Systems and methods for detecting multi-surface characteristics

Abstract

To provide a device having a thrust system for firm contact with a multi-oriented surface as the device traverses an environment.SOLUTION: According to certain embodiments, a device comprises a body, a mechanical propulsion system affixed to the body to cause the body to traverse a multi-oriented surface and to prevent contact between the body and the multi-oriented surface, a thrust system to apply a thrust force to the device that opposes a gravitational force acting on the device, and a payload with at least one sensor to detect characteristics of the multi-oriented surface.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention generally relates to a device having a thrust system for firmly contacting a multi-oriented surface as the device traverses an environment. [Background technology]

[0002] Inspecting and operating on surfaces presents challenges for humans, especially when working in confined spaces, open spaces, overhead areas, and on delicate or pressure-sensitive surfaces. Inspection of these types of locations also presents risks to humans who are asked to perform actions in such hazardous conditions. In some applications, aerial drones may be tasked with performing such tasks, but they have their own limitations, including a substantial risk of damaging the object or surface being inspected if the aerial drone comes into contact with the object. Aerial drones may also require special operator certification and are restricted for use in certain airspace. Summary of the Invention [Means for solving the problem]

[0003] According to one embodiment, the device includes a body, a mechanical propulsion system secured to the body to traverse the multi-orientation plane and to prevent contact between the body and the multi-orientation plane, a thrust system that applies a thrust to the device that counteracts gravity acting on the device, and a payload having at least one sensor for detecting characteristics of the multi-orientation plane.

[0004] According to one embodiment, a system for detecting characteristics of a multi-orientation surface includes at least one device, each of which includes a body, a mechanical propulsion system secured to the body to traverse the multi-orientation surface and prevent contact between the body and the multi-orientation surface, a thrust system that applies a thrust to the device that counteracts gravity acting on the device, and a payload having at least one sensor that detects characteristics of the multi-orientation surface. The system further includes a controller for controlling each device and for detecting characteristics of the multi-orientation surface using the sensor.

[0005] According to one embodiment, a method of detecting characteristics of a multi-orientation surface is achieved by traversing the multi-orientation surface with at least one device, each device including a body, a mechanical propulsion system secured to the body so as to cause the body to traverse the multi-orientation surface and to prevent contact between the body and the multi-orientation surface, and a thrust system that applies a thrust force to the device that counteracts gravity acting on the device, and then detecting characteristics of the multi-orientation surface with several sensors.

[0006] Certain embodiments may provide one or more technical advantages. As one example, certain embodiments provide the advantage of enabling a drone to navigate the surface of an object that may have complex topology and / or delicate surfaces. As another example, certain embodiments provide the advantage of enabling a drone to navigate the inverted surface of an object that may be non-magnetic or may not be able to withstand vacuum forces. As another example, certain embodiments may provide the advantage of achieving better efficiency and / or ensuring full fidelity of the drone to a partially inverted surface through controlling the direction and point at which thrust acts on the drone. Certain embodiments may include all, some, or none of the above advantages. Other advantages will be apparent to those skilled in the art.

[0007] For a more complete understanding of the present disclosure, reference is now made to the following descriptions read in conjunction with the accompanying drawings, in which: [Brief explanation of the drawings]

[0008] [Figure 1] FIG. 1 illustrates an exemplary crawler drone with a thrust system for firm contact on multiple surfaces. [Figure 2a] FIG. 1 illustrates a series of conditions that may be in operation when a drone traverses a surface with a complex series of orientations. [Figure 2b] FIG. 1 illustrates a series of conditions that may be in operation when a drone traverses a surface with a complex series of orientations. [Figure 2c] FIG. 1 illustrates a series of conditions that may be in operation when a drone traverses a surface with a complex series of orientations. [Figure 2d] FIG. 1 illustrates a series of conditions that may be in operation when a drone traverses a surface with a complex series of orientations. [Figure 2e] FIG. 1 illustrates a series of conditions that may be in operation when a drone traverses a surface with a complex series of orientations. [Figure 2f] FIG. 1 illustrates a series of conditions that may be in operation when a drone traverses a surface with a complex series of orientations. [Figure 3] FIG. 1 shows a two-dimensional diagram of a crawler drone climbing a slope with a representation of the instantaneous forces acting on the crawler. [Figure 4] FIG. 10 shows a three-dimensional view of a crawler drone moving horizontally across an inclined plane with a representation of the instantaneous forces acting on the crawler. [Figure 5] FIG. 10 illustrates the minimum thrust required across a range of surface orientations and headings to ensure that an exemplary crawler drone can firmly contact a multi-orientation surface without dropping, sliding, or tipping over. DETAILED DESCRIPTION OF THE INVENTION

