Surface Analyst End Effector for Composite Bond Readiness Testing
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Solution Overview
Problem
There is a need for an automated system capable of inspecting and repairing composite parts, particularly composite rotorcraft blades, to ensure airworthiness and quality control during sustainment programs.
Innovation Solution
A joint autonomous repair verification and inspection system (JARVIS) utilizing an industrial robot equipped with a surface analyst end effector that conducts bond readiness tests by placing a liquid drop on the surface and capturing images, integrated with a control system to coordinate robot positioning and inspection processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If an automated inspection system is implemented for composite parts, then inspection efficiency and consistency are improved, but system complexity and initial cost increase
Solution Approach 1:
The inspection system is divided into modular end effectors that can be independently attached and detached from the industrial robot. Each end effector contains specialized inspection tools (liquid dispensing device, imaging system) as separate functional modules, allowing the system to maintain high productivity while managing complexity through modularity and reusable components
Solution Approach 2:
The industrial robot is designed with a universal tool interface that can accommodate multiple different end effectors for various inspection tasks. This multi-functionality allows a single robot system to perform diverse inspection operations (liquid drop application, imaging, analysis) without requiring separate dedicated systems for each function, thereby improving productivity while controlling overall system complexity
2Measurement precision
If multiple specialized end effectors are used for different inspection tasks, then inspection capability and precision are improved, but tool changing time and operational complexity increase
Solution Approach 1:
Multiple specialized end effectors are pre-configured with their respective inspection tools and calibrated before use. The industrial robot system maintains a library of pre-prepared end effectors that can be quickly swapped based on the specific inspection task required, reducing tool changing time while maintaining high measurement precision through pre-calibrated specialized tools
Solution Approach 2:
The tool interface between the industrial robot and end effectors is designed with dynamic quick-change capabilities, allowing rapid attachment and detachment of different end effectors. This dynamic tool changing mechanism minimizes downtime between different inspection tasks while preserving the specialized precision capabilities of each end effector through secure, repeatable positioning
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
The system provides automated inspection and repair capabilities, ensuring composite parts meet specifications and generating robust data for continuous improvement, while adapting to various composite parts and applications.
Implementation Method 1
the control unit directs the analyzer inspection head to place a drop of liquid onto a surface of a composite part
Data Source
AI summary
A surface analyst end effector for an automated inspection and repair system for composite parts. A surface analyst system and a tool changer are supported on a chassis. A control unit of the surface analyst system is configured to conduct a bond readiness test by which the control unit directs an inspection head to place a drop of liquid onto a surface of a composite part and directs the inspection head to capture an image of the drop on the surface. The slave tool changer releasably and operatively connects the end effector to an industrial robot such that the industrial robot can move the end effector along the composite part and the inspection and repair system can signal the surface analyst to conduct a bond readiness test. The surface analyst end effector is interchangeable with other end effectors of the inspection and repair system for performing inspection and repair methods.