UAV Inspection and Repair of Large Structures With NDE Guidance
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Solution Overview
Problem
In-person inspections of large structures, such as aircraft and wind turbine blades, are time-consuming and costly, and existing technologies lack efficient methods for rapid inspection and repair, especially in cases of damage from impact or other incidents, leading to potential extended downtime and economic losses.
Innovation Solution
The use of unmanned aerial vehicles (UAVs) equipped with cameras, non-destructive evaluation (NDE) sensors, and repair tools for visual inspection, NDE, and repair of large composite structures, enabling remote assessment and rapid return to service by determining damage thresholds and performing necessary repairs autonomously or with minimal human intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If in-person human-based inspections are used for large structures, then detailed visual assessment can be performed, but the inspection process becomes time-consuming and costly
Solution Approach 1:
The patent replaces manual mechanical inspection processes with automated UAV-based inspection systems equipped with cameras and sensors. The UAV autonomously navigates to inspect structures, capturing images and data that are then analyzed by computer vision algorithms, eliminating the need for human inspectors to physically access and manually examine the structure.
Solution Approach 2:
The inspection system performs self-assessment through automated image capture and analysis. The UAV independently navigates, captures inspection data, and the onboard or ground-based computer system automatically processes the images to identify damage, reducing or eliminating the need for human inspectors to perform the actual assessment work.
2Reliability
If traditional repair methods are used for damaged structures, then comprehensive repair can be performed, but the repair process extends downtime and increases costs
Solution Approach 1:
The system performs preliminary damage assessment and repair planning through automated image analysis before actual repair begins. The computer system pre-processes inspection images to identify and characterize damage, allowing repair teams to prepare appropriate repair strategies and materials in advance, reducing overall repair time.
Solution Approach 2:
The patent replaces traditional manual repair assessment and execution with automated UAV-based inspection and computer-vision-driven repair planning. The system autonomously identifies damage locations and characteristics, enabling faster and more accurate repair decision-making compared to traditional human-based assessment methods.
3Measurement precision
If manual inspection methods are used for hard-to-reach areas, then thorough examination can be conducted, but safety risks and operational difficulty increase
Solution Approach 1:
The patent introduces a UAV as an intermediary between the inspector and hard-to-reach structures. The UAV flies to and inspects difficult-to-access areas such as tall wind turbine blades or remote infrastructure, capturing images and transmitting data back to operators without requiring human inspectors to physically access dangerous or inaccessible locations.
Solution Approach 2:
The system replaces manual human inspection in hazardous or inaccessible areas with automated UAV-based inspection. The UAV independently navigates to target structures, captures inspection images, and transmits data for analysis, eliminating the need for human inspectors to physically access dangerous environments.
Data Source
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AI summary
Methods (200) for performing repair operations using one or more unmanned aerial vehicles (UAVs). First, an unmanned aerial vehicle equipped with a camera (30) is flown to a position in a vicinity of an area of interest on a surface of a structure (18). Image data representing one or more images of the structure (18) in the area is acquired using the camera (30). Second, an unmanned aerial vehicle equipped with a non-destructive examination (NDE) sensor unit is flown until the NDE sensor unit is within measurement range of the structure (18) in the area of interest. Then NDE sensor data representing structural characteristics of the structure (18) in the area of interest is acquired. Third, an unmanned aerial vehicle equipped with a repair tool is moved to a location that places the repair tool in contact with the surface in the area of interest. Then the structure (18) in the area is repaired using the repair tool. Once the repair has been completed, a UAV equipped with a camera (30) or an NDE sensor unit may be used to determine whether the repaired structure (18) should be placed back in service or not.