[0009] The following description is presented to enable any person skilled in the art to make and use the present invention. Descriptions of specific embodiments and applications are provided by way of example only, and various modifications will be readily apparent to those skilled in the art. The general principles described herein may be applied to other embodiments and applications without departing from the scope of the present invention. Thus, the present invention is not intended to be limited to the embodiments shown, but is to be accorded the widest scope consistent with the principles and features described herein. For purposes of clarity, details relating to technical content known in the art to which the present invention pertains have not been described in detail.

[0010] Embodiments of the present disclosure and its advantages are best understood by referring to FIGS. 1-5 of the drawings, like numerals being used for like and corresponding parts of the various drawings.

[0011] During the manufacturing and assembly of large objects, inspection and quality control can be extremely important, especially for highly sophisticated products. Most of this inspection and quality control is performed manually. However, there may be areas of a manufactured object that are difficult for humans to inspect or work on. Reasons for this range from difficult-to-access areas—areas that are not fully accessible to humans, requiring special certification or other precautions—to areas that may otherwise be narrow or very tall. These issues may lead to additional costs, delays, or may pose a greater risk of damage to the manufactured object (e.g., if it can be easily damaged by a dropped tool). In addition to the challenges that exist with manual labor, efficiency improvements can also be achieved by using inspection drones. The use of drones can supplement manned labor. The use of drones can be used to deploy drone fleets that can be coordinated to maximize efficiency. Such drone fleets can be deployed for use in any coordinated manner. This control and coordination can be performed by individual control of each drone by a separate operator, or they can be controlled in groups by an operator. Semi-autonomous or fully autonomous control can also be used. Such forms of control and coordination may employ pre-arranged inspection routes or courses that may enable task completion more efficiently.

[0012] Aerial drones have become more popular in recent years. These aerial drones, such as quadcopters or multirotor drones, offer certain benefits by having their own set of inherent limitations, as described above. Existing aerial drones are generally not well-suited to perform inspections in specific orientations, and transitioning between orientations can be difficult. Furthermore, aerial drones may pose a greater risk of causing damage to the object being inspected. For example, a quadcopters with exposed blades may cause significant damage to the object if the rotating blades come into contact with the surface. Another disadvantage of aerial drones is that certain locations may have certain limitations, such as Federal Aviation Administration approval restrictions or marking line restrictions. Of course, the rapid consumption of reserve power required to continuously keep an aerial drone airborne reduces the efficiency of such aerial drones for performing inspections when the object has a large inspected surface that could otherwise be achieved with a drone resting on the surface. Other types of drones, such as drones that firmly contact surfaces using magnets or suction, may not be suitable for many applications. For example, this mechanism of firm contact with the surface is not suitable for non-magnetic objects or objects with surfaces that cannot withstand the vacuum forces (e.g., thin film surfaces or surfaces that may be destroyed by small scratches).Several other drawbacks of existing designs are also known in the art.

[0013] 1 illustrates an exemplary crawler drone 100 that can be used to traverse a multi-orientation surface 120. The multi-orientation surface 120 may include a surface that is particularly challenging to completely traverse. For example, in the aerospace manufacturing industry, the multi-orientation surface 120 may be either the interior or exterior surface of an aircraft fuselage, or a sealed fuel tank integrated into an aircraft wing, or a high vertical stabilizer that would otherwise require a human technician to use scaffolding and harnesses to reach. The multi-orientation surface 120 may also be located in an inhospitable environment, such as an environment with extreme temperatures or where pollutants and other environmental contaminants are present.

