UAV Modular Repair Tools for Inaccessible Structure Damage
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Solution Overview
Problem
Current methods for in-service repair of large structures, such as aircraft and wind turbine blades, are time-consuming, expensive, and pose safety risks due to the need for manual labor and access challenges, especially when damage occurs, leading to operational delays and significant economic impacts.
Innovation Solution
The use of unmanned aerial vehicles (UAVs) equipped with modular repair tools, including spray-on repair modules, tape applicators, and liquid-filled capsule launchers, to rapidly apply sealants or coatings to damaged areas, enabling remote and automated repair operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual labor with lifts or stands is used for repair, then repair can be performed with simple equipment, but repair time increases and operational delays occur
Solution Approach 1:
The patent replaces manual mechanical repair systems (lifts, stands, hand tools) with an automated robotic system equipped with specialized end effectors. The robot can autonomously perform inspection, preparation, and repair operations on aircraft surfaces, eliminating the need for manual labor and associated equipment setup time.
Solution Approach 2:
The system enables self-service repair through autonomous robotic operations. The robot independently navigates to damage locations, inspects the area, prepares the surface, and applies repair materials without continuous human intervention, allowing rapid return to service.
2Reliability
If access equipment like lifts or stands is used, then repair can be performed, but safety risks increase due to exposure to potential safety conditions
Solution Approach 1:
The patent replaces human operators working at heights or in hazardous positions with a robotic system. The robot can safely access and repair difficult-to-reach areas of the aircraft without exposing human workers to safety risks associated with lifts, stands, and harnesses.
3Ease of manufacture
If manual repair methods are used, then equipment cost is reduced, but repair time and labor costs increase significantly
Solution Approach 1:
The robotic system is designed with universal end effectors that can perform multiple functions: inspection, surface preparation, material application, and curing. This multi-functionality consolidates what would require multiple separate manual operations and equipment into a single integrated system.
Solution Approach 2:
The system uses modular end effectors that can be exchanged based on the specific repair task. Each effector is a self-contained module with its own actuators and tools, allowing the robot to efficiently switch between different repair operations without complex reconfiguration.
4Reliability
If extensive repair is needed, then flight may be cancelled, but this causes significant economic impact
Solution Approach 1:
The system performs preliminary inspection and assessment using onboard sensors and imaging systems before committing to a repair decision. This allows operators to evaluate damage extent and determine the most appropriate repair strategy, potentially avoiding unnecessary flight cancellations.
Solution Approach 2:
The robotic system can adjust repair parameters such as material selection, application thickness, and curing method based on the specific damage characteristics. This adaptability allows the system to provide adequate structural repair while minimizing repair time and enabling faster return to service.
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
This approach reduces repair time and costs, minimizes safety risks, and allows for quick return to service by enabling efficient and precise application of materials to inaccessible areas, thereby reducing downtime and economic losses.
Implementation Method 1
a pressurized storage canister containing a sealant or coating material in a liquid state; a valve in fluid communication with the pressurized storage canister; and a spray nozzle in fluid communication with the valve
Data Source
AI summary
Methods and apparatus for performing repair operations using an unmanned aerial vehicle. 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. In accordance with various embodiments disclosed below, the unmanned aerial vehicle may be equipped with an easily attachable/removable module that includes an additive repair tool. The additive repair tool is configured to add material to a body of material. For example, the additive repair tool may be configured to apply a sealant or other coating material in liquid form to a damage site on a surface of a structure or object (e.g., by spraying liquid or launching liquid-filled capsules onto the surface). In alternative embodiments, the additive repair tool is configured to adhere a tape to the damage site.