Robotic Structural Repair System with Automated Tool Path Generation
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Solution Overview
Problem
Manual inspection of complex objects and structural repairs, such as those involving multi-layer laminate structures in aircraft, is time-consuming and labor-intensive, requiring skilled technicians and iterative adjustments, and lacks efficient automated solutions.
Innovation Solution
A robotic inspection system that automatically moves a scanner to collect data, determines surface profiles, and generates tool paths for inspection or repair, enabling automated and systematic inspection and repair processes, reducing human intervention and increasing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual inspection methods are used by trained operators, then inspection accuracy can be maintained, but inspection time and labor intensity increase significantly
Solution Approach 1:
The patent replaces manual mechanical inspection operations with an automated robotic system that uses optical scanners and computer vision to inspect objects. The robotic device automatically positions and moves inspection tools based on generated tool paths, eliminating the need for trained operators to manually position probes while maintaining inspection accuracy through automated image processing and defect detection algorithms.
2Productivity
If automated robotic inspection is implemented, then inspection speed and productivity improve, but the system requires complex setup and adjustment for objects without CAD data
Solution Approach 1:
The patent performs preliminary scanning of the object surface to create a point cloud model and determine the actual surface profile before generating the inspection tool path. This preliminary action captures the as-built geometry of the object, allowing the system to automatically adapt to variations without requiring manual adjustment or pre-existing CAD data, thereby simplifying the setup process while maintaining high productivity.
Solution Approach 2:
The patent creates a digital copy of the object's surface geometry through laser scanning, generating a point cloud that represents the actual surface profile. This digital copy is then used to generate accurate tool paths for inspection, eliminating the need for physical measurement fixtures or manual programming, and enabling the system to handle objects without pre-existing CAD models.
3Measurement precision
If iterative manual adjustment is performed to maintain inspection path accuracy, then inspection quality is preserved, but time consumption and operational complexity increase
Solution Approach 1:
The patent uses the scanned point cloud data as feedback to automatically generate and adjust the inspection tool path. The system compares the actual surface profile obtained from scanning with the intended inspection path, and automatically modifies the tool path to match the as-built geometry, eliminating the need for manual iterative adjustments while maintaining inspection accuracy and simplifying operation.
Data Source
AI summary
A method of repairing a structure is provided. The method includes inspecting the structure with a robotic device to identify a structural defect in the structure, generating a tool path for repairing the structural defect, and transmitting the tool path to the robotic device from a location remote from the robotic device.