[0014] There may be several characteristics associated with multi-oriented surface 120. For example, the characteristics of multi-oriented surface 120 may include the tensile strength, pressure rating, and magnetic properties of multi-oriented surface 120. The characteristics of multi-oriented surface 120 may include, for example, one or more defects 121 in the manufacturing of multi-oriented surface 120. By way of example, defects 121 may include any form of defect, such as a surface scratch, stain, crack, delamination, metal peeling, cavity, improper welding, or other assembly defect.

[0015] The crawler drone 100 may have a body 101 that provides structure to the drone and supports other systems of the crawler drone 100. The crawler drone 100 may have a mechanical propulsion system 102 fixed to the crawler drone 100. As shown, the mechanical propulsion system 102 of the crawler drone 100 includes four wheels. The mechanical propulsion system 102 may include any number of wheels, continuous tracks, omnidirectional ball wheels, and casters, depending on the application and characteristics of the particular multi-orientation surface 120. For example, wider wheels or tracks may be selected for particularly delicate multi-orientation surfaces 120 to ensure a greater distribution of the crawler drone's 100's weight over the multi-orientation surface 120 or a greater distribution of thrust through the mechanical propulsion system 102. The mechanical propulsion system 102 may include motors 102a that turn the wheels or tracks of the crawler drone 100 to enable the crawler drone to travel or traverse the multi-orientation surface 120. The mechanical propulsion system 102 can include any number of electric motors, and in the illustrated embodiment, the mechanical propulsion system 102 includes one electric motor 102a for each wheel.

[0016] The wheels or tracks of the mechanical propulsion system 102 may be supported by a suspension system 103. As shown, the suspension system 103 may be integrated as part of the crawler drone 100 and secured to the body 101. The suspension system 103 may serve to ensure that all of the wheels or a sufficient portion of the tracks of the mechanical propulsion system 102 remain in contact with the multi-orientation surface 120. In some embodiments, the suspension system may have actuators 103a to raise or lower the body 101, or to adjust the tilt or orientation of the body 101 and the entire crawler drone 100 relative to the multi-orientation surface 120. This may be done to elevate the body 101 of the crawler drone 100 over protrusions of the multi-orientation surface 120 to ensure that the crawler drone 100 can be completely contact-free as it traverses the multi-orientation surface 102, other than contact between the mechanical propulsion system 102 and the multi-orientation surface 120. Additionally, actuator 103a may be selectively engaged to tilt crawler drone 100, which may have particular advantages as described in more detail in connection with the description of Figures 3-5.

[0017] The crawler drone 100 also includes a thrust system 104 that provides a normal force on the crawler drone 100. The normal force applied to the crawler drone 100 by the thrust system 104 can assist the crawler drone 100 in maintaining firm contact with the multi-orientation surface 120. When the thrust system 104 is properly sized, it can provide sufficient normal force to ensure that the mechanical propulsion system 102 of the crawler drone 100 maintains contact with the multi-orientation surface 120 throughout the entire range of orientations, including fully reversed orientations. In such cases, the thrust system 104 must provide a thrust greater than the force of gravity acting on the crawler drone 100. Appropriate thrust is described in more detail herein with respect to the disclosure of FIG. 5. It is also recognized that the thrust system 104 can be configured to reduce negative suction pressures that may be problematic at the bottom of the crawler drone 100 against otherwise particularly sensitive surfaces of the multi-orientation surface 120. This can be achieved, for example, by positioning the air inlets for the thrust system 104 on the sides of the body 101 so as to draw air in at the sides and avoid the possibility of a vacuum forming on the surface of the multi-azimuth surface 120.

[0018] As shown in FIG. 1 , the thrust system is integrated into the body 101, although other configurations for the thrust system 104, such as external rotor blades, are also contemplated. Additionally, in some embodiments, the thrust system 104 can include more than one ducted fan, for example, all four ducted fans can be positioned around the circumference of the body 101 such that the power of each ducted fan can be controlled to induce a moment acting about the center of gravity of the crawler drone 100. This moment can be beneficial for squeezing the suspension system 103, so that the angle of thrust applied to the crawler drone 100 by the thrust system 104 deviates slightly from normal. In some other embodiments, the thrust system 104 can include control vanes to adjust the angle of thrust. As can be appreciated, adjusting the angle of thrust can help control the force applied by the mechanical propulsion system 102 to the multi-azimuth surface 120 in situations where the characteristics of the multi-azimuth surface 120 cannot support a large force. This angled thrust can be beneficial in assisting the mechanical propulsion system 102 in climbing sloped portions of multi-azimuth surfaces. This angled thrust is described in more detail in connection with the description associated with Figures 2a-3.

