Methods and systems for inspection sensor placement

• US 9,149,929 B2
• Filed: 05/26/2010
• Issued: 10/06/2015
• Est. Priority Date: 05/26/2010
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Motzer, William P., Georgeson, Gary E., Lea, Scott W., Hellenbrand, Peter J., Troy, James J.
• Primary Examiner(s): To, Tuan C.
• Assistant Examiner(s): Hilgendorf, Dale W
• Application Number:
  US12/787,885
• Publication Number:
  US 20110295427A1
• Time in Patent Office: 1,959 Days
• Field of Search: 701/3, 703/8, 738/658, 738/659, 702/36, 702/94, 702/95, 702/104, 901/47, 901/4, 901/5, 901/10, 901/3, 700/258, 700/217, 700/245, 700/254, 700/114, 700/192, 700/50, 700/248, 600/424, 600/427, 600/114, 600/142, 600/146, 128/899, 324/226, 324/207.12, 356/614, 356/251, 378/58, 378/51, 348/25, 348/207.1, 348/207.11, 348/208.3, 250/561, 250/559.29, 250/559.33, 180/9.1, 318/568.12, 318/568.16, 446/278
• US Class Current: 1/1
• CPC Class Codes: B25J 9/06 characterised by multi-articulated arms
• CPC Class Codes: B25J 9/065 Snake robots
• CPC Class Codes: B25J 9/162 Mobile manipulator, movable base with manipulator arm mounted on it
• CPC Class Codes: B25J 9/1694 characterised by use of sensors other than normal servo-feedback from position, speed or acceleration sensors, perception control, multi-sensor controlled systems, sensor fusion
• CPC Class Codes: G05B 2219/39014 Match virtual world with real world
• CPC Class Codes: G05B 2219/39024 Calibration of manipulator
• CPC Class Codes: G05B 2219/40039 Robot mounted or sliding inside vehicle, on assembly line or for test, service
• CPC Class Codes: G05B 2219/40234 Snake arm, flexi-digit robotic manipulator, a hand at each end
• CPC Class Codes: G05B 2219/45071 Aircraft, airplane, ship cleaning manipulator, paint stripping

Abstract

Methods and systems are provided for positioning a remote sensor within a target object. An articulated robotic system is coupled to the remote sensor. A positioning system determines a position of the target object to be inspected and determines a first position of the remote sensor. A control system calibrates a virtual representation of the target object with respect to the position of the target object, and tracks movement of the remote sensor relative to the target object.

Claims

1. A method for positioning an inspection sensor within an aircraft, said method comprising:

determining a position of the aircraft using a first sensor disposed external to the aircraft;

calibrating a virtual representation of the aircraft with respect to the position of the aircraft;

determining a first position of the inspection sensor using the first sensor, wherein the inspection sensor and a positioning sensor are coupled to an articulating robotic system at an end effector;

extending the articulating robotic system through an access port defined in the aircraft and articulating around at least one landmark within the aircraft such that the inspection sensor and the positioning sensor are positioned in an interior of the aircraft without disassembly of the aircraft;

tracking movement of the inspection sensor within the aircraft and relative to the aircraft using the positioning sensor;

receiving landmark position information for the at least one landmark within the aircraft;

determining a current position of the inspection sensor when the inspection sensor contacts the at least one landmark;

identifying a position conflict when the determined current position is different than the received landmark position information;

adjusting the determined current position of the inspection sensor based at least partially on the identified position conflict; and

updating a virtual display of the interior of the aircraft based at least partially on the identified position conflict.

2. The method in accordance with claim 1, wherein calibrating a virtual representation of the aircraft further comprises retrieving the virtual representation of the aircraft.

3. The method in accordance with claim 1 further comprising:

providing a virtual representation of the inspection sensor based on the first position of the inspection sensor.

4. The method in accordance with claim 3 further comprising:

determining a second position of the inspection sensor relative to the first position of the inspection sensor using the positioning sensor; and

calibrating the virtual representation of the inspection sensor with respect to at least the first position and the second position of the inspection sensor.

