25018 – FLX BOT: Intelligent Robot for Tight Space Inspections & Maintenance

FLX BOT: Intelligent Robot for Tight Space Inspections & Maintenance

Robotics and Automation

Surface preparation & corrosion control are critical processes to ensure structural integrity and longevity of aircraft, ships and DoD assets. Challenges include:

• Labor-intensive/time-consuming manual processes
• Inconsistency/lack of precision in inspections/maintenance
• Inability to gain access to tight spaces on ships and aircraft, or insufficient lighting
• Reliance on subjective visual inspections
• Safety risks for personnel in confined spaces, on ladders/scaffolding

FLX BOT, a handheld, 1” diameter, articulating robot is designed to address these challenges and advance the efficiency in surface preparation & corrosion control.

• Integration of Ultrasonic NDT end effector allows for enhanced detection/monitoring of corrosion, enabling predictive maintenance and lifecycle management
• 360° articulation allows access to hard-to-reach areas critical for maintenance, reducing the need for time-consuming disassembly
• Field demos in the DoD have shown reductions in inspection times (90+% time savings), demonstrating improved efficiency vs. current manual maintenance practices
• Remote operation reduces risks associated with hazards, confined spaces avoiding ladders/scaffolding

The FLX BOT (TRL 6) successfully demonstrated in relevant environments:

• Vigor Shipyard (Seattle)
• SALVEX Battlefield Damage Assessment (BDA) Exercise (Hawaii)
• Atlantic Thunder BDA Exercise (Philadelphia)
• MTA Transit Authority (NYC)
• Air Force – Aircraft Wing Fuel Tank Inspections

Results from pilots:

• Significant reductions in inspection times (e.g., 90+% time savings in DoD exhaust duct inspections)
• Positive user feedback and rapid user adoption by DoD techs
• Successful development and testing of a custom Ultrasonic NDT end effector for corrosion detection

Benefits to the DOD:

• By automating and streamlining inspections/maintenance, the FLX BOT reduces cycle times, manpower requirements, and costs associated with corrosion control
• Faster and more efficient maintenance translates to improved operational readiness of DoD assets
• Reduces labor costs, decreases downtime, and prevents costly failures
• Remote inspections minimize risks & hazards to personnel
• The FLX BOT’s capabilities are readily applicable to any service branches of the DoD for a wide range of inspection/maintenance tasks in various environments

Innovation Challenges:

• Further development of AI-driven analytics for enhanced predictive maintenance
• Expanding the library of modular end effectors for diverse applications
• Ensuring seamless integration with existing DoD systems and data infrastructure

Next Steps:

• Scaling up FLX BOT procurement and deployment across DoD facilities
• Formalizing training programs and SOPs for widespread adoption
• Continued R&D to enhance capabilities, including AI-driven analytics and real-time corrosion monitoring
• Establishing a centralized support and maintenance system for long-term reliability
• Secure long-term funding and support for large scale deployment