. In at least some embodiments, the term "repair", when it refers to a component of the equipment, refers to performing tasks related to the regeneration of damaged portions of the component and the maintenance or protection of damaged and undamaged portions of the component. Repairs may include changes to tubes, belts, nozzles, valves, blades, etc., resurfacing operations, coating operations, cleaning operations, lubrication operations, timing adjustments, etc. The steps of repairing the equipment 706 may be performed at least in part taking into account the information captured by the aforementioned environment capture device 320.

[0137] Reference Fig.13 , shows a close-up perspective view of the distal end 314 of the robotic arm 304 with the inspection and repair tool 1300 according to an exemplary embodiment of the present disclosure. Fig.13 The inspection and repair tool 1300 shown may be used to spray combustor components, but may also be used, for example, to spray rotor blades, stator vanes, nozzles (e.g., first stage turbine nozzles), shrouds, etc. The inspection and repair tool 1300 generally includes an elongated insert member 1302 and an implement body 1304 attached to the elongated insert member 1302.

[0138] For the illustrated embodiment, the appliance body 1304 includes an appliance for performing inspection and repair operations. Specifically, for the illustrated embodiment, the appliance body 1304 includes a base 1306 extending along a longitudinal direction L and a vision system that can be associated with the environment capture device 320. More specifically, for the illustrated embodiment, the vision system is at least partially positioned within or coupled to the base 1306. More specifically, still for the illustrated embodiment, the vision system includes a plurality of cameras 1308, and specifically includes a first camera 1308A and a second camera 1308B. The first camera 1308A and the second camera 1308B are spaced apart along the longitudinal direction L of the base 1306.

[0139] The first camera 1308A may define a first field of view 1310A, and the second camera 1308B may define a second field of view 1310B. The first field of view 1310A overlaps with the second field of view 1310B. More specifically, for the illustrated embodiment, the first field of view 1310A overlaps with the second field of view 1310B at a location 1312 that is within about 12 inches from the base 1306 of the fixture body 1304, such as within about 8 inches, such as within about 6 inches, such as within about 3 inches, such as within about 1 inch from the base 1306 of the fixture body 1304.

[0140] In this manner, the vision system can provide improved feedback for navigating and inspecting the interior of the gas turbine engine using the inspection and repair tool 1300. For example, when operating the inspection and repair tool 1300, the overlapping fields of view 1310A, 1310B can provide a desired depth perception.

[0141] Furthermore, it should be understood that in certain exemplary embodiments, the tool body 1304 may additionally or alternatively include any other suitable means for determining the distance between the tool body 1304 and the inspected component. For example, the tool body 1304 may include one or more laser depth sensors, or other suitable hardware (not shown).

[0142] Furthermore, it should be understood that the one or more cameras 1308 of the vision system may be operably coupled to one or more computing devices 328 and / or 330 (see Figure 2 ), such that the vision system can be used to inspect the interior (and exterior) of a gas turbine engine. For example, the vision system can be configured to transmit an image of a thermal barrier coating, an environmental barrier coating, etc. in the interior to one or more computing devices 328 and / or 330 along with location information indicating the location of the thermal barrier coating in the interior. The one or more computing devices 328 and / or 330 can be configured to then compare the image with one or more baseline images to determine if damage to the thermal barrier coating, environmental barrier coating, etc. is present. For example, a sample image of a thermal barrier coating, environmental barrier coating, etc. can include a damaged portion known as a spalling, where the thermal barrier coating, environmental barrier coating, etc. has worn away. The one or more computing devices 328 and / or 330 can receive the image, compare it with the one or more baseline images, and use, for example, a pixel-by-pixel analysis, and determine the damage that needs to be repaired on the thermal barrier coating, environmental barrier coating, etc. As described below, the analysis performed by the one or more computing devices 328 and / or 330 can determine the extent (e.g., depth, width, area, shape, etc.) of the damaged portion to facilitate customized repair of such damaged portion.

[0143] However, it should be appreciated that in other exemplary embodiments, one or more computing devices 328 and / or 330 may utilize any other suitable analysis techniques to determine whether there is any damage to the thermal barrier coating, environmental barrier coating, etc., the extent of such damage, etc. For example, in other exemplary embodiments, one or more computing devices 328 and / or 330 may utilize a trained machine learning tool to identify the presence and / or extent of damage to the thermal barrier coating, environmental barrier coating, etc., or other components within the engine interior.

[0144] The device body 1304 may also include a spray head 1314. The spray head 1314 is movably coupled to the base 1306 of the device body 1304 and is movable between a retracted position and an extended position. Specifically, for the illustrated embodiment, the spray head 1314 is rotatably coupled to the base 1306 about a pin connection 1316. For the illustrated embodiment, the spray head 1314 rotates at least about 30 degrees, such as at least about 45 degrees, such as at least about 90 degrees and less than 360 degrees, between the retracted position and the extended position. Notably, for the illustrated embodiment, the spray head 1314 rotates along reference arrow 1318 in a plane parallel to the longitudinal direction L. In this manner, the spray head 1314 defines a first angle with the longitudinal direction L when in the extended position (e.g., about 90 degrees for the illustrated embodiment), and defines a second angle different from the first angle with the longitudinal direction L when in the retracted position (e.g., about 0 degrees for the illustrated embodiment).

[0145] In this manner, when the spray head 1314 is in the retracted position, the tool body 1304 defines a smaller cross-sectional profile to facilitate insertion of the tool body 1304 into the interior of the gas turbine engine (e.g., through an access port). Subsequently, once the tool body 1304 is inside, the spray head 1314 can be moved from the retracted position to the extended position to allow operation of the spray head 1314, as described below. The spray head 1314 can be spring loaded.

[0146] It is noted that for the illustrated embodiment, the spray head 1314 is fluidly connected to a fluid source via one or more fluid channels 1320 extending along the length of the elongated insert member 1302. The one or more fluid channels 1320 may be separate fluid conduits extending through the elongated insert member 1302, or may be integrally formed within the elongated insert member 1302. The one or more fluid channels 1320 may provide a stream of a repair material 1322 to the spray head 1314 to spray on the damaged portion of the thermal barrier coating, thereby repairing the damaged portion of the thermal barrier coating. The repair material 1322 may be a slurry formed of a powder and a carrier, which may form a patch for the thermal barrier coating. For example, the powder may be a machine-curable ceramic powder mixture that is configured to bond to the damaged portion of the thermal barrier coating.

[0147] Despite Fig.13 1300 schematically shows a single fluid channel 1320, but in other exemplary embodiments, the inspection and repair tool 1300 may include multiple channels. For example, the inspection and repair tool 1300 may include a channel 1322 for repair material, a channel for cleaning and conditioning fluids, a channel for curing fluids, etc. Each of these channels may be fixedly or selectively in fluid communication with the spray head 1314.

