Apparatus for Automated Maintenance of Aircraft Structural Elements

• US 20130289766A1
• Filed: 10/30/2012
• Published: 10/31/2013
• Est. Priority Date: 01/19/2010
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Hafenrichter, Joseph L., Georgeson, Gary E., Lea, Scott W.
• Granted Patent: US 9,643,313 B2
• Time in Patent Office: Days
• US Class Current: 700/245
• CPC Class Codes: B25J 11/005 Manipulators for mechanical processing tasks
• CPC Class Codes: B25J 11/008 Manipulators for service tasks
• CPC Class Codes: B25J 5/00 Manipulators mounted on wheels or on carriages B25J1/00 takes precedence; programme-controlled manipulators B25J9/00 ; vehicle aspects B60, B62, e.g. remote-controlled steering for motor vehicles B62D1/24; control of position of vehicles G05D1/00
• CPC Class Codes: B25J 9/02 characterised by movement of the arms, e.g. cartesian coordinate type B25J9/06 takes precedence
• CPC Class Codes: B64F 5/60 Testing or inspecting aircraft components or systems
• CPC Class Codes: F01D 5/005 Repairing methods or devices
• CPC Class Codes: G01L 11/025 using a pressure-sensitive optical fibre
• CPC Class Codes: G01M 5/0016 of aircraft wings or blades
• CPC Class Codes: G01M 5/0075 by means of external apparatus, e.g. test benches or portable test systems G01M5/005 takes precedence
• CPC Class Codes: G01N 2291/0422 Shear waves, transverse waves, horizontally polarised waves
• CPC Class Codes: G01N 2291/106 one or more transducer arrays
• CPC Class Codes: G01N 2291/2694 Wings or other aircraft parts
• CPC Class Codes: G01N 27/90 using eddy currents
• CPC Class Codes: G01N 29/043 in the interior, e.g. by shear waves
• CPC Class Codes: G01N 29/225 Supports, positioning or alignment in moving situation
• CPC Class Codes: G01N 29/265 by moving the sensor relative to a stationary material
• CPC Class Codes: G01N 29/28 providing acoustic coupling , e.g. water impedance matching G10K11/02
• CPC Class Codes: Y02T 50/60 Efficient propulsion technologies, e.g. for aircraft
• CPC Class Codes: Y10S 901/01 Mobile robot

Abstract

Automated apparatus for performing maintenance functions on airfoil-shaped bodies having short chord lengths, the apparatus being movable in a spanwise direction along the airfoil-shaped body. In accordance with various embodiments, the apparatus comprises a blade crawler capable of supporting any one of a plurality of end effectors for performing a set of maintenance functions on an airfoil-shaped body, such as a blade component. Included in these functions are multiple options for nondestructive inspection, drilling, grinding, fastening, appliqué application, scarfing, ply mapping, depainting, cleaning, and painting devices that are attached as the end effector for the blade crawler. As a whole, the blade crawler reduces maintenance time, labor hours and human errors when robotic maintenance functions are performed on blade components.

Claims

1. An automated apparatus for moving an end effector over a surface of an airfoil-shaped body having leading and trailing edges, comprising:

a chassis comprising leading and trailing edge subassemblies which are movable relative to each other to change a state of said chassis from a first state to a second state;

a plurality of rolling elements rotatably mounted to said leading and trailing edge subassemblies, said plurality of rolling elements being situated so that said airfoil-shaped body cannot be engaged with a gripping force when said chassis is in said first state and being situated so that said airfoil-shaped body can be engaged with a gripping force when said chassis is in said second state;

a first actuator coupled to rotate one of said plurality of rolling elements when activated;

a support assembly coupled to and displaceable along said chassis;

a second actuator coupled to displace said support assembly when activated;

an end effector coupled to and carried by support assembly; and

a third actuator coupled to actuate operation of said end effector when activated.

2. The apparatus as recited in claim 1, further comprising a fourth actuator coupled to change the state of said chassis from said first state to said second state when activated.

3. The apparatus as recited in claim 1, further comprising a control computer which is programmed to activate said first through third actuators at different times.

4. The apparatus as recited in claim 1, wherein when said chassis in said second state is being held on the airfoil-shaped body by a gripping force, activation of said first actuator causes said chassis to displace in a spanwise direction along the airfoil-shaped body.

5. The apparatus as recited in claim 4, further comprising a position tracking system mechanism which tracks the position of said chassis relative to the airfoil-shaped body by a gripping force during displacement of said chassis in a spanwise direction.

6. The apparatus as recited in claim 1, wherein when said chassis in said second state is being held on the airfoil-shaped body by a gripping force, activation of said second actuator causes said end effector to displace in a chordwise direction along the airfoil-shaped body.

