UAV Laser Positioning for Accurate Structural Inspection Scale

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Solution Overview

Problem

Unmanned aerial vehicles (UAVs) lack the ability to accurately determine distances between points on an object and provide a relative scale during non-destructive inspections, limiting their effectiveness in structural inspections.

Innovation Solution

Equipping UAVs with two or more laser pointers or laser range meters, combined with a digital video camera, to calculate distance to the target, reference scale, and orientation angles, enabling accurate measurement and display of scale indicators on captured images.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If GPS tracking is used for location estimation, then the UAV can provide rough location data for visual inspection, but the accuracy is insufficient for non-destructive inspection methods requiring precise distance measurements

Engineering Contradiction:
Improvedistance measurement accuracyVSAvoidpositioning system complexity
Core Design Contradiction:
Measurement precisionVSDevice complexity

Solution Approach 1:

The patent introduces laser pointers as an intermediary tool that projects reference points onto the target structure. These laser spots serve as mediators between the UAV's positioning system and the structure being inspected, enabling accurate distance and scale calculations without requiring complex high-precision GPS or other sophisticated positioning equipment.

Inventive Principle:
Principle #24Intermediary (Mediator)

Solution Approach 2:

The laser pointers create optical copies (spots) of reference points on the structure surface. By capturing images of these laser spots and calculating their positions relative to the structure features, the system obtains accurate dimensional information without directly measuring the structure itself, thus simplifying the positioning requirements.

Inventive Principle:
Principle #26Copying

2Measurement precision

If depth cameras are used to measure distance to the target object, then distance information can be obtained, but the cameras saturate in bright light and have limited range

Engineering Contradiction:
Improvedistance measurement capabilityVSAvoidoperating environment adaptability
Core Design Contradiction:
Measurement precisionVSAdaptability or versatility

Solution Approach 1:

The patent replaces the depth camera's active sensing mechanism with a passive optical measurement approach. Instead of using depth cameras that emit and detect light to measure distance, the system uses laser pointers to create reference marks and standard video cameras to capture images, calculating distances through geometric relationships and image processing. This substitution eliminates saturation issues and extends operational range.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

3Measurement precision

If a spinning laser scanner is used to provide point cloud with distance data, then comprehensive distance information is obtained, but the methodology acquires more data than needed and increases system complexity

Engineering Contradiction:
Improvedistance data accuracyVSAvoidscanning system complexity
Core Design Contradiction:
Measurement precisionVSDevice complexity

Solution Approach 1:

The patent extracts only the essential function needed for distance measurement from the complex laser scanner system. Instead of using a spinning laser scanner that captures comprehensive point cloud data, the invention uses stationary laser pointers that simply project reference spots, combined with image processing to extract distance information. This extracts the core measurement capability while eliminating unnecessary complexity.

Inventive Principle:
Principle #2Taking out (Extraction)

Solution Approach 2:

The system uses partial action by employing only the minimal necessary components (laser pointers and standard video camera) to achieve distance measurement, rather than implementing the full capability of a spinning laser scanner. The laser pointers provide just enough reference information for scale calculation without acquiring excessive data.

Inventive Principle:
Principle #16Partial or excessive action

4Measurement precision

If image processing application is used to identify objects in the scene, then scale information can be obtained, but it only works if information about objects is known and the software is capable of properly identifying them

Engineering Contradiction:
Improvescale information accuracyVSAvoidobject recognition flexibility
Core Design Contradiction:
Measurement precisionVSAdaptability or versatility

Solution Approach 1:

The patent applies preliminary action by pre-projecting laser reference points onto the structure before capturing images. These laser spots serve as known reference markers that provide scale information without requiring the system to identify or recognize specific structural features. The scale calculation is based on the known geometry of the laser pointer arrangement and the captured positions of the laser spots in the image.

Inventive Principle:
Principle #10Preliminary action

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

Enables precise determination of distances and scales on inspected structures, enhancing the usability and accuracy of UAV-based non-destructive inspection methods.

Implementation Method 1

two or more laser pointers and a digital video camera are used to acquire the information to compute: distance to the target, a reference scale for the view of the target

Methodology Applied
Scientific EffectLaser: Laser

Implementation Method 2

two or more laser pointers and a digital video camera are used to acquire the information to compute: distance to the target

Methodology Applied
Scientific EffectPhotography: Photography

Data Source

PatentEP3460392B1Positioning system for aerial non-destructive inspection
Publication Date: 2025.08.06 THE BOEING CO
  • EP3460392B1 patent drawingFigure 1
  • EP3460392B1 patent drawingFigure 2
  • EP3460392B1 patent drawingFigure 3

AI summary

Systems and methods for measuring the distance to a target object (102) and acquiring scale and point-to-point distance information for that target object in an environment using a remotely operated flying platform, such as an unmanned aerial vehicle (UAV, 20). The system uses on-board sensors (132, 138, 166) and processing techniques to provide discrete or continuous measurements of the distances between points on the target object or the scale of the target object. The addition of on-board three-dimensional measurement capabilities to UAVs (or other flying platforms) allows the collection of distance data. Having this capability enables these systems to acquire distances between points on a single object, such as determining the true scale factors of items in images captured by the UAV, in the course of performing metrology-related tasks.