Methods and systems of repairing a structure

Patent metadata

Field	Value
Publication number	US-10065318-B2
Application number	US-201514598379-A
Country	US
Kind code	B2
Filing date	Jan 16, 2015
Priority date	Sep 15, 2014
Publication date	Sep 4, 2018
Grant date	Sep 4, 2018

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.

First claim

What is claimed is:

1. A method of repairing a structure, said method comprising:
directing a robotic device to conduct a first scan of the structure using a scanner coupled to the robotic device to identify a structural defect in the structure;
generating an image of the structure based on data obtained during the first scan of the structure;
displaying the image of the structure and the identified structural defect on a user interface at a location remote from the robotic device after the inspection of the structure is complete;
receiving a selection of an area of interest on the image that includes the identified structural defect;
directing the robotic device to conduct a second scan of the structure at the area of interest with an inspection tool coupled to the robotic device, the inspection tool configured to perform a non-destructive inspection of the structure, to facilitate obtaining sub-surface geometry data of structural defect;
generating a three-dimensional point cloud of the structure and structural defect, based on surface geometry data obtained during the first scan of the structure and sub-surface geometry data obtained during the second scan of the structure;
generating a tool path for repairing the structural defect based on a user input received at the user interface; and
transmitting the tool path to the robotic device from the location remote from the robotic device.

2. The method in accordance with claim 1 , wherein directing the robotic device to conduct a second scan comprises conducting a non-destructive inspection of the structure at the area of interest.

3. The method in accordance with claim 1 , wherein generating a three-dimensional point cloud of the structural defect enables accurately sizing the structural defect to facilitate a machining procedure, and generating a tool path comprises generating a tool path for directing robotic device to remove the structural defect from structure using a cutting tool, based on user-input of at least one machining parameter.

4. 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.

5. 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.

6. 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.

7. 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, comprising a user interface, coupled in communication with said robotic device, wherein said computing device and said user interface are at a second location remote from the first location, said computing device configured to:
direct the robotic device to conduct a first scan of the structure with the at least one inspection tool to identify a structural defect in the structure;
generate an image based on data obtained during the first scan of the structure;
display the image of the structure and the identified structural defect on the user interface after the inspection of the structure is complete;
receive a selection of an area of interest on the image that includes the identified structural defect;
direct the robotic device to conduct a second scan of the structure at the area of interest; and
generate a three-dimensional point cloud of the structure and structural defect based on surface geometry data obtained during the first scan of the structure and sub-surface geometry data obtained during the second scan of the structure;
generate a tool path for repairing the structural defect based on a user input received at the user interface; and
transmit the tool path to said robotic device.

8. The system in accordance with claim 7 , wherein said at least one inspection tool comprises a surface inspection tool configured to conduct the first scan.

9. The system in accordance with claim 7 , wherein said at least one inspection tool comprises a non-destructive inspection tool configured to conduct the second scan.

10. The system in accordance with claim 7 , 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.

11. The system in accordance with claim 7 , wherein said robotic device further comprises a cutting tool configured to remove material from the structure as said robotic device executes the tool path.

12. 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 conduct a first scan of a structure with at least one inspection tool to identify a structural defect in the structure;
generate an image based on data obtained during the first scan of the structure;
display the image on a user interface at a location remote from the robotic device after the inspection of the structure is complete;
receive a selection of 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;
generate a three-dimensional point cloud of the structure and structural defect based on surface geometry data obtained during the first scan of the structure and sub-surface geometry data obtained during the second scan of the structure;
generate a tool path for repairing the structural defect based on a user input received at the user interface; and
transmit the tool path to the robotic device from the location remote from the robotic device.

13. One or more computer-readable storage media in accordance with claim 12 , 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.

14. One or more computer-readable storage media in accordance with claim 12 , 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.

Assignees

• Boeing Co

Inventors

• Bain David Michael
• Crothers Phillip John
• Szarski Martin

Classifications

• G05B2219/37449

  Inspection path planner · CPC title

• G05B2219/49378

  Tool path finding, select minimal distance · CPC title

• B25J9/1684 Primary

  Tracking a line or surface by means of sensors · CPC title

• Y10S901/41

  Tool · CPC title

• Y10S901/47

  Optical · CPC title