Location tracking and motion control of automated marking device

• US 9,221,506 B1
• Filed: 07/23/2013
• Issued: 12/29/2015
• Est. Priority Date: 07/18/2011
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Georgeson, Gary E., Linn, John R., Troy, James J., Nelson, Karl Edward, Wright, Daniel J., Lea, Scott W.
• Primary Examiner(s): Tran, Khoi
• Assistant Examiner(s): Moyer, Dale
• Application Number:
  US13/948,195
• Time in Patent Office: 889 Days
• Field of Search: 318/568.12, 701/36, 901/1, 901/44
• US Class Current: 1/1
• CPC Class Codes: B05C 1/00 Apparatus in which liquid or other fluent material is applied to the surface of the work by contact with a member carrying the liquid or other fluent material, e.g. a porous member loaded with a liquid to be applied as a coating B05C5/02, B05C7/00 take precedence
• CPC Class Codes: B05D 7/00 Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials coating of foodstuffs A23P20/17, A23P20/15, A23P20/18
• CPC Class Codes: B25J 5/007 mounted on wheels
• CPC Class Codes: B60B 19/003 Multidirectional wheels
• CPC Class Codes: B62D 57/024 specially adapted for moving on inclined or vertical surfaces endless-track vehicles for ascending or descending stairs B62D55/075; hand-carts with provision for travelling up or down stairs B62B5/02
• CPC Class Codes: B64F 5/40 Maintaining or repairing aircraft
• CPC Class Codes: B64F 5/60 Testing or inspecting aircraft components or systems
• CPC Class Codes: F02K 1/1207 of one series of flaps hinged at their upstream ends on a fixed structure F02K1/1215 - F02K1/1292 take precedence
• CPC Class Codes: F02K 1/763 with actuating systems or actuating devices; Arrangement of actuators for thrust reversers
• CPC Class Codes: G05D 1/00 Control of position, course, altitude or attitude of land, water, air or space vehicles, e.g. using automatic pilots drive control systems specially adapted for autonomous road vehicles B60W60/00
• CPC Class Codes: G05D 1/0236 in combination with a laser lasers per se H01S
• CPC Class Codes: G05D 1/0282 generated in a local control room
• CPC Class Codes: Y10S 901/01 Mobile robot

Abstract

A system in accordance with one embodiment comprises a marking device attached to a holonomic-motion crawler vehicle capable of movement on non-horizontal surfaces. Modular attachment and motion control interfaces on the platform allow attachment of various types of marking and non-destructive inspection (NDI) sensor modules. The crawling vehicle marks the location of sub-surface features on an aircraft skin or overlaid patch (doubler) using a pen or sticker or tape applicator that is guided based on either a 3-D CAD model or NDI data collected as the vehicle crawls. A second embodiment utilizes an automated NDI scanner to collect 2-D image data of the substructure to enable manual or automated feature/edge selection for marking. Location tracking of the marking device can be implemented using a local positioning system or a motion capture system.

Claims

1. An apparatus comprising a holonomic-motion crawler vehicle, an actuator and a plurality of optical targets mounted to said holonomic-motion crawler vehicle, said optical targets being arranged in a pattern, and a marking device coupled to said actuator,

wherein said actuator has a first state in which said marking device moves relative to said holonomic-motion crawler vehicle from a retracted position to an extended position, and a second state in which said marking device moves relative to said holonomic-motion crawler vehicle from said extended position to said retracted position, and

wherein said holonomic-motion crawler vehicle comprises:

a frame comprising first and second suction;

a plurality of wheels rotatably mounted to said frame, each wheel comprising a respective plurality of rollers having axes of rotation not parallel to an axis of rotation of said wheel;

a plurality of motors equal in number to the number of wheels, each motor being operable to drive rotation of a respective one of said wheels; and

first and second controllable suction devices for producing respective suction forces in said first and second suction zones when said wheels are all in contact with a surface.

2. The apparatus as recited in claim 1, wherein said marking device comprises a marking instrument having a tip.

3. The apparatus as recited in claim 1, wherein said holonomic-motion crawler vehicle further comprises a plurality of omni wheels and a plurality of wheel rotation encoders respectively coupled to said omni wheels.

4. The apparatus as recited in claim 1, further comprising a nondestructive inspection scan array mounted to said holonomic-motion crawler vehicle.

