Patent Description:
Transparent coatings are utilized in many different applications. As one example, certain portions of aircraft canopies (e.g., "transparencies") may have clear outer performance layers that provide various functions to the aircraft. Transparent coatings such as performance layers of aircraft canopies may need to be removed and replaced in some situations. For example, sun, precipitation, dirt, and other debris may damage the performance layer of the aircraft canopy, thereby requiring the removal and replacement of the performance layer.

<CIT> describes a device comprising a laser for generating a laser beam, an optical fiber for guiding the laser beam to the vicinity of an object to be irradiated, a focus position driving mechanism for changing the focus position of the laser beam, and a measurement control means for controlling the focus position driving mechanism so as to make the focus of the laser beam coincide with the surface of the object.

<CIT> (basis for the preamble of claims <NUM> and <NUM>) describes a method and apparatus for providing an automated optical robotic polishing system for removing flaws in transparencies, such as transparent canopies used in aircraft. A pneumatic random orbital polishing tool attached to a robot arm is used to polish canopies to remove flaws.

A system and method according to the present invention are defined in claims <NUM> and <NUM> respectively.

According to one embodiment, a system includes a robotic arm, a rotisserie control linkage, and a computer system. The robotic arm includes a touch probe and laser head. The rotisserie control linkage is configured to couple to a transport cart. The computer system is communicatively coupled to the robotic arm and the rotisserie control linkage and is configured to control the system to probe, using the touch probe of the robotic arm, a transparent outer layer of an aircraft canopy located on the transport cart in order to accurately determine the surface position of the aircraft canopy relative to the position of the robotic arm. The computer system also controls the system to ablate, using a plurality of predetermined parameters and the laser head of the robotic arm, an interface layer located between the transparent outer layer and the aircraft canopy, wherein positions of the laser head of the robotic arm during the ablation are determined using the surface measurements. The computer system also controls the system to rotate the aircraft canopy on the transport cart using the rotisserie control linkage during the probing with the touch probe and during the ablation with the laser head.

Technical advantages of certain embodiments may include providing systems and methods of automatically removing transparent coatings such as clear performance layers of aircraft transparencies. Instead of the typical manual processes currently used to remove such coatings, the disclosed embodiments quickly and automatically remove transparent coatings, thereby saving considerable time and expenses. Furthermore, the disclosed embodiments automatically remove transparent coatings without damaging the underlying structures (e.g., aircraft transparencies). Other technical advantages will be readily apparent to one skilled in the art from the following figures, descriptions, and claims. Moreover, while specific advantages have been enumerated above, various embodiments may include all, some, or none of the enumerated advantages.

For a more complete understanding of the present disclosure and its advantages, reference is now made to the following description, taken in conjunction with the accompanying drawings, in which:.

Transparent coatings are utilized in many different applications. As one example, certain portions of aircraft canopies (e.g., "transparencies") may have clear outer performance layers that provide various functions to the aircraft. Transparent coatings such as performance layers of aircraft canopies may need to be removed and replaced in some situations. For example, sun, precipitation, dirt, and other debris may damage the performance layer of the aircraft canopy, thereby requiring the removal and replacement of the performance layer. Removing transparent coatings such as performance layers of aircraft canopies is typically a manual process that is both labor and time intensive, requiring many man-hours to complete.

To address these and other problems with removing transparent coatings such as performance layers of aircraft canopies, the disclosed embodiments provide a system that automatically removes transparent coatings using laser ablation. Using an aircraft canopy as a main example, the system utilizes a robotic arm that automatically ablates an interface layer that mechanically bonds a transparent outer performance layer to the aircraft canopy, thereby causing the performance layer to be easily removed from the aircraft canopy. The system utilizes laser parameters that control a laser head of the robotic arm to ablate the interface layer without damaging the underlying aircraft canopy. As a result, the time required to remove and replace performance layers of aircraft canopies is greatly reduced.

To facilitate a better understanding of the present disclosure, the following examples of certain embodiments are given. In no way should the following examples be read to limit or define the scope of the disclosure. Embodiments of the present disclosure and its advantages may be best understood by referring to the included FIGURES, where like numbers are used to indicate like and corresponding parts.

<FIG> illustrates an aircraft <NUM> that includes a canopy <NUM>, according to certain embodiments. Canopy <NUM> includes a canopy transparency <NUM> and one or more non-transparent canopy components <NUM>. Non-transparent canopy components <NUM> may be any portions of canopy <NUM> that are not transparent (e.g., metal frame portions of canopy <NUM>). Canopy transparency <NUM> is a clear portion of canopy <NUM> through which a pilot may view the environment around aircraft <NUM>. In some situations, canopy transparency <NUM> includes a transparent outer performance layer <NUM> that is mechanically bonded to canopy transparency <NUM> with an interface layer <NUM>. Interface layer <NUM> may include any material such as an adhesive that bonds transparent performance layer <NUM> to canopy transparency <NUM>. Transparent performance layer <NUM> and interface layer <NUM> may be any appropriate thickness.