[0019] The crawler drone 100 also includes a payload 105 for accomplishing a number of tasks. As shown, the crawler drone 100 has sensors that detect defects 121 associated with the multi-orientation surface 120. The sensors on the payload 105 may be any combination of visible spectrum cameras, infrared cameras, thermal cameras, laser scanners, X-ray modules, ultrasonic non-destructive testing modules, or any other type of sensors that determine characteristics associated with the multi-orientation surface 120. As the crawler drone 100 traverses the multi-orientation surface 120, the sensors on the payload 105 may detect defects 121. These detected defects 121 may be captured in recorded data or otherwise identified. For example, the crawler drone 100 may indicate the presence of defects 121 by placing a marker on the multi-orientation surface 120 near the defects 121. Such markers may include ink marks, paint marks, stickers, or other possible markers. In certain other embodiments, the payload 105 may also include tools for performing repairs on the defects 121 on the multi-orientation surface 120. The tools mounted on payload 105 may include paint applicators, sealant applicators, adhesive applicators, sanding devices, deburring devices, cutting devices, welding devices, rivet applicators, markers, sticker applicators, or any other tools that would be readily apparent to one skilled in the art of manufacturing. In other embodiments, payload 105 may also include a tool delivery system or other system that transports the tools to a human operator to perform a repair.

[0020] The crawler drone 100 may also include a controller 106. As shown, the controller 106 is mounted to the body 101 of the crawler drone 100. This configuration may be used for an autonomous crawler drone 100, but may also be used for manual or semi-autonomous control where direction is provided to the controller 106 through wireless communication (e.g., Bluetooth, Wi-Fi, or other wireless telecommunications). However, in certain other embodiments, the controller may be located remotely relative to the crawler drone 100. For example, a tether may be communicatively coupled to the crawler drone 100 to provide direction and control to the crawler drone. The controller 106 may have various inputs and outputs (e.g., USB, microSD, remote media streaming, and other storage devices) to facilitate data retrieval from the payload 105's sensors.

[0021] 2a-2f illustrate a series of transitions made by a simplified representation of crawler drone 200, such as that shown in FIG. 1, as crawler drone 200 traverses complex multi-orientation plane 220. Several simplified forces acting on crawler drone 200 are depicted in each of FIGS. 2a-2f. These forces correspond to: F T is the thrust applied by the thrust system 104, and F N is the effective normal force from the multi-orientation surface 220 acting on the crawler drone 200, mg is the gravity force acting on the crawler drone 200, and F f is the friction force acting on the wheels of the mechanical propulsion system 102. With respect to the four-wheel embodiment shown in FIG. 1, it is understood that there are likely to be four friction forces and four normal forces acting along the contact points of each of the four wheels of the mechanical propulsion system 102, although these forces are shown schematically in the figures throughout FIGS. 2a-2f for clarity. Additionally, all of the various forces as shown are not to scale and serve to inform some of the functionality of the crawler drone 200 in conjunction with the following description.

[0022] As shown in FIG. 2a, when crawler drone 200 is climbing a vertically oriented multi-orientation surface 220, thrust is directed toward the bottom of the multi-orientation surface, and the thrust, combined with the friction of mechanical propulsion system 102, causes crawler drone 200 to make firm contact with the multi-orientation surface. With sufficient thrust from thrust system 104, mechanical propulsion system 102 can move around multi-orientation surface 220. As shown in FIG. 2a, crawler 220 can traverse the vertical portion of the multi-orientation surface in an upward direction until it reaches a position as shown in FIG. 2b. By slightly angling the thrust applied to crawler drone 200 by thrust system 104, the vertical component of thrust can reduce the force applied to multi-orientation surface 220, and the vertical component can assist mechanical propulsion system 102 in overcoming gravity in the forward direction.

