UAV Composite Structure Repair With Robotic Multi-Tool Access
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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, especially when damage occurs and requires immediate attention.
Innovation Solution
Equipping unmanned aerial vehicles (UAVs) with multi-tool modules and robotic arms that can selectively place and operate various repair tools at inaccessible sites, allowing for sequential repair operations based on pre-planned strategies and inspection data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual labor with lifts or stands is used for repair, then the repair can be performed with simple equipment, but the repair time is excessive and operational delays are significant
Solution Approach 1:
The patent replaces manual mechanical repair systems (lifts, stands, harnesses) with an automated robotic system mounted on a UAV. The robotic arm with interchangeable tools performs repair operations autonomously, eliminating the need for human operators to physically access and manually repair the structure, thereby dramatically reducing repair time and operational delays
Solution Approach 2:
The repair system is designed to perform repairs autonomously without continuous human intervention. The UAV navigates to the damage location, the robotic arm positions and operates repair tools based on pre-programmed instructions or real-time guidance, and the system completes the entire repair sequence independently, enabling self-service repair capabilities
2Ease of manufacture
If manual repair equipment and personnel are deployed, then the repair can be performed with available resources, but the cost of access, labor, and equipment transport is excessive
Solution Approach 1:
The UAV-based repair system is designed as a multi-functional platform that can service various types of large structures (aircraft, wind turbine blades, bridges) using a single deployable unit. The robotic arm accepts interchangeable tools for different repair operations, and the UAV itself can navigate to different locations, providing universal repair capability that eliminates the need for multiple specialized repair crews and equipment sets
Solution Approach 2:
The patent extracts the repair functionality from fixed ground-based equipment and relocates it to a mobile UAV platform. This extraction allows the repair system to reach inaccessible or remote locations on large structures without requiring complex ground support equipment, lifts, or extensive logistics infrastructure at the repair site
3Reliability
If extensive manual intervention is used for repair, then the repair can be performed thoroughly, but the downtime before return to service is excessive
Solution Approach 1:
The system performs preliminary actions by pre-programming the repair sequence based on damage assessment data, pre-positioning the UAV near the damage location, and pre-loading appropriate repair tools. The robotic arm is pre-calibrated with the exact coordinates and parameters needed for the specific repair task, allowing the actual repair execution to proceed rapidly without setup delays while maintaining thoroughness
Solution Approach 2:
The automated robotic system enables continuous repair operations without the interruptions inherent in manual repair processes. The robotic arm can continuously apply repair materials, perform surface treatments, and execute multiple repair steps in an unbroken sequence, eliminating pauses for operator repositioning, tool changes, or safety briefings, thereby reducing downtime while ensuring complete and thorough repair
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.