Aircraft Canopy Coating Removal by Robotic Laser Ablation
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Solution Overview
Problem
The manual removal of transparent coatings from aircraft canopies is labor-intensive and time-consuming, requiring many man-hours, and often damages the underlying structures.
Innovation Solution
A system comprising a robotic arm with a touch probe and laser head, controlled by a computer system, which uses laser ablation to remove the interface layer between the transparent outer layer and the aircraft canopy, allowing for precise removal without damaging the underlying structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual processes are used to remove transparent coatings, then the process is simple to implement, but it is labor-intensive and time-consuming
Solution Approach 1:
The patent replaces manual mechanical removal processes with an automated laser ablation system. The laser head delivers precisely controlled laser energy to ablate the interface layer, eliminating the need for manual scraping or chemical treatments. This substitution dramatically increases removal speed while maintaining simplicity through automated control.
Solution Approach 2:
The system uses a touch probe to automatically map the canopy surface geometry before laser ablation. The probe collects spatial data about the curved surface, and the computer system uses this information to automatically adjust laser positioning and parameters. This self-measuring and self-adjusting capability eliminates the need for complex manual measurement and setup procedures.
2Reliability
If manual processes are used to remove transparent coatings, then equipment requirements are minimal, but the process damages the underlying structures
Solution Approach 1:
The patent replaces mechanical scraping or chemical etching with laser ablation. The laser energy is precisely controlled to ablate only the interface layer between the transparent coating and the canopy, leaving the underlying structure intact. This non-contact thermal process eliminates mechanical stress and chemical damage that occur with traditional methods.
Solution Approach 2:
The laser system delivers energy with high spatial precision, targeting only the specific interface layer that needs removal. The computer-controlled laser head adjusts its position and parameters based on touch probe measurements, ensuring that energy is applied only where needed. This localized treatment protects surrounding areas and the underlying canopy structure from damage.
3Productivity
If automated laser ablation is used, then coating removal speed increases, but the system complexity increases
Solution Approach 1:
The patent combines multiple functions into an integrated robotic arm system. The robotic arm houses both the touch probe and laser head, allowing sequential operations (measurement then ablation) without repositioning. The rotisserie mechanism is integrated with the robotic arm control system, enabling coordinated rotation and positioning. This merging reduces the number of separate devices and simplifies the overall system architecture.
Solution Approach 2:
The system automatically maps the canopy surface using the touch probe, then uses this geometric data to self-adjust laser positioning and parameters. The computer system autonomously controls the robotic arm movements, laser power, and rotisserie rotation based on real-time feedback. This self-control capability eliminates the need for complex manual programming and monitoring, simplifying operation despite the automated functions.
4Loss of time
If automated laser ablation is used, then labor requirements decrease, but the initial investment and system complexity increase
Solution Approach 1:
The patent replaces manual labor with an automated laser ablation system controlled by a computer. The robotic arm automatically positions and operates the laser head, while the rotisserie mechanism rotates the canopy for access to all surfaces. This full automation eliminates the need for manual scraping operations, reducing coating removal time from many hours to minutes, despite the higher initial system 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
Automatically removes transparent coatings quickly and efficiently, reducing time and labor costs while ensuring the underlying structures are not damaged, thereby facilitating faster replacement of aircraft canopy performance layers.
Implementation Method 1
ablate, using a plurality of predetermined parameters and the laser head of the robotic arm, an interface layer located between the transparent outer layer and the aircraft canopy
Data Source
AI summary
A system includes a robotic arm, a rotisserie control linkage, and a computer system. The robotic arm includes a touch probe and laser head. The rotisserie control linkage is configured to couple to a transport cart. The computer system is communicatively coupled to the robotic arm and the rotisserie control linkage and is configured to control the system to probe, using the touch probe of the robotic arm, a transparent outer layer of an aircraft canopy located on the transport cart in order to determine surface measurements of the aircraft canopy. The computer system also controls the system to ablate, using a plurality of predetermined parameters and the laser head of the robotic arm, an interface layer located between the transparent outer layer and the aircraft canopy, wherein movements of the robotic arm during the ablation are based on the surface measurements.