Abstract: Methods and systems according to one or more examples are provided for testing an automated platform, such as a robot. In one example, a system comprises a first robot configured to perform one or more processing operations on a workpiece. The system further comprises a second robot configured to simulate one or more parameters of the workpiece and an associated processing operation to provide one or more test conditions corresponding to each of the one or more processing operations the first robot would perform on the workpiece to test the first robot.

Abstract: A method (1000) of additively manufacturing an object (200) from a powder material (202) comprises discharging the powder material (202) from a powder-deposition opening (126) in a hollow body (122) of a powder-supply arm (108) while rotating the powder-supply arm (108) and an energy-supply arm (112) about a vertical axis A1. Method (1000) also comprises, while rotating the powder-supply arm (108) and the energy-supply arm (112) about the vertical axis A1, distributing the powder material (202) within a powder-bed volume (204) using a powder-distribution blade (128) that is coupled to the hollow body (122) and extends along the powder-deposition opening (126). The method (1000) further comprises, while rotating the powder-supply arm (108) and the energy-supply arm (112) about vertical axis A1, consolidating at least a portion of the powder material (202) in the powder-bed volume (204) using the energy emitters (114), coupled to the energy-supply arm (112).

Abstract: An additive-manufacturing apparatus (100) comprises a support (102) and a powder-material source (106). The additive-manufacturing apparatus (100) further comprises a powder-supply arm (108), which comprises a hollow body (122), having an interior volume (124) that is in communication with the powder-material source (106), a powder-deposition opening (126) in the hollow body (122), and a powder-distribution blade (128), coupled to the hollow body (122) and extending along the powder-deposition opening (126). The additive-manufacturing apparatus (100) also comprises an energy source (110), an energy-supply arm (112), and energy emitters (114), coupled to the energy-supply arm (112). The additive-manufacturing apparatus (100) further comprises a rotary drive (116), configured to rotate the powder-supply arm (108) and the energy-supply arm (112) about a vertical axis A1, passing through the support (102), and intersecting a powder-supply-arm central axis A2 and an energy-supply-arm central axis A3.

Abstract: An additive-manufacturing apparatus (100) comprises a support (102) and a powder-material source (106). The additive-manufacturing apparatus (100) further comprises a powder-supply arm (108), which comprises a hollow body (122), having an interior volume (124) that is in communication with the powder-material source (106), a powder-deposition opening (126) in the hollow body (122), and a powder-distribution blade (128), coupled to the hollow body (122) and extending along the powder-deposition opening (126). The additive-manufacturing apparatus (100) also comprises an energy source (110), an energy-supply arm (112), and energy emitters (114), coupled to the energy-supply arm (112). The additive-manufacturing apparatus (100) further comprises a rotary drive (116), configured to rotate the powder-supply arm (108) and the energy-supply arm (112) about a vertical axis A1, passing through the support (102), and intersecting a powder-supply-arm central axis A2 and an energy-supply-arm central axis A3.

Abstract: A method (1000) of additively manufacturing an object (200) from a powder material (202) comprises discharging the powder material (202) from a powder-deposition opening (126) in a hollow body (122) of a powder-supply arm (108) while rotating the powder-supply arm (108) and an energy-supply arm (112) about a vertical axis A1. Method (1000) also comprises, while rotating the powder-supply arm (108) and the energy-supply arm (112) about the vertical axis A1, distributing the powder material (202) within a powder-bed volume (204) using a powder-distribution blade (128) that is coupled to the hollow body (122) and extends along the powder-deposition opening (126). The method (1000) further comprises, while rotating the powder-supply arm (108) and the energy-supply arm (112) about vertical axis A1, consolidating at least a portion of the powder material (202) in the powder-bed volume (204) using the energy emitters (114), coupled to the energy-supply arm (112).