[0023] As shown in FIG. 2b, the suspension system 103 can lift the body 101 of the crawler drone 200 above any point on the multi-azimuth surface 220, such as by the actuators 103, to avoid any damage that may result from contact or even from placing the thrust system 104 within close proximity of the multi-azimuth surface 220.

[0024] As the crawler drone 200 transitions from the vertical orientation of FIG. 2a to the tilted orientation of FIG. 2b and then to a horizontal orientation as shown in FIG. 2c, the thrust generated by the thrust system 104 may, in some embodiments, be gradually reduced until the thrust can finally be reduced to zero when the crawler drone is on a horizontal surface, as shown in FIG. 2c. In FIG. 2c, the crawler drone 200 may be fully powered by the mechanical propulsion system 102 to traverse the multi-orientation surface 200. In other embodiments, the crawler drone 200 may traverse the multi-orientation surface 200 by applying thrust in the direction of travel with the tilted thrust system 104; in such cases, the friction force will act in the opposite direction, as shown in FIG. 2c.

[0025] 2d, crawler drone 200 is shown transitioning from a horizontal to a vertical orientation on multi-orientation surface 220. Here, thrust system 104 would again need to be engaged to ensure sufficient friction can be generated at each of the contact points of mechanical propulsion system 102. Additionally, depending on the length of the overhang between crawler drone's 200 body 101 and the transition or radius of curvature of multi-orientation surface 220, suspension system 103 may raise body 101 or extend mechanical propulsion system 102 to avoid contact with multi-orientation surface 220.

[0026] For simplicity, the subsequent orientation shown in Figure 2d occurs after the crawler drone transitions through the vertical portion. See the discussion of Figure 2a regarding the intermediate operation of the crawler drone 200 between Figures 2c and 2d. In many respects, the operation of the crawler drone 200 as it traverses the concave transition in Figure 2e will be similar to that in Figure 2d, with the notable difference that thrust is increased in the partially reversed orientation of Figure 2e. This effect occurs because the thrust of the thrust system 104 directed in Figure 2e opposes the force of gravity acting on the crawler drone 200 compared to the orientation shown in Figure 2d.

[0027] Finally, as shown in FIG. 2f, crawler drone 200 is in a fully reversed orientation. To remain in firm contact with multi-orientation surface 220, thrust system 104 must generate a thrust at least as great as the force of gravity acting on crawler drone 200. In some embodiments, when in a fully reversed orientation, the thrust system can be at maximum thrust output, although in some cases, this may not be the case, as will be further described with respect to FIG. 5.

[0028] 3 shows a simplified free-body diagram of a crawler drone 300 moving in an uphill direction along an inclined multi-orientation surface 320. As shown, the crawler drone 300 has a mechanical propulsion system 302, shown as a pair of wheels in contact with the multi-orientation surface 320. A thrust force FT is also shown acting substantially at a point 315 within the body 301 of the illustrated crawler drone 300. In addition, the center of gravity 310 of the crawler drone 300 is represented as a point. Other designations shown are θ—the angle of inclination of the multi-orientation surface 320; mg—the force of gravity acting on the crawler drone 300; and F T - the thrust generated by the thrust system 104, β - the angle of the thrust out of perpendicular to the multi-azimuth plane 320, L - the length of the wheelbase of the mechanical propulsion system 302, L C the distance between the front of the mechanical propulsion system 302 and the center of gravity 310, L T the distance between the front of the mechanical propulsion system 302 and the point of thrust action 315, h C - the distance from the center of gravity 310 of the crawler drone 300 to the multi-orientation plane 320, h T - the distance from the point 315 at which the thrust acts on the multi-azimuth plane 320, F Nf,Nr - the normal forces applied to the front and rear wheels of the mechanical propulsion system 302, respectively, and F ff,fr - Friction forces applied to the front and rear wheels of the mechanical propulsion system 302, respectively.