[0148] Still reference Fig.13 It can also be appreciated that the spray head 1314 can define an outlet 1324 for spraying the repair material 1322 onto the damaged portion of the thermal barrier coating. For the illustrated embodiment, the outlet 1324 is located within the field of view 1310 of the vision system. More specifically, for the illustrated embodiment, the outlet 1324 is located within the first field of view 1310A and / or the second field of view 1310B of the first camera 1308A and the second camera 1308B of the vision system. In this manner, the one or more computing devices 328 and / or 330 can confirm the positioning of the spray head 1314 and the coverage of the sprayed repair material 1322 (or other material / fluid).

[0149] In addition, it should also be understood that the exemplary device body 1304 is capable of moving to assist in the spraying operation. More specifically, for the illustrated embodiment, the device body 1304 includes a fixed portion 1326 and a rotating portion 1328. The rotating portion 1328 includes a base 1306 and a spray head 1314, and is rotatably coupled to the fixed portion 1326 so that it can rotate along a circumferential direction C around the longitudinal direction L. The fixed portion 1326 includes one or more motors positioned therein for selectively moving the rotating portion 1328 around the circumferential direction C. Therefore, it should be understood that in certain exemplary embodiments, during the spraying operation, the device body 1304 can move the spray head 1314 along the circumferential direction C to provide a more uniform coverage of the sprayed repair material 1322 (or other material / fluid).

[0150] It should be understood that the above exemplary inspection and repair tool 1300 is provided by way of example only. In other exemplary embodiments, the inspection and repair tool 1300 may have any other suitable structure. For example, in other exemplary embodiments, the spray head 1314 may be movably coupled to the base 1306 in any other suitable manner (e.g., rotating and sliding, etc.), the spray head 1314 may have any other configuration of outlets (e.g., linear arrays or other patterned outlets), the device body 1304 may have any other suitable visual system or inspection system, the device body 1304 may be configured to rotate in any other suitable manner, etc.

[0151] Fig.14A close-up schematic diagram of the distal end 314 of the robotic arm 304 is shown, the robotic arm 304 having a different Fig.13 The inspection and repair tool 1400 of the inspection and repair tool 1300 is described. It should be understood that for the exemplary embodiment shown, the operation performed by the robotic system 300 on the equipment 706 is a physical operation (e.g., physically modifying the equipment). More specifically, for the illustrated embodiment, the operation is a material removal operation, and more specifically, still a drilling operation. It is worth noting that, as used herein, the term "drilling operation" generally refers to any operation for forming a hole in or through the equipment or its components, whether the cross-section of the hole is circular or defines some other shape. However, in other embodiments, the operation can be any other suitable physical operation (e.g., a material modification operation, or a material addition operation (e.g., a welding operation)), or other operations. For example, the operation can additionally or alternatively include one or more cutting operations, brazing operations, coating or slurry repair operations, etc. Specifically, for example, the operation can be a coating repair process (e.g., a thermal barrier coating repair process), whereby the first robotic arm is operable to remove at least a portion of the existing coating, and the second robotic arm is operable to apply a new coating. Similarly, the operation may be a slurry repair operation for a ceramic matrix composite (CMC) component (e.g., a CMC bushing, a CMC cover, etc.). With this operation, the first robotic arm may be operable to apply the slurry, while the second robotic arm may be operable to cure the slurry. Additionally, one or both of the first robotic arm and the second robotic arm (or additional robotic arms) may be operable to contour and / or level the slurry. In this manner, it will be understood that, as used herein, the term "facilitate" may refer to performing functions simultaneously (e.g., the first robotic arm and the second robotic arm work together simultaneously to perform the operation), or alternatively may refer to performing functions sequentially. By way of another exemplary embodiment, the operation may be a cleaning operation (e.g., sandblasting, pressure washing, steam washing), etc.

[0152] like Fig.14 As shown, for the exemplary embodiment shown, the inspection and repair tool 1400 includes a mechanical drill having a drill bit 1402. The first utility member 1404 can be configured to rotate the drill (and the drill bit 1402) to drill a hole H in or through the equipment 706, that is, to drill a hole H from the first side 1406 of the equipment 706 toward or to the second side 1408 of the equipment 706. The hole H can be, for example, a cooling hole, or can be provided for any other purpose. In addition, it can be understood that the hole H can be a new hole drilled by the mechanical drill of the first utility member 1404, or it can be an existing hole that is, for example, blocked, needs to be widened, etc.

[0153] Also for the illustrated embodiment, the second utility member 1410 includes at least one of a container or a suction member. More specifically, for Fig.14 In the embodiment of the present invention, the second utility member 1410 includes a container 1412 for positioning above the hole H on the second side 1408 of the equipment 706 to capture or otherwise contain debris and / or other materials generated by the operation of the mechanical drill of the first utility member 1404 to drill the hole H in the equipment 706. More specifically, for Fig.14 In the embodiment of the present invention, the container 1412 is positioned to completely surround the hole H on the second side 1408 of the equipment 706 / on the hole H, contacting the second side 1408 of the equipment 706. However, in other embodiments, the container 1412 may be alternatively positioned elsewhere to capture debris from the drilling operation. For example, in other embodiments, the container 1412 may be located below the mechanical drill of the first utility member 1404 on the first side 1406 of the equipment 706 to capture debris from the mechanical drill. Similarly, the container 1412 may be located below the opening on the second side 1408 of the equipment 706 of the hole H drilled by the mechanical drill to capture debris when the mechanical drill passes through the second side 1408 of the equipment 706, or otherwise complete the drilling operation of the hole H.

[0154] Fig.15 An exemplary path 1500 of the robotic arm 304 through the environment 1502 is shown for positioning the utility head of the robotic arm 304 at a desired task location and providing orientation. The robotic assembly 300 can be configured in substantially the same manner as the exemplary robotic assembly 300 described above, and the environment 1502 can be configured in substantially the same manner as one or more of the exemplary gas turbine engine environments described above.

[0155] More specifically, it should be understood that Fig.15In the exemplary embodiment shown, the position of the base 1504, the root end of the robot arm 304, or both relative to the environment 1502 (relative to the coordinate system of the environment 1502, which for the illustrated embodiment is the axial direction A, radial direction R, and circumferential direction C coordinate system). The position of the base 1504 or the root end can be manually input, or alternatively, can be determined by one or more computing devices 328 and / or 330 using, for example, one or more sensors of the robot assembly 300. It should be understood that in addition to the position of the base 1504 or the root end, the one or more computing devices 328 and / or 330 can also know the orientation of the base 1504 or the root end. In addition, the base 1504 and / or the root end of the robot arm 304 can be mounted on another robot or joint that allows the position and / or orientation of the base 1504 and / or the root end of the robot arm 304 to be modified. With this configuration, the position and / or orientation of the base 1504 or the root end can be transmitted to one or more computing devices 328 and / or 330.

