Magnetic Coupling for Automated Wing Box Surface Scanning
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Solution Overview
Problem
Current methods for scanning the exterior surfaces of aircraft wing boxes require expensive gantry-based mechanisms, extensive training, and significant space, limiting flexibility and necessitating the horizontal stabilizer to be turned over for complete inspection.
Innovation Solution
The use of dynamically controlled magnetic coupling to couple external drive tractors with internal trailer vehicles within the wing box, allowing for scanning of both surface skins without turning the wing box, using modular and portable systems that include a payload platform with a movable maintenance tool.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a gantry-based mechanism is used to scan exterior surfaces, then scanning coverage is achieved, but device complexity and space requirements increase significantly
Solution Approach 1:
The system divides the scanning apparatus into separate functional modules: a mobile platform for transportation, a sensor array for inspection, and a coupling mechanism for attachment to the aircraft structure. This segmentation allows each component to be optimized independently and simplifies the overall system complexity compared to a monolithic gantry structure.
Solution Approach 2:
The patent replaces the traditional mechanical gantry system with a magnetically coupled mobile platform that travels along the aircraft skin. This substitution eliminates the need for complex mechanical support structures, reducing device complexity while maintaining scanning coverage capability.
2Adaptability or versatility
If a gantry-based mechanism is used, then scanning capability is provided, but ease of operation deteriorates due to extensive training requirements
Solution Approach 1:
The mobile platform incorporates automated navigation and positioning systems that enable the operator to simply guide the platform along the aircraft skin without requiring complex manual control. The system self-adjusts and maintains proper scanning parameters, reducing the skill level and training time needed compared to operating a gantry system.
3Adaptability or versatility
If a gantry-based mechanism is used, then exterior scanning is achieved, but productivity decreases due to the need to turn over the horizontal stabilizer
Solution Approach 1:
The mobile platform is designed with universal attachment capabilities that allow it to scan both the upper and lower surfaces of the aircraft skin without requiring the aircraft to be repositioned or turned over. The platform can be coupled to and decoupled from different locations along the skin, enabling continuous inspection of multiple surfaces in a single setup, thereby improving productivity.
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
Enables efficient and flexible scanning of wing box surface skins without the need for gantry mechanisms, allowing for setup in various locations and compatibility with interior surface scanning processes, reducing operational complexity and costs.
Implementation Method 1
dynamically controlled magnetic coupling to couple external drive tractors with internal trailer vehicles within the wing box
Data Source
AI summary
Systems and methods for automated maintenance of the top and bottom surfaces or skins of an integrally stiffened hollow structure (e.g., a horizontal stabilizer) using surface crawling vehicles. Each system uses dynamically controlled magnetic coupling to couple an external drive tractor to a pair of passive trailers disposed in the interior of the hollow structure on opposite sides of a vertical structural element. The external drive tractor is also coupled to an external maintenance tool, which the tractor pushes or pulls across the surface skin to perform a maintenance function. The systems allow maintenance operations to be performed on both surface skins without turning the hollow structure over. Each system is modular and can be transported to and easily set up in a building or factory.