Aircraft <NUM> may be subjected to various conditions during flight that damage or erode transparent performance layer <NUM> of canopy transparency <NUM>. For example, sun, precipitation, dirt, and other debris/objects may damage or erode transparent performance layer <NUM> such that transparent performance layer <NUM> must be replaced. Removing transparent performance layer <NUM> of aircraft canopy <NUM> is typically a manual process that is both labor and time intensive, requiring many man-hours to complete. However, transparent layer removal system <NUM>, described in detail below, automatically removes transparent performance layer <NUM> by ablating interface layer <NUM> while avoiding damaging canopy transparency <NUM>.

<FIG> and <FIG> illustrate a transparent layer removal system <NUM> system for removing a transparent coating such as transparent performance layer <NUM> using laser ablation, according to certain embodiments. In some embodiments, transparent layer removal system <NUM> includes a robotic arm <NUM>, a transport cart <NUM>, a rotisserie control linkage <NUM>, an enclosure <NUM>, and a computer system <NUM>. Robotic arm <NUM> may include a touch probe <NUM> and a laser head <NUM>. Computer system <NUM> is communicatively coupled to robotic arm <NUM> and rotisserie control linkage <NUM>. Robotic arm <NUM>, transport cart <NUM>, and rotisserie control linkage <NUM> may be housed in enclosure <NUM>. An object to be ablated such as canopy transparency <NUM> may be placed on transport cart <NUM> and rolled into enclosure <NUM> and placed proximate to robotic arm <NUM>.

Robotic arm <NUM> is any appropriate articulating robotic arm system that is capable of positioning tools such as touch probe <NUM> and laser head <NUM> any programmed distance from an object such as canopy transparency <NUM>.

Touch probe <NUM> is, according to the present invention, a measurement device that non-destructively probes the outer surface of canopy transparency <NUM> in order to determine surface measurements of canopy transparency <NUM> (e.g., the surface position of canopy transparency <NUM> relative to the position of robotic arm <NUM>). Laser head <NUM> includes any appropriate laser capable of ablating a layer such as interface layer <NUM> of canopy transparency <NUM> with a laser beam <NUM>. In some embodiments, the laser of laser head <NUM> is a near IR (NIR) laser such as a Neodymium laser. Laser head <NUM> is coupled to a laser source <NUM>, which controls the power and frequency of the laser of laser head <NUM> (based on laser parameters <NUM>). In general, robotic arm <NUM> is controlled by computer system <NUM> and performs two main tasks for transparent layer removal system <NUM>: <NUM>) probing an outer surface of an object such as canopy transparency <NUM> using touch probe <NUM>, and <NUM>) ablating a layer such as interface layer <NUM> using laser head <NUM>.

Transport cart <NUM> is a cart for holding an object to be ablated such as canopy transparency <NUM>. In some embodiments, transport cart <NUM> includes wheels that allow transport cart <NUM> to be rolled into enclosure <NUM> and placed next to robotic arm <NUM>. Transport cart <NUM> may include mounting hardware that allows objects such as canopy transparency <NUM> to be secured to transport cart <NUM>. The mounting hardware may be configurable to accommodate various sizes and shapes of canopy transparencies <NUM> (e.g., canopy transparencies <NUM> from various types of aircraft <NUM>). In some embodiments, transport cart <NUM> includes any appropriate mechanism that allows an object such as canopy transparency <NUM> to be rotated. For example, the mounting hardware of transport cart <NUM> may be coupled to a center axis that is rotatably coupled to transport cart <NUM> at each end of transport cart <NUM>. The mounting hardware may rotate about the center axis, thereby allowing robotic arm <NUM> to access all outer surfaces of canopy transparency <NUM>.

The transparent layer removal system <NUM> includes a rotisserie control linkage <NUM> that is configured to rotate the mounting hardware of transport cart <NUM> using any appropriate motor (e.g., an electrical motor). Rotisserie control linkage <NUM> is communicatively coupled to computer system <NUM> or robotic arm <NUM> and may be mechanically coupled to the mounting hardware of transport cart <NUM> (e.g., the center axis of the mounting hardware of transport cart <NUM>). Computer system <NUM> or robotic arm <NUM> commands according to the present invention rotisserie control linkage <NUM> to rotate the mounting hardware of transport cart <NUM> during the probing of canopy transparency <NUM> with touch probe <NUM> and during the ablation of canopy transparency <NUM> with laser head <NUM>.