[0156] In addition, the task position and orientation 1506 of the utility member of the robotic arm 304 within the environment 1502 is known. The task position and orientation 1506 can be input into one or more computing devices 328 and / or 330. For example, the one or more computing devices 328 and / or 330 can notice defects through inspection of the environment 1502 and automatically determine the task position and orientation of the utility head 1508 of the robotic assembly 300. In addition, the three-dimensional constraints of the environment 1502 are known. The three-dimensional constraints of the environment 1502 can be determined by one or more computing devices 328 and / or 330. For example, one or more computing devices 328 and / or 330 can use a computer-aided design ("CAD") file, and / or can determine the three-dimensional constraints by inspecting or scanning the environment 1502. It is worth noting that for the illustrated embodiment, the environment 1502 can be similar to, for example, the environment 1502 described above with reference to FIG. Figure 1 LP compressor 22 is depicted. Thus, the three-dimensional constraints of environment 1502 may be determined using, for example, one or more CAD files of LP compressor 22 (and turbofan engine 10), a three-dimensional map of LP compressor 22, or any other suitable means. Of course, in other exemplary embodiments, environment 1502 may be any other suitable environment, such as any other suitable section of a gas turbine engine, or other engine or system.

[0157] Additionally, a set of operability limits for the robotic arm 304 is known (based on input to one or more computing devices 328 and / or 330 , or, for example, by sensing the operability of the robotic arm 304 ).

[0158] Based on the above factors, the robotic assembly 300, and more specifically, one or more computing devices 328 and / or 330 of the robotic assembly 300, is configured to determine a path 1500 for the robotic arm 304 through the environment 1502 for positioning the utility implement 1508 of the robotic arm 304 at a determined task location and orientation 1506 within the environment 1502. For example, the path 1500 may be determined by starting with a known task location and orientation 1506 and then constraining the path 1500 based on the three-dimensional constraints of the environment 1502, a set of maneuverability limits of the robotic arm 304, and the location of the base 1504, the root end 312, or both relative to the environment 1502.

[0159] The path 1500 determined for the robotic arm 304 may include a plurality of sequential coordinates (e.g., X1, Y1, Z1; X2, Y2, Z2; X3, Y3, Z3; etc., or more specifically A1, R1, C1; A2, R2, C2; A3, R3, C3; etc.) of the robotic arm to follow within the three-dimensional environment 1502. Additionally, it should be appreciated that the path 1500 may also include orientation information for the robotic arm 304 at these locations (and / or between these locations) within the three-dimensional environment 1502. The orientation information may include angular information for the links of the robotic arm 304 at each coordinate relative to each axis of the coordinate system of the environment 1502 (e.g., relative to the axial direction A, the radial direction R, and the circumferential direction C), such that the path 1500 includes information for up to six degrees of movement along some or all of the path 1500. For example, if a tool or utility member 1508 at the distal end of the robotic arm 304 has a greater extent in one dimension than another dimension (e.g., taller than it is wide), then in addition to the proper position, it may be necessary to ensure that the robotic arm 304 is properly oriented to move through the three-dimensional environment 1502. Thus, it should be appreciated that in at least some exemplary aspects of the present disclosure, determining the path 1500 may include further considering certain dimensions of the utility member 1508 and / or the orientation of the base 1504, the root end 312, or both (in addition to their position) to determine the path 1500.

[0160] In certain maintenance operations, it may be desirable to mark an index position from which future measurements can be derived. For example, during an inspection, it may be desirable to mark an index turbine, either generally or at a specific location, such as the initial turbine, from which a relative position measurement or count may be made relative to the index mark. This may reduce errors associated with, for example, incorrect rotor blade counts, while allowing comparisons to a reference point.

[0161] During a maintenance operation, it may be further useful to identify the current step in the scope of work or the current position along the equipment 706 where maintenance is currently being performed. For example, when servicing a gas turbine engine, it may be appropriate to inspect an airfoil. Since a gas turbine engine typically includes multiple stages, each stage having multiple airfoils, it may be useful to identify the current stage of the airfoil being serviced, or the exact airfoil being serviced, or even the exact position along the airfoil being serviced. In this way, problems associated with various components of the gas turbine engine may be more easily identified. In addition, being able to identify the current operating position may enable interruption of maintenance operations without the risk of omitting steps from the maintenance operation. That is, with tracking of the current step or component, maintenance operations may be stopped for a period of time (e.g., one second, one day, one month, etc.) and resumed at a later time without losing track of the current task and with some knowledge of the last component being operated at the time of the interruption. Thus, repair operations may be performed as if they had occurred uninterruptedly.

[0162] Identifying the current step in the work scope or the current location of the maintenance may include marking the location of the current operation on the equipment. For example, marking the current airfoil of the gas turbine engine being inspected. Fig.16 , the method 1600 for repairing equipment may include an initial step 1602 of performing at least one of an inspection and a repair associated with a working scope of the equipment, wherein the working scope includes a queue of tasks to be performed. At a certain point, the method 1600 may include a step 1604 of terminating the execution of the initial step 1602 before completing the queue. That is, for example, the maintenance operation may be suspended. In this case, the method 1600 may include a step 1606 of marking a stop point, which identifies the end position relative to the queue and / or the equipment 706. Marking the location of the current operation may include, for example, applying a heat-resistant marking technology that can withstand high temperatures exceeding at least 300°F, such as at least 350°F, such as at least 400°F, such as at least 500°F, such as at least 750°F, such as at least 2000°F or higher. The marking technology may also include chemical marking, non-heat-resistant physical marking, etc. In some embodiments, the marking technology may be configured to leave a permanent mark on the equipment. In other embodiments, the marking technology may be configured to leave a temporary mark on the equipment. For example, the marking may fade or otherwise disappear over time or when washed or treated with a particular marking removal material. The current step or location along the equipment 706 may be marked 1606 using a marking technique, type or other identifying factor similar, the same or different than that used for the above-described indexed location.

[0163] In an embodiment, microfeatures of the equipment 706 may be marked. For example, gas turbine engines typically include microscopic surface textures or defects that are formed due to manufacturing, use, maintenance, or other circumstances. The presence of such microscopic surface textures or defects may allow for marking of a current maintenance position associated therewith. For example, in one embodiment, marking the current operating position may include the steps of identifying one or more microfeatures of the gas turbine engine at or near the current position, and associating the current operating position with the one or more microfeatures. For example, the microfeatures may correspond to surface textures, surface marks, surface defects (e.g., nicks, scratches, etc.), surface features, surface colors, surface temperatures, etc., or any combination thereof. In order to record the current operating position, these microfeatures may be identified (e.g., mapped) relative to the current position.

[0164] In embodiments where marking is performed with non-physical markings (e.g., identification and mapping of micro-features of equipment 706), the marked position (i.e., the marked position relative to the mapped position of the micro-feature) may be appropriately stored in a memory device associated with one or more computing devices 328 and / or 330, a data lake, or another computing device. The mapped position may include, for example, a coordinate system relative to the micro-feature. Where multiple micro-features are used in combination, the coordinate system may triangulate the mapped position based on information associated with the micro-feature. Accessing the stored data associated with the marked position may allow the robotic assembly 300 (or another component, assembly 200, or a person) to easily orient to the current position, e.g., the precise three-dimensional coordinates within the working range corresponding to the current position, and quickly resume maintenance operations.

