METHODS AND SYSTEMS OF REPAIRING A STRUCTURE

• US 20160075028A1
• Filed: 01/16/2015
• Published: 03/17/2016
• Est. Priority Date: 09/15/2014
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Bain, David Michael, Crothers, Phillip John, Szarski, Martin
• Granted Patent: US 10,065,318 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B25J 9/1684 Tracking a line or surface by means of sensors
• CPC Class Codes: G05B 2219/37449 Inspection path planner
• CPC Class Codes: G05B 2219/49378 Tool path finding, select minimal distance
• CPC Class Codes: Y10S 901/41 Tool
• CPC Class Codes: Y10S 901/47 Optical

Abstract

A method of repairing a structure is provided. The method includes inspecting the structure with a robotic device to identify a structural defect in the structure, generating a tool path for repairing the structural defect, and transmitting the tool path to the robotic device from a location remote from the robotic device.

Claims

1. A method of repairing a structure, said method comprising:

inspecting the structure with a robotic device to identify a structural defect in the structure;

generating a tool path for repairing the structural defect; and

transmitting the tool path to the robotic device from a location remote from the robotic device.

2. The method in accordance with claim 1, wherein inspecting the structure comprises:

conducting a first scan of the structure;

generating an image of the structure based on data obtained during the first scan of the structure;

identifying an area of interest on the image; and

conducting a second scan of the structure at the area of interest with the robotic device.

3. The method in accordance with claim 2, wherein conducting a second scan comprises conducting a non-destructive inspection of the structure at the area of interest.

4. The method in accordance with claim 2 further comprising generating a three-dimensional point cloud of the structural defect based on data received during the first and second scans of the structure.

5. The method in accordance with claim 1, wherein generating a tool path comprises generating the tool path configured to remove the structural defect from the structure and form a recess in the structure when executed by the robotic device.

6. The method in accordance with claim 1, wherein generating a tool path comprises generating the tool path based on at least one of inspection parameters or machining parameters provided by a user.

7. The method in accordance with claim 1 further comprising verifying a position of the robotic device based on real-time feedback as the robotic device executes the tool path.

8. A system for use in repairing a structure, said system comprising:

a robotic device comprising at least one inspection tool, wherein said robotic device is at a first location; and

a computing device coupled in communication with said robotic device, wherein said computing device is at a second location remote from the first location, said computing device configured to;

direct the robotic device to inspect the structure with the at least one inspection tool to identify a structural defect in the structure;

generate a tool path for repairing the structural defect; and

transmit the tool path to said robotic device.

9. The system in accordance with claim 8, wherein said computing device is further configured to:

direct the robotic device to conduct a first scan of the structure;

generate an image based on data obtained during the first scan of the structure;

identify an area of interest on the image; and

direct the robotic device to conduct a second scan of the structure at the area of interest.

10. The system in accordance with claim 9, wherein said computing device is further configured to generate a three-dimensional point cloud of the structural defect based on data received during the first and second scans of the structure.

11. The system in accordance with claim 9, wherein said at least one inspection tool comprises a surface inspection tool configured to conduct the first scan.

12. The system in accordance with claim 9, wherein said at least one inspection tool comprises a non-destructive inspection tool configured to conduct the second scan.

13. The system in accordance with claim 8, wherein said computing device is further configured to generate the tool path based at least partially on at least one of inspection parameters or machining parameters provided by a user.

14. The system in accordance with claim 8, wherein said robotic device further comprises a cutting tool configured to remove material from the structure as said robotic device executes the tool path.

15. A computer-readable storage media having computer-executable instructions embodied thereon, wherein, when executed by at least one processor, the computer-executable instructions cause the processor to:

direct a robotic device to inspect a structure with at least one inspection tool to identify a structural defect in the structure;

generate a tool path for repairing the structural defect; and

transmit the tool path to the robotic device from a location remote from the robotic device.

16. One or more computer-readable storage media in accordance with claim 15, wherein the computer-executable instructions further cause the processor to:

direct the robotic device to conduct a first scan of the structure;

generate an image based on data obtained during the first scan of the structure;

identify an area of interest on the image; and

direct the robotic device to conduct a second scan of the structure at the area of interest.

17. One or more computer-readable storage media in accordance with claim 16, wherein the computer-executable instructions further cause the processor to generate a three-dimensional point cloud of the structural defect based on data received during the first and second scans of the structure.

18. One or more computer-readable storage media in accordance with claim 17, wherein the computer-executable instructions further cause the processor to generate the three-dimensional point cloud based on surface geometry data obtained during the first scan and sub-surface geometry data obtained during the second scan.

19. One or more computer-readable storage media in accordance with claim 15, wherein the computer-executable instructions further cause the processor to generate the tool path configured to remove the structural defect from the structure and form a recess in the structure when executed by the robotic device.

20. One or more computer-readable storage media in accordance with claim 15, wherein the computer-executable instructions further cause the processor to generate the tool path based on at least one of inspection parameters or machining parameters provided by a user.