Enclosure <NUM> is any room or structure for housing robotic arm <NUM>, rotisserie control linkage <NUM>, and transport cart <NUM>. In some embodiments, enclosure <NUM> includes one or more laser safety windows <NUM> that allow an operator to view the operation of transparent layer removal system <NUM> from outside enclosure <NUM> but prevents laser radiation from laser head <NUM> from escaping enclosure <NUM>. In some embodiments, computer system <NUM> is located outside enclosure <NUM> as illustrated in <FIG> and <FIG>. In some embodiments, enclosure <NUM> includes doors or openings that permit transport cart <NUM> to be rolled into and out of enclosure <NUM>.

Computer system <NUM> is communicatively coupled to robotic arm <NUM> and rotisserie control linkage <NUM>. Computer system <NUM> controls the operations of robotic arm <NUM>, touch probe <NUM>, laser head <NUM>, and rotisserie control linkage <NUM> in order to probe transparent performance layer <NUM> and then ablate interface layer <NUM> as described in more detail below in reference to <FIG>. A particular embodiment of computer system <NUM> is illustrated and described in reference to <FIG>.

The operation of transparent layer removal system <NUM> will now be described in reference to <FIG>. <FIG> illustrates transparent performance layer <NUM> of canopy transparency <NUM> being removed by transparent layer removal system <NUM>, and <FIG> illustrates transparent performance layer <NUM> after it has been removed by transparent layer removal system <NUM>. First, transparent layer removal system <NUM> probes, using touch probe <NUM> of robotic arm <NUM>, the outer surface of transparent performance layer <NUM> of canopy transparency <NUM> in order to determine surface measurements of canopy transparency <NUM>. The surface measurements provide transparent layer removal system <NUM> with an accurate 3D model of canopy transparency <NUM> (e.g., physical dimensions of canopy transparency <NUM>) and provide the surface position of canopy transparency <NUM> relative to the position of robotic arm <NUM>. As illustrated in <FIG>, transparent layer removal system <NUM> next utilizes laser head <NUM> to ablate interface layer <NUM>. In this step, transparent layer removal system <NUM> utilizes predetermined laser parameters <NUM> to control laser head <NUM>. Laser parameters <NUM> include at least a laser focal length <NUM> as illustrated in <FIG>. Laser parameters <NUM> are discussed in more detail below. Also in this step, transparent layer removal system <NUM> utilizes the surface measurements obtained from touch probe <NUM> to control the location of laser head <NUM> (e.g., the surface measurements control the distance between laser head <NUM> and the outer surface of transparent performance layer <NUM>). Once interface layer <NUM> has been ablated by transparent layer removal system <NUM>, transparent performance layer <NUM> will be separated from canopy transparency <NUM>, as illustrated in <FIG>, and can be removed.

Laser parameters <NUM> are predetermined parameters for controlling the operation of the laser of laser head <NUM>. In some embodiments, laser parameters <NUM> include a laser fluence, a speed, a wavelength, and laser focal length <NUM>. The laser fluence parameter controls the power per unit area of laser beam <NUM> and may be selected based on the specifications (e.g., thickness and material) of interface layer <NUM>. The laser fluence is selected to properly ablate interface layer <NUM> without damaging canopy transparency <NUM>. If the laser fluence is too high, laser beam <NUM> may damage canopy transparency <NUM>. If the laser fluence is too low, interface layer <NUM> may not be properly ablated. The speed parameter of laser parameters <NUM> controls the linear speed in which laser head <NUM> passes over canopy transparency <NUM>. The speed parameter may be selected to minimize the impact of laser beam <NUM> on canopy transparency <NUM>. If the speed parameter is too low, laser beam <NUM> may damage canopy transparency <NUM>. If the speed parameter is too high, interface layer <NUM> may not be properly ablated.

The wavelength parameter of laser parameters <NUM> is selected based on the material of interface layer <NUM>. In general, the wavelength is selected to be the most effective wavelength of laser beam <NUM> to remove interface layer <NUM>. Laser focal length <NUM> is selected so that laser beam <NUM> from laser head <NUM> passes through transparent performance layer <NUM> and is focused on interface layer <NUM>. Laser focal length <NUM> may be based on the thickness of transparent performance layer <NUM> and the thickness of interface layer <NUM>.

<FIG> illustrates a method <NUM> that is utilized by transparent layer removal system <NUM> to remove a transparent coating such as transparent performance layer <NUM> using laser ablation. At step <NUM>, method <NUM> rotates an object. The object is canopy transparency <NUM> that is located on transport cart <NUM>.

The object is rotated by an electrical motor such as rotisserie control linkage <NUM>.

In step <NUM>, method <NUM> probes, using a touch probe of a robotic arm, a transparent outer layer of an object order to determine surface measurements. The step <NUM> is performed simultaneously with step <NUM>. The object is an aircraft canopy such as canopy <NUM> or a transparency such as canopy transparency <NUM>. In some embodiments, the object is located on a transport cart such as transport cart <NUM>. In some embodiments, the touch probe is touch probe <NUM>, and the robotic arm is robotic arm <NUM>. The surface measurements obtained in step <NUM> may be used, for example, to create a 3D model of the object to be ablated and/or to control movements of the robotic arm during step <NUM>.

