Robotic Laser Scanner for Aircraft Part Measurement
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Solution Overview
Problem
Conventional automated manufacturing and assembly processes for aircraft parts face challenges in accurately measuring and installing components in confined spaces, often requiring human intervention that leads to less than optimal measurements and increased risk of error.
Innovation Solution
A robotic measurement system comprising multi-axis robots and omni-directional ground vehicles equipped with laser scanners, which can autonomously move within a facility-defined work zone to perform precise measurements of aircraft parts, generate surface-ready output files for manufacturing, and eliminate the need for shims by defining custom fillers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If human mechanics enter confined spaces to perform measurements, then measurements can be taken in difficult-to-reach areas, but measurement accuracy deteriorates and human error increases
Solution Approach 1:
The patent replaces human mechanics with an automated robotic system equipped with measurement sensors. The robot can autonomously navigate confined spaces and perform measurements without human intervention, eliminating human error while maintaining access to difficult-to-reach areas. The robotic system includes sensors for capturing geometric data and a control system for processing measurements.
Solution Approach 2:
The robotic measurement system is self-sufficient, autonomously navigating to measurement locations, capturing data, and processing results without requiring human operators to physically enter confined spaces. The system performs self-calibration and self-positioning using onboard sensors and navigation capabilities.
2Productivity
If conventional automated processes are used for manufacturing and assembly, then productivity increases, but adaptability to confined spaces and complex geometries deteriorates
Solution Approach 1:
The robotic system employs dynamic, multi-axis movement capabilities with adjustable degrees of freedom, allowing it to adapt its motion paths and positioning to accommodate confined spaces and complex part geometries. The system can dynamically reconfigure its measurement approach based on real-time environmental feedback.
Solution Approach 2:
The robotic measurement system is designed as a universal platform capable of performing multiple functions: navigation in confined spaces, geometric measurement, data processing, and integration with manufacturing systems. This multi-functional design allows a single system to handle diverse measurement tasks across different aircraft components.
3Manufacturing precision
If shims are used to account for manufacturing tolerances, then assembly fit can be achieved, but additional components and assembly complexity increase
Solution Approach 1:
The system performs preliminary measurement and characterization of manufacturing tolerances before assembly, capturing precise geometric data of all components. This advance measurement allows for digital modeling and simulation of fit scenarios, enabling tolerance compensation through software algorithms rather than physical shims.
Solution Approach 2:
The patent replaces the mechanical shim-based tolerance compensation method with a digital, software-driven approach. The robotic measurement system captures precise geometric data, and control system algorithms calculate optimal positioning and fit solutions, eliminating the need for physical shims and reducing assembly complexity.
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 accurate, autonomous, and precise measurement and installation of aircraft parts without human intervention, reducing errors and increasing productivity by allowing robotic assembly of custom parts within confined spaces.
Implementation Method 1
The robot measurement system also includes a laser scanner, which may be coupled to each of the multi-axis robots
Implementation Method 2
laser scanner...configured to move in at least two linear directions and one rotational direction
Data Source
AI summary
Systems and methods for robotic measurement of parts are provided. One system includes one or more omni-directional ground vehicles configured to move within a facility defined work zone to a setup calibration station and an engineering defined work space, wherein the engineering defined work space includes a part to be measured. The system also includes a multi-axis robot removably coupled to each of the omni-direction ground vehicles and configured to move a laser scanner, wherein the laser scanner of each of the multi-axis robots is configured to move in at least two linear directions and one rotational direction. The system further includes a processor configured to automatically generate a surface ready output file from measurement data received from the laser scanners, wherein the surface ready output file is configured to command a machine to manufacture a mating component to the part.