Automated Fuselage Corrosion Inhibitor Spraying via AGV
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Solution Overview
Problem
The manual application of corrosion inhibitors in aircraft fuselage interiors is hazardous, inefficient, and prone to errors due to confined spaces, lack of visibility, and high temperatures, leading to issues like puddling, inadequate application, bare surfaces, and excess product application, which result in longer cycle times, increased labor costs, and reduced quality.
Innovation Solution
An automated system using an automated guided vehicle (AGV) with a robotic spray system and deployment guide wheels, supported by a carriage assembly and sealing door assembly, allows for fully automated application of corrosion inhibitors within the fuselage, ensuring precise and consistent coverage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual spray application is used by technicians, then flexibility and adaptability are maintained, but safety risks increase due to confined spaces, high temperatures, and lack of visibility
Solution Approach 1:
An automated robotic spray system acts as an intermediary between the operator and the hazardous environment. The robot enters the confined fuselage space through a door assembly, allowing technicians to remain outside the hazardous zone while the robot performs the corrosive inhibitor application, thereby eliminating direct human exposure to high temperatures, poor visibility, and chemical hazards
Solution Approach 2:
The patent replaces the manual mechanical spray operation with an automated robotic system. The robotic arm with spray gun is controlled by a computer system that manages positioning, spray patterns, and application parameters, substituting human physical operation with automated mechanical control to eliminate safety risks associated with manual work in confined spaces
2Adaptability or versatility
If manual spray application is used, then human judgment and adaptability are utilized, but manufacturing precision deteriorates due to puddling, bare surfaces, and inconsistent coverage
Solution Approach 1:
The automated system incorporates sensors and control systems that provide real-time feedback on spray application. The computer-controlled robotic system monitors spray patterns, fluid application rates, and surface coverage, automatically adjusting parameters to maintain consistent coating quality and prevent defects such as puddling or bare spots that occur with manual application
Solution Approach 2:
The fuselage interior surface is divided into multiple predefined zones or segments that are systematically addressed by the robotic system. The computer control breaks down the complex spraying task into manageable sections with specific spray patterns and parameters for each zone, ensuring uniform coverage across the entire surface while maintaining adaptability to different geometric features
3Area of stationary object
If multiple technicians are deployed for manual application, then coverage capability is improved, but productivity decreases due to long cycle times and rework requirements
Solution Approach 1:
The robotic spray system is designed as a universal platform capable of handling the entire fuselage interior coating operation. A single robotic system with programmable control can cover the complete surface area that previously required multiple technicians, integrating masking, spraying, and inspection functions into one automated workflow, thereby reducing cycle time while maintaining full coverage capability
Solution Approach 2:
The automated robotic system operates continuously without interruption, moving systematically through the fuselage interior and applying corrosive inhibitor without the breaks, repositioning delays, or coordination interruptions that occur with manual multi-technician operations. The robot maintains continuous spray application with optimized travel paths, eliminating idle time and maximizing productive action throughout the entire coating process
4Ease of operation
If manual application is performed, then labor flexibility is maintained, but loss of time increases due to precautionary breaks and rework
Solution Approach 1:
The robotic system is self-sufficient in performing the coating operation without requiring human intervention during the spraying process. The automated system manages its own operation including navigation, spray control, and parameter adjustment, eliminating the need for technician breaks due to heat exposure or chemical sensitivity, thereby reducing time loss while maintaining operational flexibility through programmable control
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
The automated system enhances safety, reduces cycle times, improves product quality, and increases productivity by ensuring thorough and consistent application of corrosion inhibitors, thereby reducing aircraft weight and environmental impact.
Implementation Method 1
a robotic spray system... to spray a treatment fluid onto interior surfaces of the fuselage
Data Source
AI summary
Methods are provided by which a treatment fluid (e.g., a liquid corrosion inhibitor) may be applied onto the interior surfaces of an aircraft fuselage. The methods include (a) deploying an automated guided vehicle (AGV) comprising a carriage assembly and a robotic spray system carried by the carriage assembly within the interior of the fuselage, (b) closing the cabin door opening of the fuselage with the AGV positioned therewithin, and (c) operating the AGV so as to move within the fuselage along a longitudinal axis thereof to spray the treatment fluid onto the surfaces thereof.