[0165] The method 1600 may also include a step 1608, which includes locating a termination position after a period of time by identifying the marked stop point performed at step 1606. In response to locating the termination position at step 1608, the method 1600 may further include a step 1610, starting at least one of a resume inspection and a repair at the termination position relative to the queue or equipment. For example, in the case where an operation related to the inspection of the surface of the airfoil was previously performed, resuming the inspection at step 1610 after a period of time may include bypassing the area of ​​the airfoil that has been inspected and immediately resuming the inspection at the termination position of the previous inspection process. In this way, the inspection can be performed more quickly without repeated, time-consuming operations.

[0166] In some cases, one or more repair operations may be performed with the help of a local human operator. In an embodiment, when performing a repair operation, at least one local human operator may wear a Fig.17The augmented reality device 1700 shown. As an example, the augmented reality device 1700 may include a pair of augmented reality glasses 1702, which include a camera 1704 and one or more displays 1706, and the display 1706 is configured to generate a current field of view display. For example, the camera 1704 may include a 3D camera capable of capturing three-dimensional images, a standard two-dimensional camera, a video camera, an infrared imager, etc. The camera 1704 may also include other types of sensors, such as an inertial navigation system (INS), to provide accurate position feedback to one or more computing devices 328 and / or 330. Compared with visual detection and processing protocols, INS can be a less intensive use of resources. The augmented reality device 1700 may also include other types of augmented reality devices, such as personal computing devices, including smart phones, laptops, and tablets. The augmented reality device 1700 can be used to obtain real-time images as seen by a local human operator from the camera 1704, and use the display 1706 to display the enhanced image to the operator.

[0167] Augmented reality device 1700 may include a computing device including, for example, a processor and a memory configured to store software executable by the processor. The computing device may be configured to store, access, and display instruction images to an operator on display 1706.

[0168] During the repair operation, the current field of view display 1706 on the augmented reality device 1700 can be used to display a rendering of the component, instructions about the operation to be performed, directional arrows or contextual information associated with the component or equipment, etc. The augmented reality device 1700 can also be configured to generate audible instructions. In some cases, the augmented reality device 1700 can communicate with the robot assembly 300. In other cases, the augmented reality device 1700 can communicate with one or more computing devices 328 and / or 330. In yet another case, the augmented reality device 1700 can communicate with the data lake. In a further case, the augmented reality device 1700 can communicate with any combination of the robot assembly 300, one or more computing devices 328 and / or 330, and the data lake. Using the augmented reality device 1700, a local human operator can initiate a repair operation on the equipment. In addition, in some embodiments, the augmented reality device 1700 can promote on-site safety, for example, by displaying certain warnings associated with hazardous environments (e.g., hot surfaces, hot fluids, slippery floors, the presence of electric charges, etc.) to the operator. These warnings may be generated, for example, by one or more computing devices 328 and / or 330 based on changes in environmental conditions, predetermined hazardous conditions, or a combination thereof. The augmented reality device 1700 may also provide conventional safety functions or be combined with safety functions by providing physical protection for the eyes of the human operator.

[0169] Fig.18 is a flow chart of a method 1800 for repairing equipment, such as an engine, using an augmented reality device. The method 1800 includes a step 1802 of receiving information corresponding to one or more components of the engine. The information may be received by one or more computing devices 328 and / or 330. The method 1800 may also include a step 1804 of determining, by the one or more computing devices, a location of the one or more components of the equipment relative to a location of the augmented reality device. The method 1800 may also include a step 1806 of presenting at least a portion of the information corresponding to the one or more components of the equipment in a current field of view display of the augmented reality device. The portion of the information may include at least one of the following: a rendering of the one or more components, instructions regarding an operation to be performed on the one or more components, a directional arrow or contextual information associated with the one or more components, or any combination thereof. An operator may utilize a portion of the information presented in the current field of view as part of a repair operation. For example, where inspection of a particular component of the equipment requires human interaction, the augmented reality device may be configured to direct the operator to that location and / or present any relevant or necessary information, such as a local temperature of the equipment or component, tools required for inspection, access paths to the component, and the like. In some cases, the augmented reality device may be configured to automatically detect actions taken by the operator. In other cases, the operator may manually notify the augmented reality device of the completion or occurrence of one or more actions taken. For example, the operator may audibly describe the action being performed, or tactilely input information associated with the action.

[0170] In an embodiment, the robot assembly 300 may be configured to provide information to a human operator through one or more user interfaces. In an embodiment, the user interface may include a screen. In another embodiment, the user interface may include a projected image. In some cases, the projected image may be projected onto a surface of the repair location, such as a floor near the equipment. In other cases, the projected image may be projected onto the equipment. The projected image may be projected onto, for example, a flat surface of the equipment, a smooth surface of the equipment, or at a location along the equipment where the manual maintenance operation is to be performed. The projected image may include instructions, signs, or other information that may help the human operator perform the maintenance operation. The projected image may be static, dynamic, or both. The projected image may move relative to the equipment to indicate the next task or the components associated therewith. In an embodiment, the projected image may be seen without the aid of the augmented reality device 1700 described above. In another embodiment, the projected image may require the use of equipment, such as the augmented reality device 1700, glasses, etc. In some cases, the human operator may utilize the augmented reality device 1700 and the projected image to complete the manual maintenance operation. In other cases, the human operator may use the augmented reality device 1700 alone or rely on the projected image alone.

[0171] Upon completion of the repair operation, the equipment 706 may be re-inspected by the robotic assembly 300. In embodiments, the re-inspection process may be similar to the initial and / or additional inspection processes described above. For example, the re-inspection process may be performed using the autonomous robotic assembly 300 to verify successful and completed repair process execution. The re-inspection may verify the condition of the equipment 706, that the parts and / or tools 404 were properly used and / or returned to the robotic assembly 300, that repair objectives were met, etc.

[0172] The data collected during the re-inspection can be uploaded to the aforementioned data lake for analysis. The results can be used to predict component life based on the current condition of the repaired equipment and re-anchor engine-specific condition data to predict future engine life and inspection and maintenance requirements.

[0173] For example, a pre-maintenance (initial) condition profile CP1 of an engine that can be used to develop a preliminary working scope during an initial maintenance operation can be updated or supplemented with an updated condition profile CP2, which has a re-anchored condition and analysis of the engine determined as a result of the initial maintenance. Continuous maintenance operations can be based at least in part on CP2, and further optionally on CP1. Further maintenance operations can also be performed similarly, including steps of utilizing the previous condition profile of the engine and updating or supplementing the condition profile according to the maintenance performed at that time. For example, a further updated condition profile CP3 can be formed in response to further maintenance operations, and so on. Condition profiles, such as CP1, CP2, CP3, CP4, etc., can be locally saved by one or more computing devices 328 and / or 330, such as saved at the robot assembly 300, saved in a data lake, etc. At this point, data from the re-inspection can re-anchor the engine condition to inform future working scopes associated with the equipment. In addition, in an embodiment, the data can be used to set a time interval until a specific task performed during the maintenance operation requires future action. For example, when a maintenance operation reveals a crack surface on equipment, data associated with the crack can be used to predict the expected remaining operating life cycle of the cracked portion of the equipment and inform the date of a future scope of work to repair or replace the cracked portion, for example, based on the expected remaining operating life cycle. While certain cracks may be predicted to require replacement after 25 additional operating cycles, other cracks with different characteristics and severity levels may not require replacement until another 100 additional operating cycles. Thus, the analysis associated with the crack can be used to determine not only the scope of the work to be performed, but also the timing of that work. As previously discussed, the logistics associated with the supporting operations to repair the crack can also be determined so that the parts and tools associated with the scope of the crack repair work arrive at the maintenance location at the correct time.

