Collaborative Robotic System for Efficient Aircraft Confined Space Inspections

Aircraft maintenance, particularly confined space inspections within wing fuel tanks, presents significant challenges in terms of efficiency, safety, and operational readiness. Traditional methods require human entry into cramped, hazardous environments, limiting the pool of available technicians, increasing inspection times, and potentially exposing personnel to toxic chemicals and physical injury. Wing fuel tanks are so tight and dangerous that 3 workers (2 spotters) are required while only 10% of maintenance personnel can even fit into the wing leading to maintenance bottlenecks. For context, 22 hours of maintenance are required per flight hour on C-130s. Any delays keep critical aircraft from their mission. The FLX BOT, a modular, snake-like collaborative robot, is designed to address these challenges by enabling remote, high-precision inspections in confined aircraft structures without requiring human entry. It has the ability to inspect complex geometries within aircraft fuel tanks utilizing various end effectors such as high-resolution cameras, microphones, and sensors in real-time. This lightweight, handheld system is designed for single-operator use, with an intuitive interface requiring minimal training. Unlike traditional robotic crawlers or drones, which struggle with maneuverability in small, obstructed environments, the FLX BOT’s adaptive design allows it to traverse tight, structurally complex cavities. It can be inserted into an inspection port and guided to critical areas with real-time operator control or semi-autonomous navigation. By eliminating the need for ladders, respiratory gear, and human entry, FLX BOT can significantly enhance technician safety while reducing inspection time by over 50%. The proposed Phase II effort aims to adapt the FLX BOT’s design to military aviation applications, integrating ingress protection, durability enhancements, and improved data transmission capabilities that meet Air Force cybersecurity requirements. Prototype units containing these improvements will be manufactured for demonstration in operational environments, advancing the technology to TRL-7. Field trials will be conducted at Warner Robins Air Logistics Complex (WR-ALC) to validate performance in operational settings. The expected outcomes include increased aircraft mission readiness, improved maintenance efficiency, and enhanced worker safety by removing technicians from hazardous environments. The FLX BOT's dual-use potential extends beyond military aviation to naval ship inspections, transit maintenance, and industrial infrastructure, making it a transformative solution for confined-space inspections across multiple industries. This effort aligns with the Air Force’s broader modernization goals, leveraging robotics to streamline maintenance operations and reduce downtime. FLX BOT provides a scalable, cost-effective solution to enhance the speed, safety, and accuracy of confined-space inspections in defense and commercial sectors.