Abstract: An inspection apparatus for performing an automated inspection operation across a surface of a workpiece is disclosed. The inspection apparatus may include a positioning apparatus, a platen fabricated from a magnetic material and having a platen surface, with the platen being mounted on the positioning apparatus and the positioning apparatus being operational to move the platen relative to the surface of the workpiece, and an inspection module disposed on the platen surface and having an inspection end effector. The inspection module may generate a magnetic field that biases the inspection module toward the platen, and may be operable to generate a magnetic flux to control movement of the inspection module over the platen surface to perform the automated inspection operation across the surface of the workpiece.

Abstract: Systems, methods, and apparatus are disclosed for machining a part. Methods include generating a first spatial representation identifying a first orientation of a machining tool, and mechanically coupling an end effector to the part at a first position, the end effector including the machining tool and a coupling tool. Methods include generating a second spatial representation identifying a second orientation of the machining tool relative to the part, the first and second spatial representations being generated based on images captured by at least one imaging device and measurements from a plurality of sensors. Methods include identifying a plurality of differences that result from the coupling and that include a rotational distance and translational distance, the identifying being based on a comparison of a first image and a second image. Methods include adjusting the machining tool to return the machining tool to the first orientation at the first position.

Abstract: Systems and methods for retuning a surface to a nominal geometry using local reference points are disclosed. The system can include an imaging device for detecting the location of local features on an object. The system can use the location of local features, as opposed to an absolute reference frame, to determine one or more reference areas and one or more surface defects on an object. The system can then determine a nominal geometry for the surface (i.e., a surface that is substantially free of surface defects) and calculate the tool path necessary to create a nominal geometry. The system can machine the surface and, in some cases, rescan the surface to ensure the operation has machined the part to the nominal geometry.

Abstract: Systems, methods, and apparatus are disclosed for machining a part. Methods include generating a first spatial representation identifying a first orientation of a machining tool, and mechanically coupling an end effector to the part at a first position, the end effector including the machining tool and a coupling tool. Methods include generating a second spatial representation identifying a second orientation of the machining tool relative to the part, the first and second spatial representations being generated based on images captured by at least one imaging device and measurements from a plurality of sensors. Methods include identifying a plurality of differences that result from the coupling and that include a rotational distance and translational distance, the identifying being based on a comparison of a first image and a second image. Methods include adjusting the machining tool to return the machining tool to the first orientation at the first position.

Abstract: Systems, methods, and apparatus are disclosed for machining a part. The methods may include generating a plurality of spatial representations associated with a plurality of positions identified by a machining pattern associated with the part. The plurality of spatial representations may include a first spatial representation identifying a first orientation of a machining tool relative to the part at a first position. The methods may include moving an end effector to the first position. The methods may include mechanically coupling, using a coupling tool, the end effector to the part at the first position. The methods may include generating a second spatial representation identifying a second orientation of the machining tool relative to the part at the first position. The methods may include adjusting the machining tool in response to determining that the second spatial representation is different than the first spatial representation.

Abstract: Methods and systems according to one or more examples are provided for testing an automated platform, such as a robot. In one example, a system comprises a first robot configured to perform one or more processing operations on a workpiece. The system further comprises a second robot configured to simulate one or more parameters of the workpiece and an associated processing operation to provide one or more test conditions corresponding to each of the one or more processing operations the first robot would perform on the workpiece to test the first robot.

Abstract: Systems and methods are provided for designing flat composites that are formed into 3D shapes. One embodiment is a method that includes loading data defining a three dimensional (3D) shape for a composite part, identifying constraints based on dimensions of the 3D shape, simulating flattening of the 3D shape into a planar shape, and acquiring a mandrel having the planar shape. The method also includes placing features at the mandrel which permit a laminate laid-up onto the mandrel to compensate for the constraints during forming of the laminate into the 3D shape, and generating a Numerical Control (NC) program that directs an Automated Fiber Placement (AFP) machine laying up the laminate. The NC program includes instructions for laying up tows of constituent material onto the mandrel having the features, to form layers of the laminate.