At step <NUM>, method <NUM> ablates an interface layer located beneath the transparent outer layer of the object. In some embodiments, the interface layer is interface layer <NUM> located between transparent performance layer <NUM> and canopy transparency <NUM>. Z The step <NUM> uses predetermined parameters and a laser head of the robotic arm. The predetermined parameters may be laser parameters <NUM>, and the laser head may be laser head <NUM>. The movements of the robotic arm (e.g., the positions of the laser head of the robotic arm during the ablation) are determined or otherwise based on the surface measurements of step <NUM>. After step <NUM>, method <NUM> may end.

<FIG> illustrates an example of computing components <NUM>, in accordance with certain embodiments. The computing components <NUM> may be used to implement computer system <NUM>. The computing components <NUM> may comprise any suitable hardware and/or software configured to perform the functionality described above. The computing components <NUM> may be implemented using shared hardware or separate hardware. In certain embodiments, computing components <NUM> may be distributed in a cloud network environment.

In certain embodiments, the components include one or more interface(s) <NUM>, processing circuitry <NUM>, and/or memory unit(s) <NUM>. In general, processing circuitry <NUM> controls the operation and administration of a structure by processing information received from memory <NUM> and/or interface <NUM>. Memory <NUM> stores, either permanently or temporarily, data or other information processed by processing circuitry <NUM> or received from interface <NUM>. Interface <NUM> receives input, sends output, processes the input and/or output and/or performs other suitable operations. An interface <NUM> may comprise hardware and/or software.

Examples of interfaces <NUM> include user interfaces, network interfaces, and internal interfaces. Examples of user interfaces include one or more graphical user interfaces (GUIs), buttons, microphones, speakers, cameras, and so on. Network interfaces receive information from or transmit information through a network, perform processing of information, communicate with other devices, or any combination of the preceding. Network interfaces may comprise any port or connection, real or virtual, wired or wireless, including any suitable hardware and/or software, including protocol conversion and data processing capabilities, to communicate through a LAN, WAN, or other communication system that allows processing circuitry <NUM> to exchange information with or through a network. Internal interfaces receive and transmit information among internal components of a structure.

Processing circuitry <NUM> communicatively couples to interface (s) <NUM> and memory <NUM>, and includes any hardware and/or software that operates to control and process information. Processing circuitry <NUM> may include a programmable logic device, a microcontroller, a microprocessor, any suitable processing device, or any suitable combination of the preceding. Processing circuitry <NUM> may execute logic stored in memory <NUM>. The logic is configured to perform functionality described herein. In certain embodiments, the logic is configured to perform the method described with respect to <FIG>.

Memory <NUM> includes any one or a combination of volatile or non-volatile local or remote devices suitable for storing information. For example, memory comprises any suitable non-transitory computer readable medium, such as Read Only Memory ("ROM"), Random Access Memory ("RAM"), magnetic storage devices, optical storage devices, or any other suitable information storage device or a combination of these devices. Memory <NUM> may be local/integrated with the hardware used by processing circuitry <NUM> and/or remote/external to the hardware used by processing circuitry <NUM>.

Claim 1:
A system (<NUM>) comprising:
a robotic arm (<NUM>) comprising a laser head (<NUM>) and being characterised by the following:
the robotic arm further comprising a touch probe (<NUM>), wherein the touch probe (<NUM>) is a measurement device that non-destructively probes the outer surface of a canopy transparency (<NUM>) in order to determine surface measurements of the canopy transparency (<NUM>);
a rotisserie control linkage (<NUM>) configured to couple to a transport cart (<NUM>); and
a computer system (<NUM>) communicatively coupled to the robotic arm (<NUM>) and the rotisserie control linkage (<NUM>), the computer system (<NUM>) configured to control the system (<NUM>) to:
rotate an aircraft canopy (<NUM>) on the transport cart (<NUM>) using the rotisserie control linkage (<NUM>) ;
during rotation of the aircraft canopy (<NUM>), probe, using the touch probe (<NUM>) of the robotic arm (<NUM>), a transparent outer layer (<NUM>) of the aircraft canopy (<NUM>) located on the transport cart (<NUM>) in order to determine surface measurements of the aircraft canopy (<NUM>); and
during rotation of the aircraft canopy (<NUM>), ablate, using a plurality of predetermined parameters and the laser head (<NUM>) of the robotic arm (<NUM>), an interface layer (<NUM>) located between the transparent outer layer (<NUM>) and the aircraft canopy (<NUM>), wherein movements of the robotic arm (<NUM>) during the ablation are based on the surface measurements.