Articulated Robot Sensor Positioning via Virtual Model Calibration
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Solution Overview
Problem
Existing methods for inspecting aircraft components face challenges due to spatial restrictions, requiring disassembly or removal of components, and articulated robot manipulator arms struggle with accurate, real-time positioning and orientation, leading to increased complexity and error.
Innovation Solution
A system that includes an articulated robotic system coupled with a positioning sensor and a control system to determine and track the position of a remote sensor relative to a target object, using a virtual representation and local coordinate measurement system for accurate calibration and movement tracking, allowing for precise placement of inspection sensors within limited access areas without disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If articulated robot manipulator arms are used to position inspection sensors in limited access areas, then access to components is improved without disassembly, but positioning accuracy and real-time tracking deteriorate due to joint flexibility and high degrees of freedom
Solution Approach 1:
The patent creates a virtual model (copy) of the aircraft structure that mirrors the physical structure. This virtual model is used to track and compensate for positioning errors of the robotic manipulator, allowing accurate sensor placement without requiring the physical manipulator to maintain perfect positioning accuracy throughout its flexible joints and segments
Solution Approach 2:
The system implements feedback by continuously tracking the position of the inspection sensor relative to the virtual model and using this information to compensate for positioning errors. The feedback loop corrects for errors introduced by joint flexibility and high degrees of freedom in the articulated manipulator arms
2Adaptability or versatility
If articulated robot manipulator arms with high degrees of freedom are used, then flexibility and access to complex geometries are improved, but error accumulation increases with each articulated segment
Solution Approach 1:
A virtual copy of the aircraft structure is created and used as a reference framework. This virtual model allows the system to track sensor position accurately without being affected by error accumulation in the physical manipulator chain, enabling flexible access to complex geometries while maintaining precision through virtual rather than physical positioning
3Reliability
If routine inspection of numerous aircraft components is performed, then inspection thoroughness is improved, but inspection time and cost increase
Solution Approach 1:
The system enables self-service inspection by allowing the inspection sensor to autonomously access and inspect components without requiring disassembly of occluding structures or removal of components. The articulated manipulator combined with virtual model tracking provides autonomous positioning capability that maintains thoroughness while improving efficiency
Solution Approach 2:
The virtual model of the aircraft structure is created beforehand, allowing for pre-planning of inspection paths and sensor positioning. This preliminary action enables more efficient inspection routing and reduces the time required for on-site inspection operations
Data Source
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AI summary
Methods and systems are provided for positioning a remote sensor within a target object. An articulated robotic system is coupled to the remote sensor. A positioning system determines a position of the target object to be inspected and determines a first position of the remote sensor. A control system calibrates a virtual representation of the target object with respect to the position of the target object, and tracks movement of the remote sensor relative to the target object.