7. The apparatus as recited in claim 1, further comprising a powered mechanism for changing an orientation of said end effector to achieve specific angularities.

8. The apparatus as recited in claim 1, wherein said chassis comprises a linear telescoping sleeve mechanism.

9. The apparatus as recited in claim 1, wherein said chassis comprises a frame and a pincer arm that is rotatable relative to said frame, and a distal end of said pincer arm supports one of said plurality of rolling elements.

10. The apparatus as recited in claim 1, wherein said chassis comprises a frame having a linear slot formed therein, and first and second scissor arms which are pivotably coupled to each other, wherein one end of said first scissor arm is pivotably coupled to said frame while another end of said first scissor arm supports one of said plurality of rolling elements, and one end of second scissor arm carries a pin which is slidably disposed inside said linear slot of said frame while another end of said second scissor arm supports another of said plurality of rolling elements.

11. The apparatus as recited in claim 1, wherein said chassis comprises a plurality of links pivotably coupled in a clam-shell configuration, one of said plurality of links supports one of said plurality of rolling elements, and another of said plurality of links supports another of said plurality of rolling elements.

12. The apparatus as recited in claim 1, wherein said chassis comprises a plurality of links pivotably coupled in a press configuration, one of said plurality of links supports one of said plurality of rolling elements, and another of said plurality of links supports another of said plurality of rolling elements.

13. The apparatus as recited in claim 1, further comprising a brake mechanism which is activatable for braking the apparatus when said chassis in said second state is being held on the airfoil-shaped body by a gripping force.

14. An automated apparatus for moving an end effector over a surface of an airfoil-shaped body having leading and trailing edges, comprising:

a first support assembly comprising a forward body part, a rearward body part, and an intercostal element that interconnects said forward and rearward body parts, at least one of said forward and rearward body parts being displaceable along an axis of said intercostal element to facilitate adjustment of a distance separating said forward and rearward body parts;

a first drive motor carried by said forward body part;

a drive mechanism coupled to and depending from an output shaft of said drive motor and arranged to contact the airfoil-shaped body;

a rolling element supported by said rearward body part and arranged to contact the airfoil-shaped body;

a biasing mechanism coupled to said intercostal element and one of said forward and rearward body parts for exerting a force that urges said drive mechanism and said rolling element to grip the airfoil-shaped body;

a guide element supported by said first support assembly;

a second support assembly which is mounted on and displaceable along said guide element; and

an end effector coupled to and carried by said second support assembly,

wherein said first support assembly is displaceable in a spanwise direction along the airfoil-shaped body when said drive mechanism is driven by said drive motor, and said end effector is displaceable in a chordwise direction independent of spanwise displacement of said first support assembly.

15. The apparatus as recited in claim 14, further comprising a powered mechanism for changing an orientation of said end effector to achieve specific angularities.

16. An apparatus comprising a ladder, a frame member attached to said ladder, a height adjustment mechanism comprising a lower part attached to said ladder and an upper part which is coupled to said lower part of said height adjustment mechanism, a pair of cable pay-out rollers rotatably coupled to said frame member, and a grip attached to said upper part of said height adjustment mechanism, wherein said grip is configured to engage and stabilize a tip of a rotorcraft blade, and the height of said upper part of said height adjustment mechanism is adjustable by movement relative to said lower part.

17. The apparatus as recited in claim 16, further comprising a laser leveler attached to said upper part of said height adjustment mechanism.

18. A system comprising:

an airfoil-shaped body having leading and trailing edges which extend from a root to a tip;

a tip support assembly comprising a frame, a height adjustment mechanism comprising a lower part attached to said frame and an upper part which is coupled to said lower part of said height adjustment mechanism, first and second cable pay-out rollers rotatably coupled to said frame, and a grip attached to said upper part of said height adjustment mechanism and coupled to said tip of said airfoil-shaped body, wherein the height of said upper part of said height adjustment mechanism is adjustable by movement relative to said lower part;

an automated blade crawler mounted to said airfoil-shaped body, said automated blade crawler comprising an end effector, first means for moving said blade crawler in a spanwise direction along said airfoil-shaped body, and second means for moving said end effector in a chordwise direction; and

a cable having one end connected to said automated blade crawler and having another portion disposed between said first and second cable pay-out rollers.

19. The system as recited in claim 18, wherein said end effector comprises one of the following:

a nondestructive inspection sensor, a rotary tool, a ply mapper, a squirter, a sprayer, a roller that carries liquid and a suction device.

20. The system as recited in claim 18, further comprising a control computer connected to another end of said cable, said control computer being programmed to control said first and second means for moving and said end effector.

21. An automated crawler configured to be mountable on a rotorcraft blade and capable of spanwise travel along the rotorcraft blade, comprising an end effector configured to perform a maintenance function.