[0029] The rotational moment applied to crawler drone 300 can be controlled by taking into account the distance between point 315 and center of gravity 310. This distance from point 315 to center of gravity 310 can be controlled, for example, by controlling different fan rotational speeds to position the point of effective thrust closer to the fan with the larger magnitude when thrust system 104 includes more than one ducted fan. This moment can induce a rotational force that causes suspension system 103 to sag in response to the rotational force. Thus, sagging of suspension system 103 causes body 301 of crawler drone 300 to slightly change its angle. In doing so, thrust angle β can be controlled even for embodiments of crawler drone 300 with fixed-angle thrust system 104. Additionally, as described above, angle β can be adjusted by operating suspension system 103 with actuator 103a, by thrust system 104, by thrust system 302 in combination with suspension system 103, or any combination thereof.

[0030] As a simple example, when thrust is held constant, as angle β increases, the normal force F acting on the mechanical propulsion system 302 Nf,Nrdecreases, and the force parallel to the multi-orientation surface 320 increases; hereafter, this parallel force, which is a component of thrust, is referred to as the pushing force. Over a range of thrust, there will be a corresponding angle β where the pushing force will equal the sliding component of gravity acting on the crawler drone 300, so that the crawler drone 300 can stabilize in place without rolling down the multi-orientation surface 320 having a slope of θ. Increasing the thrust, increasing the thrust angle β for the same slope of θ, or a combination thereof, can cause the crawler drone 300 to climb the slope of the multi-orientation surface 320, or can be used in combination to assist the mechanical propulsion system 302 in climbing the multi-orientation surface 320. Similarly, as the thrust and thrust angle β decrease, the sliding component of gravity may tend to cause the crawler drone 300 to roll down the multi-orientation surface 320. This can be advantageous when it is desirable to descend a multi-azimuth surface by essentially allowing gravity to move the crawler drone 300 down the multi-azimuth surface, resulting in reduced energy consumption by one or both of the thrust system 104 and the mechanical propulsion system 302.

[0031] Furthermore, as the angle of inclination θ of the multi-azimuth surface 320 increases, the angle of thrust β or thrust magnitude must correspondingly increase. These effects can be better explained with respect to a simplified three-dimensional view of the crawler drone 400, as shown in FIG. 4, along with the associated thrust diagram in FIG. 5.

[0032] FIG. 4 introduces some additional concepts to the simplified two-dimensional free-body diagram of FIG. 3. Here, as shown, a crawler drone 400 has a body 401 with a mechanical propulsion system 402. In one embodiment, the mechanical propulsion system 402 can include four wheels that traverse a multi-orientation plane 420. For clarity, the concepts introduced with respect to FIG. 3 will not be repeated here, instead focusing on concepts specific to a three-dimensional view of the crawler drone 400 on the multi-orientation plane 420. Vector notation has been implemented for the crawler drone 400 illustration of FIG. 4. In contrast to the two-dimensional diagram, here, there is a friction force on each wheel of the mechanical propulsion system 402, and two components of the friction force are shown as being applied to each wheel. The first is in the direction of travel. Friction force F in JPEG0007746007000001.jpg64 f and the second is the force of gravity F acting on the crawler drone 400. g Direction of travel to counter the resulting sliding forces Friction force F perpendicular to JPEG0007746007000002.jpg64 f The third force acting on each wheel is the normal force F N Each of these three forces on the four wheels is followed by a series of letters to indicate which wheel the force corresponds to. The notation system is as follows: Force 摩擦力又は法線力、前部又は後部、左又は右方向 For example, friction force JPEG0007746007000003.jpg611 is Friction force F on the front left wheel in the direction of 64 f Similarly, the normal force F Nrr is the normal force F applied to the rear right wheel of the mechanical propulsion system 402 NAll of these frictional and normal forces acting on the mechanical propulsion system 402 occur at the contact points between the wheels and the multi-azimuth surface 420, which can extend further away from the center of gravity than the edges of the body 401, where the distance from the contact point and the axis of rotation about the center of gravity 410 is half the distance L and half the distance W. These distances are important in considering the possibility of tipping over of the crawler drone 400 over the entire range of tilt angles θ of the multi-azimuth surface 420.

