UAV Repair Modules for Inaccessible Aircraft and Blade 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, allowing for remote and automated repair operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If manual labor with lifts or stands is used for repair, then repair can be performed on accessible structures, but repair time increases and operational delays occur
Solution Approach 1:
The patent replaces manual mechanical repair systems (lifts, stands, safety harnesses) with an automated UAV-based repair system. The UAV carries repair tools and materials autonomously to the damage site, eliminating the need for manual access equipment and significantly reducing repair time while maintaining repair effectiveness on inaccessible structures.
Solution Approach 2:
The UAV system performs self-service repair operations by autonomously navigating to the damage location, positioning repair tools, and applying repairs without human intervention. This self-service capability allows rapid repair of inaccessible structures that would otherwise require complex manual access arrangements.
2Ease of repair
If manual repair personnel are deployed to inaccessible structures, then repair can be performed, but safety risks increase
Solution Approach 1:
The patent eliminates human safety risks by replacing manual repair personnel with an automated UAV system. The UAV performs all repair operations autonomously, removing workers from hazardous environments while maintaining full repair capability through integrated tools and materials on the UAV platform.
Solution Approach 2:
The UAV acts as an intermediary between the ground control station and the inaccessible damage site. It transports repair materials, positions tools, and executes repair operations remotely, serving as a mediator that enables repair capability while eliminating direct human exposure to safety hazards.
3Ease of repair
If aircraft is grounded for extensive repair, then thorough repair can be performed, but economic impact increases
Solution Approach 1:
The UAV system enables self-service repair operations that can be performed rapidly without requiring the aircraft to be grounded for extended periods. The autonomous capability allows repair personnel to quickly assess damage, access the site, and complete repairs efficiently, minimizing downtime and economic impact while maintaining repair thoroughness.
Solution Approach 2:
The system enables preliminary repair actions to be taken quickly at the location of damage, preventing the need for extensive grounding. By having repair tools and materials already loaded on the UAV and the ability to immediately begin repair operations upon arrival, the system reduces the time the aircraft remains out of service.
4Ease of repair
If repair equipment is not available or repair is extensive, then thorough repair can be performed, but flight cancellation occurs
Solution Approach 1:
The UAV is designed with multi-functionality, carrying a variety of repair tools, materials, and equipment in a single platform. This universal capability allows the UAV to perform diverse repair operations (structural repairs, surface treatments, component replacements) without requiring multiple separate pieces of equipment or ground support, thereby maintaining flight operation continuity while ensuring repair completeness.
Solution Approach 2:
The system provides dynamic adaptability by allowing the UAV to adjust its payload and repair approach based on the specific damage assessment. The modular tool systems can be configured for different repair scenarios, enabling the UAV to respond flexibly to varying repair requirements and prevent flight cancellations by matching the right tools to the specific damage conditions.
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 enables quick and cost-effective repair of large composite structures by reducing downtime, minimizing safety risks, and eliminating the need for manual access, thereby facilitating rapid return to service while reducing operational and economic impacts.
Implementation Method 1
a spray nozzle in fluid communication with the valve. The spray nozzle is configured and located to distribute the sealant or coating material over an area on a surface of a structure
Implementation Method 2
a pressurized storage canister containing a sealant or coating material in a liquid state
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.