UAV Composite Structure Repair With Robotic Multi-Tool Modules
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Solution Overview
Problem
In-service repair of large composite structures such as aircraft and wind turbine blades is time-consuming and costly due to the need for manual labor, leading to excessive operational delays and economic losses when damage occurs, especially in inaccessible areas.
Innovation Solution
Equipping unmanned aerial vehicles (UAVs) with multi-tool modules and robotic arms that can select and place various tools at repair sites, allowing for automated and sequential repair operations based on pre-planned procedures and inspection results.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual labor with lifts and stands is used for repair, then repair can be performed with simple equipment, but repair time and operational delays increase significantly
Solution Approach 1:
The patent replaces manual mechanical repair systems (lifts, stands, hand tools) with an automated robotic system that includes a mobile platform, robotic arm, and specialized repair tools. This substitution enables automated material removal, surface preparation, and repair application, dramatically reducing repair time while eliminating the need for complex manual support equipment.
Solution Approach 2:
The robotic repair system is self-contained and autonomous, carrying all necessary tools, materials, and control systems on its mobile platform. The system can independently navigate to the repair location, position the robotic arm, execute repair operations, and return without human intervention, enabling rapid repairs even in remote or inaccessible locations.
2Reliability
If extensive manual labor and equipment are used for repair, then thorough repair can be achieved, but repair costs and economic impact increase
Solution Approach 1:
The mobile robotic platform is designed as a universal repair system that can handle multiple repair operations (material removal, surface preparation, coating application, curing) with a single integrated platform. The robotic arm can interchange between different tools, and the system can repair various types of structures (aircraft fuselages, wind turbine blades, bridges) making the complex equipment applicable to diverse repair scenarios.
Solution Approach 2:
The robotic arm acts as an intermediary between the mobile platform and the repair site, providing precise positioning and control of repair tools. This intermediary mechanism enables the system to achieve high repair quality through automated precision operations while keeping the overall equipment design modular and manageable rather than requiring direct human manipulation of complex equipment.
3Productivity
If automated UAV-based repair is implemented, then repair speed and efficiency improve, but system complexity and initial cost increase
Solution Approach 1:
The repair system is segmented into distinct functional modules: a mobile platform for navigation and positioning, a robotic arm for tool manipulation, interchangeable repair tools for different operations, and an onboard control system. This segmentation allows each component to be optimized independently and facilitates maintenance and upgrades, making the complex system more manageable despite its advanced capabilities.
Data Source
AI summary
Methods and apparatus for performing repair operations using an unmanned aerial vehicle (UAV). The methods are enabled by equipping the UAV with tools for rapidly repairing a large structure or object (e.g., an aircraft or a wind turbine blade) that is not easily accessible to maintenance personnel. A plurality of tools are available for robotic selection and placement at the repair site. The tools are designed to perform respective repair operations in sequence in accordance with a specified repair plan, which plan may take into account the results of a previously performed UAV-enabled inspection.