[0174] The data can also be incorporated into the fleet-wide model, allowing fleet-wide coverage agreements to be adjusted. For example, if multiple engines are showing more wear than expected over time, the fleet-wide coverage agreement can be updated, such as by adding additional inspection steps, to adjust maintenance actions to account for the accelerated wear rate.

[0175] Fig.19A flow chart of an exemplary method 1900 for servicing an engine using a condition profile re-anchored according to a previous maintenance operation is shown. The method 1900 may include a step 1902 of receiving information including an initial condition profile CP1 of the engine. In some cases, the information may be received by one or more computing devices (e.g., one or more computing devices 328 and / or 330 described previously). The method 1900 also includes a step 1904 of servicing the engine using the initial condition profile CP1. That is, for example, information from CP1 may be used to determine an operating range of equipment, set thresholds for inspections, etc. After the maintenance is completed, the method 1900 may include a step 1906 of determining an updated condition profile CP2 of the engine. The step 1906 of determining CP2 may be performed according to the maintenance performed using CP1 in step 1904. For example, if the maintenance according to CP1 results in a change in the thickness of the thermal coating, the updated thickness may be stored in the updated condition profile CP2. Likewise, the performance, condition, etc. of the engine may be considered when updating the condition profile. Method 1900 may further include step 1908, storing the updated condition profile CP2 for subsequent maintenance operations, such as a second maintenance based on CP2 (and optionally CP1), a third maintenance based on CP3 (determined based on the results of the maintenance of CP2), and so on.

[0176] Fig.23 A graph depicting an initial condition profile CP1 associated with a prediction of a certain engine parameter is shown. The initial condition profile CP1 parameter may be, for example, a maximum useful life measured in time or cycles until the coating is predicted to reach failure. After an initial inspection IN1 reveals that the coating is better than the predicted value provided by the initial condition profile CP1 at a time or cycle associated with IN1, a new updated condition profile CP2 may be generated that effectively updates the expected maximum useful life as measured in time or cycles until the coating is predicted to reach failure. After an additional inspection IN2 again reveals that the coating is better than the predicted value provided by the updated condition profile CP2 at a time or cycle associated with IN2, a further updated condition profile CP3 may be generated that effectively updates the expected maximum useful life as measured in time or cycles until the coating is predicted to reach failure. The process may be repeated (e.g., IN3, CP4, etc.) until the expected failure date is determined to be outside an acceptable safety range or other determinable range, at which time repairs may be performed or scheduled for a future date.

[0177] In an embodiment, the recheck process may look for foreign object debris (FOD) left in the engine. FOD may include, for example, material that did not originate from the engine. In another embodiment, the recheck process may look for local object debris (DOD) left in the engine. DOD may include, for example, material from the engine that has moved and is found in a location where they should not be found. Examples include loose fasteners, debris material such as coatings, etc.

[0178] The re-inspection process may include inspecting, by the robotic assembly 300, repair equipment left near, on, or in the equipment. The repair equipment may include, for example, tools, unused parts, packaging and containers (e.g., associated with one or more parts used in the repair), repair accessories, etc. In some cases, the re-inspection may inspect pieces of repair equipment, such as disconnected parts of the repair equipment that may be within the equipment. Inspecting the repair equipment left in the engine may include an initial step of, for example, capturing an initial view of the repair equipment before the repair, and a second step of, for example, capturing a rear view of the repair equipment after the repair and comparing the initial view to the rear view. The comparison may be performed by one or more computing devices 328 and / or 330. When an unexpected event is detected, for example, the initial view and the rear view are different, an alert may be generated to inspect the equipment to find the repair equipment. Inspecting the equipment may include scanning or viewing the equipment at one or more locations to search for missing parts of the repair equipment.

[0179] As previously mentioned, in some cases, maintenance operations can be performed autonomously. An exemplary process for autonomous maintenance operations includes the steps of performing an initial maintenance operation, which is monitored by one or more computing devices, such as an environment capture device 320, and determining whether the continuous operation is related to the initial maintenance operation. For example, performing the initial maintenance operation may include servicing the equipment within a provided working range, monitoring the maintenance operation, recording the maintenance operation, and creating an autonomous maintenance protocol in response to the monitored maintenance operation. When it is determined that the continuous maintenance operation is related to the working range of the initial maintenance operation, that is, if the continuous maintenance operation is similar or identical to the initial maintenance operation, the continuous maintenance operation can be autonomously performed according to the autonomous maintenance protocol. If the determined continuous maintenance operation is not related to the working range of the initial operation, the method may further include receiving an updated working range, servicing the equipment within the provided updated working range, monitoring the updated maintenance operation, recording the updated maintenance operation, and creating an updated autonomous maintenance protocol associated with the updated working range. At this point, future maintenance operations can then check whether they are related to the initial maintenance operation or the updated maintenance operation, and select an autonomous maintenance protocol or formulate a further updated autonomous maintenance protocol accordingly.

[0180] Fig. 20 An example implementation 2000 of a machine learning model according to an exemplary embodiment of the present disclosure is depicted. The machine learning model may utilize a machine learning algorithm. As shown, one or more computing devices may provide input data 2002 to a model 2004. The input data 2002 may include one or more inputs associated with a maintenance operation. In some embodiments, the input data 2002 may include inspection results from an inspection operation. In other embodiments, the input data 2002 may include repair results from a repair operation. In further embodiments, the input data 2002 may include information associated with an inspection operation and a repair operation. The model 2004 may weight the various inputs 2002 to determine one or more characteristics of the equipment being maintained, the maintenance operation itself, the scope of work (past, present, or future), fleet-wide data, and the like. One or more computing devices may receive data 2006 as an output of the model 2004, the data 2006 indicating one or more characteristics of the equipment being maintained, the maintenance operation itself, the scope of work (past, present, or future), fleet-wide data, and the like.

[0181] In some embodiments, the outputs (and / or associated characteristics) of model 2004 for a given object (e.g., at a first time step) may be provided as inputs to model 2004 for another object (e.g., at a subsequent time step). In this manner, fleet-wide data may be processed and utilized to create fleet-wide standards. In other words, in some embodiments, the process may be iterative such that over time, fleet-wide data may be recalculated as it becomes clearer which maintenance operations are required for the fleet. For example, model 2004 may include one or more autoregressive models. In some embodiments, model 2004 may include one or more machine learning recurrent neural networks. For example, the recurrent neural network may include a long short-term memory recurrent neural network, a gated recurrent unit network, or other form of recurrent neural network.