5. The apparatus as recited in claim 1, wherein said optical targets are retro-reflective markers.

6. The apparatus as recited in claim 1, wherein said optical targets are indicator lights.

7. A system comprising:

a target object having a surface;

a holonomic-motion crawler vehicle in contact with said surface and located at an initial location relative to a frame of reference of the target object;

an actuation system for causing said holonomic-motion crawler vehicle to move relative to the frame of reference of the target object;

a marking device supported by said holonomic-motion crawler vehicle;

an actuator for causing said marking device to move relative to said holonomic-motion crawler vehicle between a retracted state wherein a part of said marking device is not in contact with said surface and an extended state wherein said part of said marking device is in contact with said surface;

a location tracking system programmed to be capable of determining a current location of said part of said marking device relative to the frame of reference of the target object when said part of said marking device is in contact with said surface; and

a motion controller programmed to be capable of controlling motion of said holonomic-motion crawler vehicle relative to said surface and controlling motion of said marking device relative to said holonomic-motion crawler vehicle, the motion of said holonomic-motion crawler vehicle relative to said surface being a function of a difference between said current location of said part of said marking device as determined by said location tracking system and a target location of said part of said marking device.

8. The system as recited in claim 7, further comprising a non-destructive inspection scanner supported by said holonomic-motion crawler vehicle.

9. The system as recited in claim 7, wherein said marking device comprises a marking instrument and said part of said marking device comprises a tip of said marking instrument.

10. The system as recited in claim 7, wherein said holonomic-motion crawler vehicle comprises a plurality of omni wheels and a plurality of wheel rotation encoders respectively coupled to said omni wheels.

11. The system as recited in claim 7, wherein said motion platform comprises a robotic arm and a non-destructive inspection scan probe mounted to said robotic arm.

12. The system as recited in claim 7, wherein said location tracking system comprises a local positioning system.

13. The system as recited in claim 7, wherein said location tracking system comprises a motion capture system.

14. A method of marking locations on a surface, comprising:

moving a holonomic-motion platform over a surface area along a programmed motion path by causing omni wheels of the holonomic-motion platform to rotate;

scanning the surface area using a scan probe mounted to the platform as the holonomic-motion platform is moved along the programmed motion path to acquire scan data, wherein said scan data comprises subsurface feature data;

correlating model feature data with said subsurface feature data;

selecting a target location on the surface area to be marked based on results of said correlating step;

moving the holonomic-motion platform over the surface area to a location whereat a part of a retracted marking device carried by the holonomic-motion platform would overlie said target location if the marking device were extended; and

extending the marking device so that the part of the marking device contacts the surface or a patch overlying the surface.

15. The method as recited in claim 14, further comprising moving the holonomic-motion platform over the surface area along a motion path that causes the part of the extended marking device to contact the surface along a line that starts at said target location.

16. The method as recited in claim 14, wherein said selecting step comprises using a feature or edge recognition software application to recognize a feature or edge the location of which should be marked.

17. The method as recited in claim 14, further comprising tracking a location of optical targets arranged in a known pattern on the platform using a local positioning system of a type which has a camera and a laser range meter on a controllable pan-tilt unit.

18. The method as recited in claim 14, further comprising tracking a location of optical targets arranged in a known pattern on the holonomic-motion platform using a motion capture system of a type that triangulates a three-dimensional position of the holonomic-motion platform between multiple cameras configured to provide overlapping projections.

19. A method for marking a surface on a target object using a computer-controlled holonomic-motion crawler vehicle that moves on a plurality of omni wheels and carries a marking device and a non-destructive scan probe, said method comprising:

causing the omni wheels of the holonomic-motion crawler vehicle to rotate so that the non-destructive scan probe scans an area of the surface to acquire a scan image of that scanned surface area;

selecting a feature having a target location within the scanned surface area;

causing the omni wheels of the holonomic-motion crawler vehicle to rotate until a part of the marking device overlies the target location; and

actuating the marking device so that the part marks the target location.

20. The method as recited in claim 19, further comprising:

acquiring relative motion data representing incremental motion of the holonomic-motion crawler vehicle; and

controlling the motion of the holonomic-motion crawler vehicle as a function of the relative motion data.