[0033] As shown, the crawler drone 400 is oriented along a multi-orientation plane 420 having a slope of angle θ. JPEG0007746007000005.jpg64. This represents a heading angle φ of 90°, while a heading angle φ of 0° would correspond to being directly above the slope θ of the multi-azimuth surface 420. Similarly, a heading angle φ of 180° would correspond to being directly below the slope θ of the multi-azimuth surface 420. In addition, the internal forces resisting changes in the movement of the crawler drone 400 are F I It is addressed by and represented by

[0034] FIG. 5 is a diagram illustrating the minimum thrust required for an example crawler drone such as that shown in FIG. 1 when the surface is subjected to a set of forces applied to the example crawler drone as described with respect to FIG. 4. The diagram illustrates the thrust required to be generated by thrust system 104 along the vertical axis. Along the other two axes are the tilt angle θ or surface inclination and crawler heading angle φ of multi-orientation surface 120 throughout a range of surface orientations and headings. Any thrust greater in magnitude than that indicated by the surface of the plot needs to be sufficient to ensure that crawler drone 100 remains in firm contact with multi-orientation surface 100 without falling, sliding, or tipping at a particular heading φ and slope θ. However, it is recognized that greater thrust may consume reserve energy as speed increases and may, in some cases, impart unnecessarily large additional forces on multi-orientation surface 120.

[0035] Using this insight, instantaneous thrust can be controlled to allow for some safety margin but not consume excessive reserve energy, thereby increasing the duration for which the crawler drone 100 can perform its mission. Furthermore, thrust can be controlled relative to normal forces that are likely to be applied to the crawler drone 100 in multiple orientations to prevent damage to the crawler drone 100 while it is performing its mission. This insight can also be used to pre-calculate an ideal path or course for the crawler drone 100. For example, the crawler drone 100 may have a path that initially operates primarily in an inverted orientation while the crawler drone's reserve power or battery is at its maximum, and then moves to a less steep orientation that is likely to consume less energy as the reserve power depletes. When multiple crawler drones 100 are used as a platoon or unit, the amount of operations to be performed in areas requiring greater thrust can be more efficiently distributed among several crawler drones 100. These considerations and others can be initially programmed or calculated by the controller 106, or dynamically calculated and communicated to other crawler drones 100 or a human operator.

[0036] As used herein, "or" is inclusive and not exclusive, unless expressly indicated otherwise or otherwise indicated by context. Thus, as used herein, "A or B" means "A, B, or both," unless expressly indicated otherwise or otherwise indicated by context. Furthermore, "and" is both jointly and separately, unless expressly indicated otherwise or otherwise indicated by context. Thus, as used herein, "A and B" means "A and B, jointly or separately," unless expressly indicated otherwise or otherwise indicated by context.

[0037] While the present disclosure includes several embodiments, it may suggest countless changes, variations, modifications, alterations, and alterations to those skilled in the art, and the present disclosure is intended to encompass all such changes, variations, modifications, alterations, and alterations as fall within the scope of the appended claims. [Explanation of symbols]

[0038] 100 Crawler Drones 102 Mechanical Propulsion System 104 Thrust System 120 Multi-directional plane 121 Defects

Claims

1. 1. An apparatus comprising: The main body and a mechanical propulsion system fixed to the body, the mechanical propulsion system including a plurality of wheels and at least one motor coupled to the plurality of wheels, causing the body to traverse multiple azimuthal planes; and preventing contact between the body and the multi-directional surface; the mechanical propulsion system configured as follows: a ducted fan configured to apply a thrust force to the device against gravity acting on the device; a suspension system mounting the mechanical propulsion system to the body, Lifting the body of the device over the multi-faceted protrusion; adjusting the orientation of the body; and raising and lowering each of the plurality of wheels relative to the body to maintain contact between the mechanical propulsion system and the multi-component surface. the suspension system including a plurality of actuators configured to a payload including at least one sensor configured to detect one or more characteristics associated with the multi-component surface; Including, the ducted fan is further configured to reduce vacuum pressure created on the multi-plane by positioning an air inlet for the ducted fan on a side of the body.

2. 2. The apparatus of claim 1, wherein the ducted fan is further configured such that a magnitude of a vertical component of the thrust force exceeds the gravity force.