[0182] In some embodiments, a machine learning computing system may train a machine learning model using a model trainer. The model trainer may be implemented using hardware, firmware, and / or software that controls one or more processors. The model trainer may use one or more training or learning algorithms to train a machine learning model. An example training technique is back propagation of errors. In some embodiments, the model trainer may use a set of labeled training data to perform supervised training techniques. In other embodiments, the model trainer may use a set of unlabeled training data to perform unsupervised training techniques. The model trainer may perform a variety of generalization techniques to improve the generalization capabilities of the model being trained. Generalization techniques include weight decay, descent, or other techniques.

[0183] In particular, the model trainer can train a machine learning model based on a set of training data. The training data can include, for example, multiple sets of reference data obtained from previously observed maintenance operations. In some embodiments, the reference data used to create the training data can be taken from the same equipment or the same type of equipment. In this way, the model can be trained in a manner customized for the equipment to determine equipment information (e.g., working range).

[0184] In some embodiments, to train the model, the training computing system may input a first portion of a set of reference data into the model to be trained. In response to receiving such a first portion, the model outputs one or more output variables that predict the remainder of the set of reference data (e.g., a second portion of the data). After such prediction, the training computing system may apply or otherwise determine a loss function that compares one or more second portions of the data generated by the model to the remainder of the reference data (e.g., the second portion of the data) that the model is attempting to predict. The training computing system may then back-propagate the loss function through the model to train the model (e.g., by modifying one or more weights associated with the model).

[0185] The technology discussed here relates to computing devices, databases, software applications and other computer-based systems, as well as the actions taken and the information sent to and from such systems. Those of ordinary skill in the art will recognize that the inherent flexibility of computer-based systems allows for various possible configurations, combinations and divisions of tasks and functions between and among components. For example, the computer-implemented processes discussed here can be implemented using a single computing device or multiple computing devices working in combination. Databases and applications can be implemented on a single system or distributed on multiple systems. Distributed components can operate sequentially or in parallel. In addition, the computing tasks discussed here performed at a computing device away from equipment and / or robotic components can be performed instead at equipment and / or robotic components, and vice versa. Such a configuration can be implemented without departing from the scope of the present disclosure.

[0186] The systems and methods described herein are particularly advantageous for maintenance equipment where a preliminary work scope informs autonomous maintenance operations, which can be autonomously, or semi-autonomously, modified or otherwise adjusted in response to autonomously observed information and data and problems encountered during maintenance operations. The embodiments described herein can facilitate faster maintenance operations. In addition, the embodiments described herein can allow for improved maintenance operations over time due to updated overall fleet models formed over the course of multiple consecutive maintenance operations analyzed by one or more computing devices and / or human operators.

[0187] In some cases, the use of systems and methods such as those described herein can reduce the wasted life of parts and components of equipment (such as gas turbine engines). For example, manual inspections may result in premature repair operations due to the higher safety factors associated with part failures. That is, without the use of robotic assemblies and / or autonomous processes such as those described herein for maintenance operations and notification of future maintenance operations, certain aspects of the equipment can be replaced, repaired, or otherwise operated before such operations are required. As a non-limiting example, certain coatings may be functionally satisfactory when inspected by the robotic assemblies described herein but not by human inspection. Therefore, the frequency of replacement or repair of the coating may be higher during manual maintenance, which results in longer engine downtime, increased costs, and reduced efficiency.

[0188] It should be understood that although for the exemplary embodiments and aspects described herein, the "environment" through which the exemplary robotic arm extends is described as a gas turbine engine, such as a turbine of a gas turbine engine, in other exemplary embodiments and aspects, the exemplary robotic arm described herein can extend through other suitable environments. For example, using the systems and methods described herein, the robotic arm can extend through hazardous environments, such as can be found in the nuclear industry, the oil drilling industry, etc. Other environments are also contemplated.

[0189] This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements that do not differ substantially from the literal language of the claims.

[0190] Further aspects of the invention are provided by the subject matter of the following clauses:

[0191] A method for equipping a robotic assembly for repairing equipment, the method comprising: determining a current working range associated with the equipment; determining one or more parts and tools associated with the current working range; equipping the robotic assembly with at least some of the determined parts and tools; the robotic assembly autonomously navigating within a position corresponding to the equipment; and the robotic assembly autonomously performing at least one of an inspection and a repair of the equipment using the equipped parts and tools.

[0192] A computer-implemented method for preparing a robotic assembly for repairing equipment, the method comprising: determining, by one or more computing devices, a current working range associated with the equipment; determining, by the one or more computing devices, parts and tools associated with the current working range; enabling, by the one or more computing devices, at least some of the parts and tools to be equipped on the robotic assembly; determining, by the one or more computing devices, a path for navigating the robotic assembly within a location corresponding to the equipment; and enabling, by the one or more computing devices, the robotic assembly to autonomously perform at least one of an inspection and a repair of the equipment using the equipped parts and tools.

[0193] A method for maintaining equipment, the method comprising: determining a work scope associated with the equipment, the work scope comprising a plurality of tasks associated with at least one of inspection and repair of the equipment; determining risk factors for at least two tasks of the work scope; and creating a queue of tasks based on the determined risk factors, wherein tasks with higher risk factors are prioritized in the queue.

[0194] A method for servicing equipment, the method comprising: performing at least one of an inspection and a repair associated with a working range of the equipment, wherein at least one of the inspection and the repair comprises a queue of tasks to be performed; terminating at least one of the inspection and the repair before completing the queue; marking a stop point identifying a termination position relative to the queue and the equipment; and initiating resumption of at least one of the inspection and the repair at the termination position relative to the queue and the equipment.

[0195] A computer-implemented method for repairing equipment, the method comprising: receiving, by one or more computing devices, information including an initial status profile CP1 of the equipment; repairing the equipment using information associated with CP1; after the repair is completed, determining an updated status profile CP2 of the equipment; and storing, by one or more computing devices, information associated with CP2 for use in subsequent repair operations.

[0196] A method for servicing equipment, the method comprising: before performing a task associated with servicing the equipment, capturing and recording the original condition of the equipment; after performing the task, capturing and recording the updated condition of the equipment; using one or more computing devices to compare the updated condition of the equipment with the original condition of the equipment; and generating an alarm when the updated condition deviates from the original condition by more than a preset threshold.

[0197] A method for preparing to repair equipment, the method comprising: inspecting one or more components of the equipment; and comparing the inspected components of the equipment with reference data, the reference data being associated with the inspected components, wherein comparing the inspected components with the reference data is used to: determine whether tools or parts used in repairing the equipment are properly sized and shaped to fit relative to the equipment during repair, and to detect damage to the inspected components.

[0198] A computer-implemented method for servicing equipment, the method comprising: recording aspects of the equipment during an nth maintenance; storing aspects of the record of the equipment during the nth maintenance on one or more computing devices; recording aspects of the same equipment during an n+1th maintenance performed at a different time than the nth maintenance; storing aspects of the record of the equipment during the n+1th maintenance on the one or more computing devices; synchronizing aspects of the record from the nth maintenance with aspects of the record from the n+1th maintenance, wherein the synchronized aspects provide a maintenance history for the equipment; and using the maintenance history of the equipment by the one or more computing devices to autonomously inform aspects of a future scope of operation of the equipment.

