Multi-Robot Defect Repair via Metal Powder Sintering
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Solution Overview
Problem
Existing methods for repairing internal defects in structures often require dismantling, which is costly, time-consuming, and can introduce additional defects.
Innovation Solution
A method using a multi-robot system with small-scale mobile robots that detect defects, generate repair plans, and deploy metal powder to fill and fuse cracks and cavities without dismantling the structure, employing swarm robotics and AI for precise material placement and sintering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If the structure is completely dismantled to access internal defects, then the defect can be repaired, but the repair process becomes costly and time-consuming
Solution Approach 1:
The invention uses multiple small-scale mobile robots that can independently navigate to different locations within the structure to repair defects. The repair process is segmented into multiple steps: detection, staging area creation, material delivery, and repair execution, allowing parallel operations that reduce overall time and avoid complete dismantling.
Solution Approach 2:
The patent implements a nested structure where small-scale robots operate within larger structural components. A staging area is created within the structure to hold repair materials, and multiple robots nest within the structure's passages to deliver materials and perform repairs, eliminating the need for complete external dismantling.
2Ease of repair
If the structure is completely dismantled to access internal defects, then the defect can be repaired, but additional defects may be introduced
Solution Approach 1:
The repair system uses multiple specialized robots that can access defects through existing structure passages without requiring complete dismantling. This segmented approach allows repair while preserving structural integrity by working through natural access points rather than creating new openings.
Solution Approach 2:
The system enables self-service repair where robots autonomously navigate to defects, deliver materials, and perform repairs without human intervention or structure dismantling. The structure repairs itself through automated systems that work within existing architectural constraints, maintaining reliability.
3Ease of manufacture
If traditional repair methods are used, then simple defects can be fixed, but complex geometry repairs are not possible
Solution Approach 1:
The patent employs dynamically controllable robots with adjustable movements and orientations that can adapt to complex geometric defects. The robots can change their configuration and approach angles to access irregularly shaped defects, and the repair material delivery system can adapt to various defect geometries, enabling repairs that were previously impossible.
Solution Approach 2:
The system changes parameters such as robot position, orientation, material flow rate, and deposition patterns to accommodate complex defect geometries. By dynamically adjusting these parameters, the system can repair defects with varying shapes, sizes, and locations that traditional fixed-method approaches cannot handle.
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 non-destructive repair of internal defects by using small-scale robots to access and fill defects with metal powder, reducing costs and minimizing structural damage, while allowing for complex geometry repairs.
Implementation Method 1
fusing the repair material with the located target area to fix the detected defect
Data Source
AI summary
A method, computer system, and a computer program product for defect repair is provided. The present invention may include detecting a defect in a structure. The present invention may include generating a repair plan to fix the defect using a plurality of work robots. The present invention may include programming the plurality of work robots with task assignments. The present invention may include deploying the programmed plurality of work robots to a staging area proximate to the defect. The present invention may include locating a target area of the defect using the programmed plurality of work robots. The present invention may include placing a repair material at the staging area. The present invention may include filling the located target area with the repair material using the programmed plurality of work robots. The present invention may include fusing the repair material with the located target area to fix the detected defect.