Abstract: A finishing apparatus for performing an automated finishing operation on a surface of a workpiece is disclosed. The finishing apparatus may include a platen fabricated from a magnetic material and having a platen surface, and a finishing module disposed on the platen surface and having a finishing operation end effector. The finishing module may generate a magnetic field that biases the finishing module toward the platen, and may be operable to generate a magnetic flux to control movement of the finishing module over the platen surface to perform the automated finishing operation on the surface of the workpiece.

Abstract: An inspection apparatus for performing an automated inspection operation across a surface of a workpiece is disclosed. The inspection apparatus may include a positioning apparatus, a platen fabricated from a magnetic material and having a platen surface, with the platen being mounted on the positioning apparatus and the positioning apparatus being operational to move the platen relative to the surface of the workpiece, and an inspection module disposed on the platen surface and having an inspection end effector. The inspection module may generate a magnetic field that biases the inspection module toward the platen, and may be operable to generate a magnetic flux to control movement of the inspection module over the platen surface to perform the automated inspection operation across the surface of the workpiece.

Abstract: A system includes a robotic device for moving an inspection tool, a scanner coupleable to the robotic device such that the robotic device is configured to automatically move the scanner to collect data associated with a surface of the object, and a computer system configured to determine a surface profile associated with the surface of the object based on the data, and generate a tool path for inspecting the object using the inspection tool based on the surface profile.

Abstract: An inspection apparatus for performing an automated inspection operation across a surface of a workpiece is disclosed. The inspection apparatus may include a platen fabricated from a magnetic material and having a platen surface, and an inspection module disposed on the platen surface and having an inspection end effector. The inspection module may generate a magnetic field that biases the inspection module toward the platen, and may be operable to generate a magnetic flux to control movement of the inspection module over the platen surface to perform the automated inspection operation across the surface of the workpiece.

Abstract: Systems and methods for generating a coordinate transformation are disclosed. The system can include a non-destructive imaging (NDI) device for detecting the location of local surface and subsurface features in an object (e.g., an aircraft). The system can compare the location of these local features to the location of features from engineering drawings (e.g., CAD files) to generate a coordinate transformation from a machine coordinate system, for example, to an absolute coordinate system. The system can then accurately locate a work piece to perform repairs or replacements, as necessary. The system can also include a robotic arm to enable repairs to be performed at reduced cost and with increased accuracy. The system can also compare two or more NDI scans to locate or relocate a machine that has been moved. This can enable the machine to be repositioned for repairs, maintenance, or to perform a two part repair.

Abstract: Systems and methods are provided for designing flat composites that are formed into 3D shapes. One embodiment is a method that includes loading data defining a three dimensional (3D) shape for a composite part, identifying constraints based on dimensions of the 3D shape, simulating flattening of the 3D shape into a planar shape, and acquiring a mandrel having the planar shape. The method also includes placing features at the mandrel which permit a laminate laid-up onto the mandrel to compensate for the constraints during forming of the laminate into the 3D shape, and generating a Numerical Control (NC) program that directs an Automated Fiber Placement (AFP) machine laying up the laminate. The NC program includes instructions for laying up tows of constituent material onto the mandrel having the features, to form layers of the laminate.

Abstract: An inspection apparatus for performing an automated inspection operation across a surface of a workpiece is disclosed. The inspection apparatus may include a platen fabricated from a magnetic material and having a platen surface, and an inspection module disposed on the platen surface and having an inspection end effector. The inspection module may generate a magnetic field that biases the inspection module toward the platen, and may be operable to generate a magnetic flux to control movement of the inspection module over the platen surface to perform the automated inspection operation across the surface of the workpiece.

Abstract: A finishing apparatus for performing an automated finishing operation on a surface of a workpiece is disclosed. The finishing apparatus may include a platen fabricated from a magnetic material and having a platen surface, and a finishing module disposed on the platen surface and having a finishing operation end effector. The finishing module may generate a magnetic field that biases the finishing module toward the platen, and may be operable to generate a magnetic flux to control movement of the finishing module over the platen surface to perform the automated finishing operation on the surface of the workpiece.