[0199] A method for servicing equipment, the method comprising: autonomously checking the remaining life of components of the equipment; and repairing one or more components of the equipment, or generating a new scope of work, or marking for future repair, the one or more components of the equipment being determined to have a remaining life that is less than the duration until the next scheduled maintenance.

[0200] A method for maintaining equipment, the method comprising: recording information associated with the equipment at a first location; sending the recorded information to a node; receiving maintenance input from an operator located at a second location different from the first location, the operator having prepared the maintenance input in response to the recorded information on the node; and performing maintenance based on the operator's input.

[0201] A computer-implemented method for maintaining equipment, the method comprising: recording information associated with aviation equipment at a first location; sending the recorded information to one or more nodes; evaluating the recorded information from the one or more virtual nodes at a second location different from the first location; preparing maintenance input in response to the recorded information; and sharing the prepared maintenance input to the first location by the one or more computing devices.

[0202] A robotic assembly for repairing equipment, the robotic assembly comprising: a supporting area, which is configured to receive supporting components associated with a working range of the equipment; an environment capture device, which is configured to capture one or more images of an environment in which the repair equipment is located; and one or more computing devices, which are configured to: locate the equipment in the environment, autonomously navigate the robotic assembly through the environment to reach the equipment, and autonomously adjust the position of the robotic assembly in response to the working range.

[0203] A method for repairing equipment, the method comprising: receiving a working range associated with the equipment; selecting one or more supporting parts associated with the working range, the one or more supporting parts being arranged in one or more storage areas; loading the supporting parts onto a robot assembly; navigating the repair equipment with the supporting parts to the equipment; and autonomously performing the repair operation using the supporting parts using the robot assembly.

[0204] A method for servicing equipment at high temperatures, the method comprising: navigating an autonomous robotic assembly to a location associated with the equipment; applying lubrication from the robotic assembly to one or more adjustable components of the equipment; waiting for a period of time; and operating on the one or more adjustable components using the robotic assembly.

[0205] A robotic assembly for servicing equipment at high temperatures, the robotic assembly comprising: a robotic arm; a lubricant dispenser disposed on the robotic arm and configured to dispense lubricant to one or more fasteners of the equipment; and a wrenching device configured to operate on the one or more fasteners, wherein the robotic assembly is configured to operate autonomously on the one or more fasteners before the equipment cools to a threshold temperature that enables human interaction.

[0206] A robotic assembly comprising a lubricant dispenser and a wrenching device configured to autonomously operate on one or more fasteners of an equipment at elevated temperatures, wherein the robotic assembly is configured to exploit a temperature gradient between the one or more fasteners and the remainder of the engine in order to reduce the torque requirement to loosen the one or more fasteners.

[0207] A method for detecting damage in equipment, the method comprising: observing a thermal response of the equipment during a transition between an elevated temperature and a lower temperature; determining one or more thermal gradients of the equipment during the transition; comparing the one or more thermal gradients to one or more predetermined thermal gradient margins; determining when the one or more thermal gradients exceed the one or more predetermined thermal gradient margins; and generating an alarm when the one or more thermal gradients exceed the one or more predetermined thermal gradient margins.

[0208] A robotic assembly for detecting damage to equipment, the robotic assembly comprising: an autonomous platform configured to move through an environment containing the equipment; an environmental capture device coupled to the autonomous platform and configured to observe a thermal response of the equipment during a cooling duration occurring from a high temperature to a lower temperature; and one or more computing devices configured to: determine a cooling gradient in the equipment during the cooling duration based on information from the environmental capture device, compare the cooling gradient to a predetermined cooling gradient margin, determine when the cooling gradient exceeds the predetermined cooling gradient margin; and generate an alarm when the cooling gradient exceeds the predetermined cooling gradient margin.

[0209] A computer-implemented method for detecting damage to equipment, the method comprising: receiving, by one or more computing devices, information from an environmental capture device, the information capturing a thermal condition of the equipment during a cooling duration that occurs from a high temperature to a lower temperature; determining, by the one or more computing devices, a cooling gradient in the equipment during the cooling duration; comparing, by the one or more computing devices, the cooling gradient to a predetermined cooling gradient margin; determining, by the one or more computing devices, when the cooling gradient exceeds the predetermined cooling gradient margin; and generating, by the one or more computing devices, an alarm when the cooling gradient exceeds the predetermined cooling gradient margin.

[0210] A method for servicing equipment, the method comprising: receiving, by one or more computing devices, information corresponding to one or more components of the equipment; determining, by the one or more computing devices, positions of the one or more components of the equipment relative to a position of an augmented reality device; and presenting at least a portion of the information corresponding to the one or more components of the equipment in a current field of view display of the augmented reality device.

[0211] A system for servicing equipment, the system comprising a memory storing processor-executable instructions and a processor, the processor executing the processor-executable instructions so that the system: receives information corresponding to one or more components of the engine; determines the position of the one or more components of the equipment relative to the position of an augmented reality device; and presents at least a portion of the information corresponding to the one or more components of the engine in a current field of view display of the augmented reality device.

[0212] An autonomous robotic assembly configured to navigate relative to and repair equipment, the autonomous robotic assembly comprising an environment capture device, a memory storing processor-executable instructions, and a processor that executes the processor-executable instructions to cause the autonomous robotic assembly to repair the equipment by: determining completed repair tasks and repair tasks yet to be completed; maintaining an activity log representing current steps in repairing the equipment; moving relative to the equipment during repair; and inspecting the equipment after repair.

[0213] A method for inspecting and repairing equipment, the method comprising: autonomously navigating a robotic assembly to the equipment using an environment capture device of the robotic assembly; capturing supplies of the equipment using the environment capture device; comparing a current maintenance task being performed on the equipment with a queue of tasks associated with maintenance of the equipment; determining completed maintenance tasks and maintenance tasks yet to be completed; and marking the current maintenance location of the equipment.

[0214] An autonomous robotic assembly configured to repair equipment, wherein the autonomous robotic assembly includes an environment capture device configured to provide information to one or more computing devices, wherein the one or more computing devices are configured to use the information to (i) autonomously navigate the robotic assembly within an environment containing the equipment, and (ii) repair the equipment.

[0215] A method for repairing equipment, the method comprising: regarding initial operation of the equipment: repairing the equipment within a provided working range; monitoring the repair operation by one or more computing devices; recording the repair operation by the one or more computing devices; and creating an autonomous repair protocol associated with the working range by the one or more computing devices; and regarding continuous operation of the equipment: determining by the one or more computing devices whether the continuous operation involves the working range of the initial operation; and if it is determined that the continuous operation is related to the working range of the initial operation, autonomously performing the repair protocol.

[0216] A method or assembly as described in any one or more of these clauses, wherein the equipment comprises aviation equipment.

[0217] A method or assembly according to any one or more of these clauses, wherein the equipment comprises a gas turbine engine.

[0218] A robotic assembly configured to repair an engine, the robotic assembly comprising: an environment capture device configured to provide information associated with an environment in which the engine is disposed to one or more computing devices, and wherein the one or more computing devices are configured to use the information to inspect the engine before and after a repair operation associated with the repair to verify repair equipment or portions thereof remaining in the engine after the repair.

