UAV Non-Destructive Inspection System with Releasable Sensor Mounting

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Solution Overview

Problem

Current methods for non-destructive inspection of structures, such as composite materials and infrastructure, are limited by the need for human intervention, which is costly, time-consuming, and poses safety risks due to environmental hazards, and existing remote inspection technologies like human-piloted helicopters and static cameras are inefficient and inaccurate.

Innovation Solution

A non-destructive inspection system utilizing an unmanned aerial vehicle (UAV) equipped with various sensors and a mounting mechanism that allows secure attachment to structures using magnetic, vacuum, electrostatic, adhesive, or gripper-based systems, enabling precise data collection and navigation with off-board tracking, and allowing for the deployment of self-contained inspection devices for comprehensive structural analysis.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If human-based inspections are used, then inspection accuracy and judgment quality improve, but safety risks and operational costs increase

Engineering Contradiction:

Improveinspection accuracyVSAvoidsafety risks

Core Design Contradiction:

Measurement precisionVSObject-affected harmful factors

Solution Approach 1:

The inspection system performs autonomous operations using onboard sensors, processors, and navigation systems. The UAV independently navigates to inspection locations, captures data, and transmits information without requiring human presence at hazardous sites, thereby eliminating safety risks while maintaining inspection quality

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces human physical inspection with an automated UAV system equipped with sensors and image processing capabilities. The mechanical and cognitive tasks previously performed by human inspectors are substituted by robotic navigation, sensor data acquisition, and automated image analysis algorithms

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of manufacture

If static cameras are used for periodic inspection, then operational costs decrease, but inspection coverage and effectiveness deteriorate

Engineering Contradiction:

Improveoperational costVSAvoidinspection coverage

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The system transitions from static fixed cameras to a dynamic UAV platform that can actively navigate, position itself at optimal inspection points, and adapt its inspection path based on real-time conditions. This dynamic capability enables comprehensive coverage of large or complex structures that static cameras cannot monitor effectively

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The UAV inspection system serves multiple functions: it can inspect various types of structures (bridges, buildings, towers), perform different inspection tasks (visual inspection, thermal imaging, structural analysis), and adapt to different inspection requirements. This multi-functionality replaces the need for multiple specialized static camera systems

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Adaptability or versatility

If human-piloted helicopters are used for inspection, then inspection capability improves, but operational costs and safety risks increase

Engineering Contradiction:

Improveinspection capabilityVSAvoidoperational cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The system employs unmanned aerial vehicles that are significantly cheaper to operate than manned helicopters. The UAVs can be deployed for single-use or limited-duration inspection missions, eliminating the need for expensive pilot salaries, helicopter maintenance, and fuel costs associated with manned aircraft

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent extracts the inspection capability from the expensive manned helicopter platform and transfers it to a simplified UAV system. By removing the human pilot and associated life-support systems, the core inspection function is preserved while operational costs are dramatically reduced

Inventive Principle:

Principle #2Taking out (Extraction)

4Ease of operation

If GPS tracking is used for location estimation, then navigation capability improves, but measurement precision for NDI deteriorates

Engineering Contradiction:

Improvenavigation capabilityVSAvoidlocation accuracy

Core Design Contradiction:

Ease of operationVSMeasurement precision

Solution Approach 1:

The system combines multiple positioning technologies including GPS, inertial measurement units (IMU), and visual odometry to create a hybrid navigation system. This fusion of multiple sensing modalities compensates for the limitations of GPS alone and achieves the high location accuracy required for precise non-destructive inspection measurements

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentEP3315406B1Method and system for non-destructive testing using an unmanned aerial vehicle

Publication Date: 2020.05.20 THE BOEING CO

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AI summary

Provided is a nondestructive inspection ("NDI") system that includes an unmanned aerial vehicle ("UAV") comprising a body structure, the body structure comprising one or more support structures where each of the one or more support structures comprise a releasable end structure; and one or more NDI sensors integrated to a respective releasable end structure. The NDI system can also include a location tracking system that can determine a position, an orientation, or both of the UAV and/or one or more NDI sensors relative to a structure being inspected.