Remote Aircraft Test Automation With Robotic Actuation and Vision
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Solution Overview
Problem
Current Functional Test Procedures (FTP) for aircraft systems require significant manual operations, leading to increased time, physical strain, and human error due to the need for operators to interpret instructions and perform manual tasks, which negatively impacts operator health and safety.
Innovation Solution
A system comprising an actuation unit, a visual recognition unit, and a test unit that remotely interfaces with the aircraft system to perform tests automatically, using a robotic arm and image acquisition devices with graphic recognition capabilities to simulate operations, measure signals, and validate test results in real-time, reducing the need for manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual operations are used to perform FTP instructions, then operators can interpret and execute test procedures, but the time required increases and operator safety is compromised due to frequent travel to and from the aircraft
Solution Approach 1:
The system enables self-service testing by automating the FTP execution process. The actuation unit autonomously performs test operations based on FTP instructions without requiring continuous operator intervention. The system self-manages the test procedure by automatically navigating to test locations, executing test actions, and recording results, thereby eliminating the need for operators to physically travel between the aircraft and test equipment.
Solution Approach 2:
The patent replaces the mechanical system of manual operator actions with an automated actuation unit. The actuation unit uses robotic mechanisms to perform physical test operations such as connecting/disconnecting test equipment, manipulating aircraft systems, and positioning test devices. This substitution eliminates the need for operators to physically move around the aircraft while maintaining the ability to execute complex test procedures.
2Reliability
If operators manually interpret and perform FTP instructions, then test procedures can be executed, but human error increases and physical strain on operators worsens
Solution Approach 1:
The system performs self-service by automatically interpreting FTP instructions and executing corresponding test actions without human intervention. The control system parses FTP procedure text, identifies required test operations, and autonomously executes them through the actuation unit. This eliminates human interpretation errors while maintaining operational simplicity, as the system handles the complex task of translating test procedures into physical actions.
Solution Approach 2:
The patent replaces manual operator interpretation and execution with an automated control system and actuation unit. The control system uses software to parse and interpret FTP instructions, while the actuation unit uses robotic mechanisms to execute test actions. This substitution eliminates human error in interpretation and execution while reducing operator workload to merely initiating and monitoring the automated process.
3Productivity
If automated actuation is used to perform test operations, then operator safety improves and time is reduced, but system complexity increases due to integration of robotic components
Solution Approach 1:
The actuation unit is designed as a universal, multi-functional device capable of performing various test operations across different aircraft systems and locations. It can connect and disconnect test equipment, manipulate different aircraft components, and position itself at multiple test points. This multi-functionality reduces the need for multiple specialized devices, thereby managing system complexity while maintaining high productivity across diverse testing scenarios.
Solution Approach 2:
The control system acts as an intermediary between the FTP instructions and the actuation unit. It translates high-level test procedures into specific actuation commands, manages the coordination between multiple components, and handles the integration complexity. This intermediary layer simplifies the overall system architecture by providing a clear separation between the intelligence (control software) and the physical execution (actuation unit), making the system more manageable despite its complexity.
4Measurement precision
If visual recognition is used to monitor test operations in real-time, then test validation improves, but system complexity increases due to image processing requirements
Solution Approach 1:
The visual recognition system acts as an intermediary between the physical test operations and the validation process. It captures images of test operations, processes them to extract relevant information, and compares the results against expected outcomes. This intermediary layer provides automated validation without requiring complex manual inspection procedures, improving measurement precision while managing complexity through specialized image processing algorithms.
Solution Approach 2:
The patent replaces manual visual inspection with an automated visual recognition system. Instead of operators visually monitoring test operations, the system uses cameras and image processing algorithms to automatically capture, analyze, and validate test results. This substitution improves measurement precision by eliminating human subjectivity and fatigue, while the complexity of image processing is managed through dedicated software modules that specialize in this function.
Data Source
AI summary
A system and method for performing a test procedure on a system under test are provided. An actuation unit operatively coupled to the system under test is configured to perform at least one operation thereon. A visual recognition unit is configured to capture at least one image of the system under test in real-time. A test unit remotely interfaced with the system under test is configured to perform the test procedure. Using the test unit, the test procedure is retrieved from the memory, at least one control signal is output to the actuation unit for causing the at least one operation to be performed in real-time for testing the system under test in accordance with the one or more test instructions, and the at least one image of the system under test is monitored as the at least one operation is performed for validating the test procedure in real-time.