01 Jun 2004
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A crawler robot in operation on a smooth surface
A robot that crawls up walls and can even hang upside down is set to revolutionise aircraft inspection.
The laser guided, R2- D2 style droid clings to surfaces by suction pads while its sensitive instruments go about their task. The prototype, developed at the ATC in conjunction with Air Systems, is now ready for action in a range of uses in aircraft and ships.
Robots have long been proclaimed as our saviours from tedious, repetitive tasks. The ATC crawler robot is no exception. For example, some inspections carried out during manufacture of aircraft wings need technicians to scrutinise large areas, inch by inch. The new Airbus A380 which is now taking shape, has a wing span longer than two tennis courts placed end to end. It's easy to imagine how a robot could take the drudge and cost out of inspecting such a mighty structure.
The crawler robot is a compact platform that can carry loads of up to 25 kilos. It sits on round pads that act as feet. A partial vacuum in the pads holds the robot to the surface over which it crawls. Wheels inside each pad allow it move in any direction under the guidance of an onboard control system. The vacuum is supplied through hoses connected to a portable groundstation that also contains a laser tracking system.
"Its all done by suction," says Steve Harris, who is co-developing the robot with colleague, Tim White at the ATC. "There's enough vacuum in the pads to make sure it sticks to the surface but not too much to stop it moving," he says.
Bellows in the pads allow the robot to adapt to curved as well as flat surfaces. The smart, onboard electronics control the level of suction to ensure that the machine doesn't slip. "It can go upside down, over seams and gaps and can even cope with greasy, non-stick patches," says Steve. "The current model can cover a wall 10 metres from top to bottom at a speed of up to 1 metre per second. The on-board electronics includes a wireless link to the outside world, controllers for the on-board tool package and a laser tracking target," he says.
The effectiveness of the robot has been demonstrated on a number of shaped test structures in joint trials with BAE SYSTEMS partners in Air Systems and Aerostructures at Samlesbury. It has successfully negotiated curves and overhangs while carrying tools for precision drilling or inspection instruments for 'Non- Destructive Testing' (NDT). These include ultrasound and electrical probes for finding cracks in metals and other sensors for measuring the thickness of paint layers and finding corrosion.
"The robot is perfect for NDT" says Steve "It can carry all the necessary weights, it has the speed and dexterity and more than enough precision to do the task." he says. The Gold Innovation Award winning robot is already into its third generation of design. The next version is being developed and has a target weight of just 7 kilos and will be more controllable and adaptable. Ultimately the designers aim for a fully selfpowered design. "Our vision is to have miniaturised vacuum pumps on board with selfcontained power from a battery or compact petrol engine." says Steve.
The invention has aroused considerable interest in business units across the company including Air Systems and CS&S for potential use in the support of aircraft and naval platforms. Outside of BAE SYSTEMS, the RAF, QinetiQ and Airbus are also taking notice.
