Methods for maintaining difficult-to-access structures using unmanned aerial vehicles

Patent metadata

Field	Value
Publication number	US-11079760-B2
Application number	US-201816202347-A
Country	US
Kind code	B2
Filing date	Nov 28, 2018
Priority date	Nov 28, 2018
Publication date	Aug 3, 2021
Grant date	Aug 3, 2021

Abstract

Methods for performing maintenance operations using unmanned aerial vehicles (UAVs). The methods are enabled by equipping a UAV with a maintenance tool capable of performing a desired maintenance operation (e.g., nondestructive inspection) on a limited-access surface of a large structure or object (e.g., a wind turbine blade). The UAV uses re-orientation of lifting means (e.g., vertical rotors) to move the maintenance tool continuously or intermittently across the surface of the structure while maintaining contact with the surface of the structure undergoing maintenance.

First claim

The invention claimed is:

1. A method for performing a maintenance operation using an unmanned aerial vehicle, comprising:
(a) the unmanned aerial vehicle flies to a first location whereat a plurality of standoff contact elements of the unmanned aerial vehicle contact respective areas on a surface of a structure;
(b) the unmanned aerial vehicle hovers at the first location with the standoff contact elements in contact with the surface of the structure;
(c) the unmanned aerial vehicle skims along a path on the surface of the structure along a path that extends from the first location to a second location; and
(d) a maintenance tool on-board the unmanned aerial vehicle performs a maintenance operation while the unmanned aerial vehicle is located along the path with the standoff contact elements in contact with the surface of the structure.

2. The method as recited in claim 1 , wherein the maintenance tool is a sensor array, step (c) comprises moving the sensor array along a scan path that follows the surface of the structure, and step (d) comprises activating the sensor array to acquire nondestructive inspection sensor data representing characteristics of the structure during movement of the sensor array along the scan path.

3. The method as recited in claim 1 , wherein the maintenance tool is a nondestructive inspection sensor unit, step (c) comprises moving the nondestructive inspection sensor unit along a scan path that follows the surface of the structure, and step (d) comprises activating the nondestructive inspection sensor unit to acquire nondestructive inspection sensor data representing characteristics of the structure during movement of the nondestructive inspection sensor unit along the scan path.

4. The method as recited in claim 1 , wherein the unmanned aerial vehicle is propelled by thrust produced by at least one rotor during skimming of the unmanned aerial vehicle along the path.

5. The method as recited in claim 4 , wherein step (c) comprises controlling the operation of a rotor motor that drives rotation of a rotor to produce a thrust that maintains the plurality of standoff contact elements in contact with the surface.

6. The method as recited in claim 4 , wherein step (c) further comprises controlling the operation of rotor motors that drive rotation of respective rotors having respective axes of rotation that are vertical when the unmanned aerial vehicle is hovering and level.

7. The method as recited in claim 6 , wherein step (c) further comprises controlling the operation of gimbal motors that drive tilting of respective rotor masts of the respective rotors relative to a frame of the unmanned aerial vehicle.

8. The method as recited in claim 6 , wherein step (c) further comprises:
controlling the operation of a first set of gimbal motors that drive rotation of respective gimbal rings relative to respective deflector rings attached to a frame of the unmanned aerial vehicle; and
controlling the operation of a second set of gimbal motors that drive rotation of respective rotors relative to the respective gimbal rings.

9. The method as recited in claim 1 , wherein the structure is a wind turbine blade.

10. The method as recited in claim 1 , wherein the structure is an aircraft.

11. The method as recited in claim 1 , wherein the structure is a storage tank.

12. The method as recited in claim 1 , wherein step (c) comprises controlling the operation of a rotor motor that drives rotation of a rotor to produce a thrust that maintains the plurality of standoff contact elements in contact with the surface.

13. The method as recited in claim 1 , wherein step (c) further comprises controlling the operation of rotor motors that drive rotation of respective rotors having respective axes of rotation that are vertical when the unmanned aerial vehicle is hovering and level.

14. The method as recited in claim 13 , wherein step (c) further comprises controlling the operation of gimbal motors that drive tilting of respective rotor masts of the respective rotors relative to a frame of the unmanned aerial vehicle.

15. The method as recited in claim 13 , wherein step (c) further comprises:
controlling the operation of a first set of gimbal motors that drive rotation of respective gimbal rings relative to respective deflector rings attached to a frame of the unmanned aerial vehicle; and
controlling the operation of a second set of gimbal motors that drive rotation of respective rotors relative to the respective gimbal rings.

16. A method for performing a maintenance operation on an airfoil-shaped body using an unmanned aerial vehicle, the method comprising:
(a) equipping the unmanned aerial vehicle with a maintenance tool and a plurality of standoff contact elements, the plurality of standoff contact elements being arranged to simultaneously contact a surface of the airfoil-shaped body, and the maintenance tool being arranged to confront an area on the surface of the airfoil-shaped body while the plurality of standoff contact elements are in contact with the surface;
(b) flying the unmanned aerial vehicle to a first location whereat the plurality of standoff contact elements of the unmanned aerial vehicle contact respective areas on a surface of an airfoil-shaped body;
(c) skimming the unmanned aerial vehicle along a path on the surface of the airfoil-shaped body along a path that extends from the first location to a second location; and
(d) while the plurality of standoff contact elements are in contact with the surface of the airfoil-shaped body, activating the maintenance tool to perform a maintenance operation on the surface of the airfoil-shaped body.

17. The method as recited in claim 16 , wherein one of the first and second locations is adjacent to a side surface of the airfoil-shaped body and the other of the first and second locations is adjacent to a leading edge of the airfoil-shaped body.

18. The method as recited in claim 16 , wherein the maintenance tool is a sensor array, step (c) comprises moving the sensor array along a scan path that follows the surface of the airfoil-shaped body, and step (d) comprises activating the sensor array to acquire nondestructive inspection sensor data representing characteristics of the airfoil-shaped body during movement of the sensor array along the scan path.

19. The method as recited in claim 16 , wherein the maintenance tool is a nondestructive inspection sensor unit, step (c) comprises moving the nondestructive inspection sensor unit along a scan path that follows the surface of the structure, and step (d) comprises activating the nondestructive inspection sensor unit to acquire nondestructive inspection sensor data representing characteristics of the structure during movement of the nondestructive inspection sensor unit along the scan path.

20. The method as recited in claim 16 , wherein the airfoil-shaped body is a wind turbine blade.

21. The method as recited in claim 16 , wherein the airfoil-shaped body is part of an aircraft.

Assignees

• Boeing Co

Inventors

• Hafenrichter Joseph L
• Georgeson Gary E

Classifications

• B64U2201/20

  Remote controls · CPC title

• B64U2101/00

  UAVs specially adapted for particular uses or applications · CPC title

• B64U30/26

  Ducted or shrouded rotors · CPC title

• B64U10/13

  Flying platforms · CPC title

• B64U50/19

  using electrically powered motors · CPC title