3. the ducted fan includes a plurality of control vanes; Controlling the direction of the thrust; and exerting the thrust force on the device relative to the center of gravity of the device; It is configured as follows:

2. The device of claim 1 .

4. 10. The apparatus of claim 1, wherein the suspension system is further configured to adjust the orientation of the body so that the direction of the thrust is more closely aligned with the direction of gravity.

5. 10. The apparatus of claim 1, wherein the suspension system is further configured to adjust the orientation of the body so that the direction of the thrust is more opposed to a direction of rotation of the mechanical propulsion system.

6. 10. The apparatus of claim 1, wherein the ducted fan is further configured to control the thrust to cause the suspension system to adjust the orientation of the body.

7. 10. The apparatus of claim 1, wherein the suspension system is further configured to elevate the body a distance away from the multi-plane in response to the topology of the multi-plane.

8. 10. The apparatus of claim 1, wherein the payload comprises at least one of a visible spectrum camera, an infrared camera, a thermal camera, a laser scanner, an X-ray module, and an ultrasonic non-destructive testing module.

9. 1. A system for detecting characteristics associated with a multi-plane, comprising: At least one device, Main body, a mechanical propulsion system secured to the body and configured to traverse multiple azimuth planes and prevent contact between the body and the multiple azimuth planes, the mechanical propulsion system including a plurality of wheels and at least one motor coupled to the plurality of wheels; a ducted fan configured to apply a thrust force to the at least one device that counteracts gravity acting on the at least one device; and a suspension system mounting the mechanical propulsion system to the body, Lifting the body of the device over the multi-faceted protrusion; adjusting the orientation of the body; and raising and lowering each of the plurality of wheels relative to the body to maintain contact between the mechanical propulsion system and the multi-component surface. the suspension system including a plurality of actuators configured to the at least one device each including at least one sensor configured to detect a characteristic associated with the multi-component surface; a controller configured to control the at least one device and further configured to detect one or more characteristics associated with the multi-component surface based at least in part on the at least one sensor; Including, the ducted fan is further configured to reduce vacuum pressure created on the multi-plane by positioning an air inlet for the ducted fan on a side of the body.

10. The system of claim 9 , wherein the at least one device further comprises at least one tool.

11. 11. The system of claim 10, wherein the tool comprises at least one of a paint applicator, a sealant applicator, an adhesive applicator, a sanding device, a deburring device, a cutting device, a welding device, a rivet applicator, a marker, a sticker applicator, a repair tool, and a tool delivery system.

12. 1. A method for detecting a characteristic, comprising: traversing multiple azimuthal planes with at least one device; the at least one device Main body, a mechanical propulsion system secured to the body and configured to traverse the multiple azimuth planes and prevent contact between the body and the multiple azimuth planes, the mechanical propulsion system including a plurality of wheels and at least one motor coupled to the plurality of wheels; a ducted fan configured to apply a thrust force to the at least one device that counteracts gravity acting on the at least one device; and a suspension system mounting the mechanical propulsion system to the body, Lifting the body of the device over the multi-faceted protrusion; adjusting the orientation of the body; and raising and lowering each of the plurality of wheels relative to the body to maintain contact between the mechanical propulsion system and the multi-component surface. the suspension system including a plurality of actuators configured to Including, the method including detecting, with at least one sensor, one or more characteristics associated with the multi-component surface; wherein the ducted fan is further configured to reduce vacuum pressure created on the multi-plane by positioning an air inlet for the ducted fan on a side of the body.

13. 13. The method of claim 12, wherein traversing the multiple azimuth planes with the at least one device further comprises guiding by at least one of manual control, semi-autonomous control, and autonomous control.

14. 14. The method of claim 13, wherein the directing step further comprises communicating with the at least one device by at least one of a tether wire and a wireless communication protocol.

15. 14. The method of claim 13, wherein the guiding is determined at least in part based on a path selected to reduce energy consumption by at least one of the mechanical propulsion system and the ducted fan.

16. further comprising the step of responding to said one or more characteristics; the responding step includes at least one of painting, gluing, sealing, sanding, deburring, cutting, welding, riveting, marking, repairing, and adding a sticker; 13. The method of claim 12.

Images