5. The method in accordance with claim 4, wherein tracking movement of the inspection sensor is based on at least the first position and the second position of the inspection sensor.

6. The method in accordance with claim 1 further comprising:

providing a virtual representation of the articulated robotic system based on the first position of the inspection sensor.

7. A control system for positioning an inspection sensor within an aircraft, said control system configured to:

determine a position of the aircraft using a first sensor disposed external to the aircraft;

calibrate a virtual representation of the aircraft with respect to the position of the aircraft;

determine a first position of the inspection sensor using the first sensor, wherein the inspection sensor and a positioning sensor are coupled to an articulating robotic system at an end effector;

extend the articulating robotic system through an access port defined in the aircraft and articulate around at least one landmark within the aircraft such that the inspection sensor and the positioning sensor are positioned in an interior of the aircraft without disassembly of the aircraft;

track movement of the inspection sensor within the aircraft and relative to the aircraft using the positioning sensor;

receive landmark position information for the at least one landmark within the aircraft;

determine a current position of the inspection sensor when the inspection sensor contacts the at least one landmark;

identify a position conflict when the determined current position is different than the received landmark position information;

adjust the determined current position of the inspection sensor based at least partially on the identified position conflict; and

update a virtual display of the interior of the target object based at least partially on the identified position conflict.

8. The control system in accordance with claim 7, wherein said control system is further configured to retrieve the virtual representation of the aircraft.

9. The control system in accordance with claim 7, wherein said control system is further configured to provide a virtual representation of the inspection sensor based on the first position of the inspection sensor.

10. The control system in accordance with claim 9, wherein said control system is further configured to:

determine a second position of the inspection sensor relative to the first position of the inspection sensor using the positioning sensor; and

calibrate the virtual representation of the inspection sensor with respect to at least the first position and the second position of the inspection sensor.

11. The control system in accordance with claim 10, wherein said control system is further configured to track movement of the inspection sensor based on at least the first position and the second position of the inspection sensor.

12. The control system in accordance with claim 7, wherein said control system is further configured to provide a virtual representation of the articulating robotic system based on the first position of the inspection sensor.

13. The control system in accordance with claim 12, wherein said control system is further configured to move the articulating robotic system.

14. A system for positioning an inspection sensor within an aircraft, said system comprising:

an articulated robotic system having an end effector coupled to the inspection sensor and a positioning sensor, and extendable through an access port defined in the aircraft such that the inspection sensor and the positioning sensor are positioned in an interior of the aircraft without disassembly of the aircraft;

a positioning system disposed external to the aircraft and configured to determine a position of the aircraft and to determine a first position of the inspection sensor; and

a control system that calibrates a virtual representation of the aircraft with respect to the position of the, tracks movement of the sensor within the aircraft and relative to the aircraft using the positioning sensor, receives landmark position information of at least one landmark within the aircraft, determines a current position of the inspection sensor when the inspection sensor contacts the at least one landmark, identifies a position conflict when the determined current position is different than the received landmark position information, adjusts the determined current position of the inspection sensor based at least partially on the identified position conflict, and updates a virtual display of the interior of the aircraft based at least partially on the identified position conflict.

15. The system in accordance with claim 14, wherein the positioning sensor comprises an inertial sensor.

16. The system in accordance with claim 14, wherein said control system retrieves the virtual representation of the aircraft.

17. The system in accordance with claim 14, wherein said control system provides a virtual representation of the inspection sensor based on the first position of the inspection sensor.

18. The system in accordance with claim 17, wherein said control system determines a second position of the inspection sensor relative to the first position of the inspection sensor and calibrates the virtual representation of the inspection sensor with respect to at least the first position and the second position of the inspection sensor.

19. The system in accordance with claim 18, wherein said control system tracks movement of the inspection sensor based on at least the first position and the second position of the inspection sensor.

20. The system in accordance with claim 14, wherein said control system provides a virtual representation of said articulated robotic system based on the first position of the inspection sensor, and moves said articulated robotic system.