Autonomous Aircraft Inspection with Non-Coplanar 2D LiDAR Arrays
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Solution Overview
Problem
Current automated inspection systems for aerostructures, particularly in aerospace manufacturing and MRO, are costly and complex, with existing solutions using expensive 3D scanners that may not provide adequate response times and pose health and safety issues, while manual or automated 2D scanners are inefficient and limited in range and accuracy.
Innovation Solution
An autonomous mobile robot system equipped with multiple non-coplanar and non-parallel two-dimensional LiDAR scanners that eliminate the need for dedicated 3D scanners, providing accurate 3D scanning capabilities with commercially available and cost-effective 2D LiDAR technology, allowing for efficient and wide-ranging inspection without the need for scanner movement during use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If expensive 3D scanners are used for aircraft inspection, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The system divides the 3D scanning function into multiple 2D LiDAR scanners arranged at different orientations. Each scanner captures data in a specific plane, and the processor combines these segmented 2D datasets to reconstruct the complete 3D geometry of the aircraft structure, replacing the need for a single complex 3D scanner
Solution Approach 2:
The system merges data from multiple 2D LiDAR scanners with different scanning plane orientations (horizontal, vertical, angled) to create a comprehensive 3D model. The processor integrates these multiple data sources to achieve complete surface coverage and accurate 3D reconstruction, combining simple 2D scanners into a powerful 3D inspection system
2Device complexity
If 2D scanners are used to reduce cost, then device complexity is reduced, but productivity and inspection speed decrease
Solution Approach 1:
The system uses multiple 2D scanners oriented in different spatial dimensions (horizontal planes, vertical planes, angled planes) to capture comprehensive data. By arranging scanners in non-coplanar orientations, the system achieves complete 3D coverage using only 2D scanning technology, eliminating the need for expensive 3D scanners while maintaining high inspection speed
Solution Approach 2:
The mobile robot platform provides multi-functionality by integrating navigation, positioning, and data processing capabilities. The system can inspect various aircraft structures (wings, fuselage, tail sections) using the same hardware configuration, making it universally applicable across different inspection scenarios without requiring specialized equipment
3Adaptability or versatility
If handheld 2D scanners are used for flexibility, then adaptability is improved, but measurement precision and response time worsen
Solution Approach 1:
The system employs a mobile robot platform that can dynamically navigate to different positions and orientations around the aircraft structure. The scanners are mounted on the moving platform, allowing the system to adapt to various inspection locations while maintaining fixed, stable scanning positions during data capture, combining flexibility with precision
Solution Approach 2:
The system replaces manual handheld operation with an autonomous mobile robot platform. The robot autonomously navigates to predetermined positions and maintains stable scanning operations, eliminating the precision losses associated with manual handling while retaining the adaptability to inspect different aircraft components
4Productivity
If automated systems are implemented in aerospace manufacturing, then productivity is improved, but device complexity and implementation difficulty increase
Solution Approach 1:
The automated inspection system is segmented into independent functional modules: mobile robot platform, multiple 2D LiDAR scanners, navigation system, and data processing unit. Each module performs a specific function, making the overall system easier to implement, maintain, and upgrade compared to integrated automated systems
Solution Approach 2:
The system uses multiple inexpensive 2D LiDAR scanners instead of expensive 3D scanners. While individual 2D scanners are simpler and more affordable, their combined use through data fusion achieves equivalent or superior inspection capabilities, reducing overall system cost and complexity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution reduces costs and complexity, enabling faster and more accurate three-dimensional scanning with improved data quality, capable of scanning large items with high precision, such as aircraft structures, while reducing scanning time by up to 80% compared to conventional methods.
Implementation Method 1
The autonomous mobile robot includes a multiple two-dimensional LiDAR (light directional and ranging) scanners
Data Source
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Figure 3A~3B
AI summary
Disclosed is an autonomous inspection system comprising at least one autonomous mobile robot. The robot has a plurality of two-dimensional LiDAR scanners each scanner having a two-dimensional scanning plane. The plurality of scanners are mounted on the autonomous mobile robot with scanning plane orientations which are non-coplanar. A processor comprises an input to receive point data from the plurality of LiDAR arrays and an output to provide inspection data. The processor is configured to compile the point data from the plurality of LiDAR scanners into three-dimensional plot of the surrounding of the autonomous mobile robot and identify the dimensions and profile of articles within the three-dimensional plot. A method of inspection is also disclosed.