Tethered Robot for Coating Application and Inspection

To address the Air Force (AF) need for a new coating application robot capable of navigating small, unique shaped Environmental Control System/Air-Cooled Fuel Cooler (ECS/ACFC) ducts of the F-22 aircraft, Intellisense Systems, Inc. (Intellisense) proposes to develop a new Tethered Robot for Coating Application and Inspection (TeRCA). The TeRCA system is based on (1) a tethered, flexible, robotic system with one degree of freedom (linear motion), which allows controllable and safe insertion into F-22 ECS/ACFC ducts to navigate the small, unique shaped geometry and implement controlled application of coatings, and (2) the novel integration of a borescope camera, which supports visual inspections before and after application of coatings. As a result, the TeRCA system will directly fulfill the AF need for a coating application robot capable of navigating small, unique shaped ECS/ACFC ducts of the F-22 aircraft. In Phase I, Intellisense will demonstrate the feasibility of the TeRCA system by developing a general concept and building a Phase I prototype. Intellisense will define the key technical requirements in collaboration with the AF SBIR liaisons and develop a technical concept and general architecture of the TeRCA system. Based on the developed system architecture, we will identify and procure the major TeRCA hardware and electronics components capable of supporting the required functionality of the proposed system. The Phase I development will culminate in a feasibility demonstration of TeRCA wherein the key functionalities are applied in a system representing the small and unique geometry of the ECS/ACFC. The Phase II development will culminate in development and demonstration of a fully functional TeRCA system that can apply coatings in small space in the unique geometry of the ECS/ACFC in F-22 aircraft. Intellisense will deliver the TeRCA prototype for evaluation by AF users. Intellisense will work with AF end users and primes (such as Lockheed Martin) to acquire feedback regarding the features and requirements for the TeRCA system and will identify any issues or updates needed for successful deployment of the TeRCA system.