Aircraft Stiffener Repair Using Point-Cloud Alignment
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Solution Overview
Problem
Current airplane structure stiffener repair methods are inefficient and imprecise due to manual machining, leading to uncontrollable repair processes and varying structural differences across aircraft, which complicates the repair of cracks and structural deformations.
Innovation Solution
A method utilizing point cloud data scanning, feature extraction, pre-alignment, and signed distance constraint alignment to generate an accurate machining path for precise repair, incorporating algorithms like RANSAC, SVD, and Prim to ensure efficient and accurate repair of airplane structure stiffeners.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual machining is adopted in the current repair process, then flexibility in handling different crack states is maintained, but machining precision and repair controllability deteriorate
Solution Approach 1:
The patent replaces manual mechanical machining with an automated machining system guided by point cloud data and optimization algorithms. The system uses measured data from 3D scanning to generate precise machining paths, substituting human-operated mechanical tools with computer-controlled automation that maintains adaptability to different crack states while significantly improving machining precision through algorithmic optimization.
Solution Approach 2:
The patent transforms the repair process from manual parameter estimation to data-driven parameter determination. By using point cloud data to calculate actual crack dimensions, structural deformations, and stiffener positions, the system dynamically adjusts machining parameters based on measured values rather than manual assessment, thereby improving precision while maintaining flexibility through adaptive parameter optimization.
2Device complexity
If manual machining is adopted in the current repair process, then equipment complexity is reduced, but repair time and productivity deteriorate
Solution Approach 1:
The patent implements preliminary actions by performing 3D scanning and point cloud data acquisition before the actual machining process. The system pre-calculates the optimal machining paths and repair parameters using optimization algorithms, preparing all necessary data and instructions in advance. This preliminary data processing and path planning enables the subsequent automated machining to proceed efficiently without delays, significantly reducing overall repair time despite the added measurement and computation steps.
3Ease of manufacture
If large-size stiffening scheme is adopted for production organization, then manufacturing standardization is improved, but repair accuracy for specific aircraft deteriorates
Solution Approach 1:
The patent applies local quality by transitioning from uniform large-size stiffening schemes to customized repair solutions tailored to each aircraft's specific crack conditions. The system uses point cloud data to measure the actual crack dimensions, positions, and structural deformations of each aircraft, then generates optimized machining paths and stiffener configurations specific to that aircraft's needs, thereby achieving high repair accuracy while maintaining manufacturing efficiency through standardized measurement and processing workflows.
Data Source
AI summary
The present invention relates to an airplane structure stiffener repair method based on measured data guidance. The method includes: respectively measuring point cloud data on a surface of a structure stiffener and point cloud data on a surface of a to-be-assembled position of a body; respectively extracting all assembly plane features in two point cloud data based on an RANSAC algorithm; performing pre-alignment according to the plane features; performing accurate alignment based on a signed distance constraint according to repair tolerance requirements; and calculating a repair allowance, and generating a machining path to serve as an accurate machining basis. According to the method in the present invention, a repair amount can be accurately calculated by virtue of an alignment algorithm of the signed distance constraint, and an envelope relationship during model matching is met.