[0219] A robotic assembly according to any preceding clause, wherein verifying the repair equipment remaining in the engine comprises comparing an initial view of the repair equipment before the repair with a rear view of the repair equipment after the repair.

[0220] The robotic assembly of any preceding clause, wherein inspecting repair equipment remaining in the engine comprises inspecting for native object debris (DOD), foreign object debris (FOD), or both.

[0221] The robotic assembly of any preceding clause, wherein the one or more computing devices are further configured to inspect the engine for damage after the repairing.

[0222] The robotic assembly of any preceding clause, wherein the one or more computing devices are further configured to generate an alarm when repair equipment is left in the engine.

[0223] A robot assembly according to any preceding clause, wherein the repair equipment includes tools, unused parts, packaging and containers, repair accessories, etc.

[0224] A robotic assembly according to any preceding clause, wherein the robotic assembly is at least partially autonomous, and wherein inspecting the repair equipment remaining in the engine is performed at least partially autonomously.

[0225] A method for servicing an engine, the method comprising: capturing information associated with the engine using an environmental capture device; performing a repair operation on the engine; and comparing one or more portions of the information captured before performing the repair operation with one or more portions of the information captured after performing the repair operation to verify local object debris and foreign object debris.

[0226] A method as in any preceding clause, wherein comparing the information is performed by one or more computing devices.

[0227] A method as in any preceding clause, wherein verifying native object debris and foreign object debris in the engine comprises verifying differences between the information captured before performing the repair operation and the information captured after performing the repair operation.

[0228] A method as described in any preceding clause, further comprising generating an alarm when local object debris or foreign object debris is detected.

[0229] A method according to any preceding clause, wherein the foreign object debris includes tools, unused parts, packaging and containers, repair accessories, etc.

[0230] A method according to any preceding clause, wherein the environment capture device is coupled to an at least partially autonomous robotic assembly, and wherein capturing the information is performed at least partially autonomously.

[0231] A method according to any preceding clause, wherein the at least partially autonomous robotic assembly, or one or more parts associated therewith, is configured to move relative to the engine whilst capturing the information.

[0232] A robotic assembly that is at least partially autonomous and configured to navigate relative to and service an engine, the robotic assembly comprising an environment capture device, a memory storing processor-executable instructions, and a processor that executes the processor-executable instructions so that the robotic assembly services the engine by: determining completed service tasks and uncompleted service tasks; maintaining an activity log representing a current step in servicing the engine; moving relative to the engine during the servicing; and inspecting the engine after the servicing.

[0233] A robotic assembly according to any preceding clause, wherein the environment capture device is configured to determine a completed maintenance task, move relative to the engine, and inspect the engine after the maintenance.

[0234] A robotic assembly as described in any preceding clause, wherein the step of maintaining the activity log is performed by determining at least one of an operating area relative to the engine or a task performed by the at least partially autonomous robotic assembly, and comparing the operating area or task performed to a work range map or a queue of tasks performed.

[0235] A robotic assembly according to any preceding clause, wherein the step of comparing the operating area or completed tasks to the work range map or queue is performed continuously.

[0236] The robotic assembly of any preceding clause, wherein the at least partially autonomous robotic assembly is further configured to perform said maintenance, including at least one of inspection and repair of said engine.

[0237] A robotic assembly according to any preceding clause, wherein the at least partially autonomous robotic assembly is configured to service the engine when the engine is at an elevated temperature.

Claims

1. A robot assembly configured to repair an engine, characterized in that: The robot assembly comprises: An environment capture device configured to provide information associated with an environment in which the engine is disposed to one or more computing devices, and wherein the one or more computing devices are configured to use the information to inspect the engine before and after a repair operation associated with maintenance to verify repair equipment or portions thereof remaining in the engine after the repair operation, wherein verifying the repair equipment remaining in the engine includes verifying local object debris (DOD), foreign object debris (FOD), or both.

2. The robot assembly according to claim 1, characterized in that: Wherein verifying the repair equipment remaining in the engine includes comparing an initial view of the repair equipment before the repair operation with a post view of the repair equipment after the repair operation.

3. The robot assembly according to claim 1, characterized in that: Wherein the one or more computing devices are further configured to verify damage to the engine after the repair operation.

4. The robot assembly according to claim 1, characterized in that: Wherein the one or more computing devices are further configured to generate an alarm when the repair equipment is left in the engine.

5. The robot assembly according to claim 1, characterized in that: The repair equipment includes tools, unused parts, packaging and containers, and repair accessories.

6. The robot assembly according to claim 1, characterized in that: wherein the robotic assembly is at least partially autonomous, and wherein inspecting the repair equipment remaining in the engine is performed at least partially autonomously.

7. A method for repairing an engine, characterized in that: The method comprises: capturing information associated with the engine using an environment capture device; performing repair operations on said engine; and One or more portions of the information captured before performing the repair operation are compared with one or more portions of the information captured after performing the repair operation to verify native object debris and foreign object debris.

8. The method according to claim 7, characterized in that Wherein comparing the information is performed by one or more computing devices.

9. The method according to claim 7, characterized in that: Wherein verifying the engine for local object debris and foreign object debris includes verifying differences between the information captured before performing the repair operation and the information captured after performing the repair operation.

10. The method according to claim 7, characterized in that Further comprising generating an alarm when local object debris or foreign object debris is detected.

11. The method according to claim 7, characterized in that The foreign object debris includes tools, unused parts, packaging and containers, and repair accessories.

12. The method according to claim 7, characterized in that Wherein the environment capture device is coupled to an at least partially autonomous robotic assembly, and wherein capturing the information is performed at least partially autonomously.

13. The method according to claim 12, characterized in that Wherein the at least partially autonomous robotic assembly, or one or more parts associated therewith, is configured to move relative to the engine while capturing the information.

14. The robot assembly according to claim 1, characterized in that The one or more computing devices include a memory storing processor-executable instructions and a processor, wherein the processor executes the processor-executable instructions to cause the robotic assembly to repair the engine by: Determine the maintenance tasks that have been completed and those that have not been completed; maintaining an activity log representing current steps in servicing said engine; moving relative to said engine during said servicing; and The engine is inspected after the servicing.

15. The robot assembly according to claim 14, characterized in that The environment capture device is configured to determine a completed maintenance task, move relative to the engine, and inspect the engine after the maintenance.

16. The robot assembly according to claim 14, characterized in that Wherein the step of maintaining the activity log is performed by determining at least one of an operating area relative to the engine or a task being performed by the robotic assembly and comparing the operating area or the task being performed to a work range map or a queue of tasks being performed.

17. The robot assembly according to claim 14, characterized in that Therein the step of comparing the operating area or completed tasks with a work scope map or queue is performed continuously.

18. The robot assembly according to claim 14, characterized in that Wherein the robotic assembly is further configured to perform the maintenance, including at least one of inspection and repair of the engine.

19. The robot assembly according to claim 14, characterized in that Wherein the robotic assembly is configured to service the engine when the engine is at a high temperature.

Images