Flexible Track System for 3D Scanning Curved Surfaces

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Solution Overview

Problem

Conventional scanning systems for curved surfaces are time-consuming and costly due to manual adjustments in orientation and focal distance, which hinder efficient generation of consistent 3D point clouds.

Innovation Solution

A flexible track system with a robotic device that includes a circumferential carriage and transversal carriage, mounted on a rail that conforms to the curvature of the surface, allowing automated scanning without manual adjustments, using a worm gear drive motor and cross slide motor for precise movement along the rail.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If manual scanning with hand-held scanner is used, then operator can adjust orientation and focal distance, but scanning process is time-consuming and increases manufacturing cost

Engineering Contradiction:

Improvemanual adjustment capabilityVSAvoidscanning speed

Core Design Contradiction:

Ease of operationVSProductivity

Solution Approach 1:

The robotic device automatically adjusts its own orientation and position along the rail system, eliminating the need for manual operator intervention. The system self-regulates scanning parameters through automated control mechanisms, thereby increasing productivity while maintaining operational precision.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

Manual mechanical adjustment by operator is replaced with automated robotic mechanisms. The robotic device uses motorized actuators and control systems to adjust orientation and focal distance, substituting human mechanical operations with automated mechanical systems to improve scanning speed.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Measurement precision

If manual scanning process is used, then operator can control scanning parameters, but assembly time and manufacturing cost increase

Engineering Contradiction:

Improvescanning accuracyVSAvoidassembly time

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The rail system is pre-configured with predetermined orientations and positions that ensure correct scanning angles and focal distances before the robotic device begins operation. This preliminary setup eliminates the need for time-consuming manual adjustments during the scanning process while maintaining measurement precision.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system automatically changes scanning parameters such as orientation angles and focal distance through automated robotic mechanisms. These parameter changes are executed precisely and rapidly, maintaining scanning accuracy while significantly reducing the time required compared to manual parameter adjustment.

Inventive Principle:

Principle #35Parameter changes

3Extent of automation

If automated robotic device is introduced, then scanning process is automated and consistent, but device complexity increases

Engineering Contradiction:

Improveautomation levelVSAvoidsystem complexity

Core Design Contradiction:

Extent of automationVSDevice complexity

Solution Approach 1:

The robotic device is designed with multi-functional capabilities, integrating scanning, positioning, and orientation adjustment into a single automated system. This universal design reduces overall system complexity by consolidating multiple functions into one device rather than requiring separate systems for each function.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The rail system is designed to conform to the curved surface geometry, allowing the robotic device to maintain consistent orientation and focal distance automatically as it moves along the curved path. This curved rail design simplifies the automation complexity by providing natural geometric guidance rather than requiring complex active control mechanisms.

Inventive Principle:

Principle #14Spheroidality (Curvature)

Data Source

PatentUS11505217B2Flexible track system and robotic device for three-dimensional scanning of curved surfaces

Publication Date: 2022.11.22 THE BOEING CO

AI summary

An example robotic device includes: a circumferential carriage configured to drive the robotic device along a rail configured to be mounted to a curved surface, the circumferential carriage comprising: (i) a frame base, (ii) a frame mounted to the frame base, (iii) one or more wheels coupled to the frame base and configured to engage with the rail, (iv) a worm gear arrangement, and (v) a main drive gear coupled to the worm gear arrangement and configured to engage with a rack disposed on the rail; and a transversal carriage comprising: (i) a cross slide slidably mounted to the frame, (ii) a transversal rack coupled to the cross slide, (iii) a cross slide motor mounted to the circumferential carriage, and (iv) a cross slide drive gear coupled to the cross slide motor and having gear teeth engaging with respective teeth of the transversal rack.