Apparatus for Automated Maintenance of Aircraft Structural Elements

Patent metadata

Field	Value
Publication number	US-2016334301-A1
Application number	US-201615222028-A
Country	US
Kind code	A1
Filing date	Jul 28, 2016
Priority date	Oct 30, 2012
Publication date	Nov 17, 2016
Grant date	—

Abstract

Automated apparatus for performing maintenance functions on airfoil-shaped bodies having short chord lengths, the apparatus being movable in a spanwise direction along the airfoil-shaped body. In accordance with various embodiments, the apparatus comprises a blade crawler capable of supporting any one of a plurality of end effectors for performing a set of maintenance functions on an airfoil-shaped body, such as a blade component. Included in these functions are multiple options for nondestructive inspection, drilling, grinding, fastening, appliqué application, scarfing, ply mapping, depainting, cleaning, and painting devices that are attached as the end effector for the blade crawler. As a whole, the blade crawler reduces maintenance time, labor hours and human errors when robotic maintenance functions are performed on blade components.

First claim

1 . A method for deploying an automated apparatus on an airfoil-shaped body having a root and a tip, comprising:
supporting the tip of the airfoil-shaped body to prevent the tip from displacing downward; placing an automated apparatus on the airfoil-shaped body while the tip of the airfoil-shaped body is being supported; placing a cable having one end connected to the automated apparatus between a pair of rollers; and moving the automated apparatus in a spanwise direction along the airfoil-shaped body while the cable is between the rollers and the tip of the airfoil-shaped body is being supported.

2 . The method as recited in claim 1 , further comprising:
ceasing movement of the automated apparatus in the spanwise direction; and moving an end effector of the automated apparatus in a chordwise direction relative to the airfoil-shaped body while the automated apparatus is not moving in the spanwise direction.

3 . The method as recited in claim 2 , further comprising activating the automated apparatus to perform a programmed function during movement of the end effector in the chordwise direction.

4 . The method as recited in claim 1 , wherein said supporting step comprises:
setting up an adjustable tip stabilizing apparatus at the tip of the airfoil-shaped body; placing a stabilizer tip grip of the adjustable tip stabilizing apparatus to contact and support the tip of the airfoil-shaped body; and adjusting a height of the stabilizer tip grip while the stabilizer tip grip is in contact with the tip of the airfoil-shaped body.

5 . A method for coupling an automated apparatus to an airfoil-shaped body having a root and a tip, comprising:
setting up an adjustable tip stabilizing apparatus at a tip of an airfoil-shaped body; placing a stabilizer tip grip of the adjustable tip stabilizing apparatus to contact and provide support for the tip of the airfoil-shaped body; adjusting a height of the stabilizer tip grip while the stabilizer tip grip is in contact with the tip of the airfoil-shaped body; and placing an automated apparatus on the airfoil-shaped body while the tip of the airfoil-shaped body is being supported by the stabilizer tip grip.

6 . The method as recited in claim 5 , wherein said adjusting step comprises moving a movable portion of the adjustable tip stabilizing apparatus that supports the stabilizer tip grip while a stationary portion of the adjustable tip stabilizing apparatus remains stationary.

7 . The method as recited in claim 6 , further comprising:
attaching a sensor to a root of the airfoil-shaped body; transmitting a laser beam from a laser attached to the movable portion of the adjustable tip stabilizing apparatus as the movable portion is moving; and determining when the sensor is aligned with the laser beam.

8 . The method as recited in claim 7 , further comprising:
stopping movement of the movable portion when the sensor is aligned with the laser beam; and locking the movable portion relative to the stationary portion.

9 . The method as recited in claim 5 , further comprising moving the automated apparatus in a spanwise direction along the airfoil-shaped body.

10 . The method as recited in claim 9 , wherein said placing step comprises placing a rolling element in rolling contact with a trailing edge of the airfoil-shaped body.

11 . The method as recited in claim 9 , further comprising verifying movement and performance of the automated apparatus during movement in the spanwise direction.

12 . The method as recited in claim 9 , further comprising:
ceasing movement of the automated apparatus in the spanwise direction; and moving an end effector of the automated apparatus in a chordwise direction relative to the airfoil-shaped body while the automated apparatus is not moving in the spanwise direction.

13 . The method as recited in claim 12 , further comprising activating the automated apparatus to perform a programmed function during movement of the end effector in the chordwise direction.

14 . The method as recited in claim 5 , further comprising placing a cable having one end connected to the automated apparatus between a pair of rollers disposed above the stabilizer tip grip.

15 . The method as recited in claim 9 , further comprising placing a cable having one end connected to the automated apparatus between a pair of rollers disposed above the stabilizer tip grip before the automated apparatus is moved in the spanwise direction.

16 . An apparatus comprising a ladder, a frame member attached to said ladder, a height adjustment mechanism comprising a lower part attached to said ladder and an upper part which is coupled to said lower part of said height adjustment mechanism, a pair of cable pay-out rollers rotatably coupled to said frame member, and a grip attached to said upper part of said height adjustment mechanism, wherein said grip is configured to engage and stabilize a tip of a rotorcraft blade, and the height of said upper part of said height adjustment mechanism is adjustable by movement relative to said lower part.

17 . The apparatus as recited in claim 16 , further comprising a laser leveler attached to said upper part of said height adjustment mechanism.

18 . A system comprising:
an airfoil-shaped body having leading and trailing edges which extend from a root to a tip; a tip support assembly comprising a frame, a height adjustment mechanism comprising a lower part attached to said frame and an upper part which is coupled to said lower part of said height adjustment mechanism, first and second cable pay-out rollers rotatably coupled to said frame, and a grip attached to said upper part of said height adjustment mechanism and coupled to said tip of said airfoil-shaped body, wherein the height of said upper part of said height adjustment mechanism is adjustable by movement relative to said lower part; an automated blade crawler mounted to said airfoil-shaped body, said automated blade crawler comprising an end effector, first means for moving said blade crawler in a spanwise direction along said airfoil-shaped body, and second means for moving said end effector in a chordwise direction; and a cable having one end connected to said automated blade crawler and having another portion disposed between said first and second cable pay-out rollers.

19 . The system as recited in claim 18 , wherein said end effector comprises one of the following: a nondestructive inspection sensor, a rotary tool, a ply mapper, a squirter, a sprayer, a roller that carries liquid and a suction device.

20 . The system as recited in claim 18 , further comprising a control computer connected to another end of said cable, said control computer being programmed to control said first and second means for moving and said end effector.

Assignees

• Boeing Co

Inventors

• Hafenrichter Joseph L
• Georgeson Gary E
• Lea Scott W

Classifications

• G01M5/0075 Primary

  by means of external apparatus, e.g. test benches or portable test systems (G01M5/005 takes precedence) · CPC title

• B25J5/00

  Manipulators mounted on wheels or on carriages (B25J1/00 takes precedence; programme-controlled manipulators B25J9/00 {; vehicle aspects B60, B62, e.g. remote-controlled steering for motor vehicles B62D1/24; control of position of vehicles G05D1/00}) · CPC title

• B25J11/008

  Manipulators for service tasks · CPC title

• B25J11/005

  Manipulators for mechanical processing tasks · CPC title

• Y10S901/01

  Mobile robot · CPC title