Abstract: A non-destructive inspection system is presented. The non-destructive inspection system comprises a robotic end effector having an extendable actuator and a flange-mounted roller containing an ultrasonic sensor, the flange-mounted roller connected to the extendable actuator by a pivot connection, the extendable actuator configured to extend the flange-mounted roller until the flange-mounted roller contacts an inspection surface.

Abstract: A non-destructive inspection system is presented. The non-destructive inspection system comprises a robotic end effector having an extendable actuator and a flange-mounted roller containing an ultrasonic sensor, the flange-mounted roller connected to the extendable actuator by a pivot connection, the extendable actuator configured to extend the flange-mounted roller until the flange-mounted roller contacts an inspection surface.

Abstract: Methods are presented. Signals are sent into a first surface of a structure using an ultrasonic transducer. Ultrasound response signals are received at the ultrasonic transducer. A portion of a second surface of the structure is heated while the ultrasonic transducer is sending signals into the first surface, wherein the second surface is on an opposite side of the structure from the first surface. Infrared images of the portion of the second surface of the structure are taken after heating the second surface.

Abstract: A signal is sent into a structure at an angle substantially parallel to a ramp of the structure using a transducer array positioned at a first surface of the structure. An ultrasound response signal is formed at a second surface of the structure. The ultrasound response signal is received at the transducer array.

Abstract: Methods are presented. Signals are sent into a first surface of a structure using an ultrasonic transducer. Ultrasound response signals are received at the ultrasonic transducer. A portion of a second surface of the structure is heated while the ultrasonic transducer is sending signals into the first surface, wherein the second surface is on an opposite side of the structure from the first surface. Infrared images of the portion of the second surface of the structure are taken after heating the second surface.

Abstract: A signal is sent into a structure at an angle substantially parallel to a ramp of the structure using a transducer array positioned at a first surface of the structure. An ultrasound response signal is formed at a second surface of the structure. The ultrasound response signal is received at the transducer array.

Abstract: An automated blade crawler capable of scanning a multiplicity of non-destructive inspection sensors over a surface of an airfoil-shaped body such as a blade component. The blade crawler is movable in a spanwise direction, thereby enabling a sensor array to inspect the surface area on one or both sides of the blade component in one pass. The sensors concurrently output scan imaging data which is multiplexed, the multiplexed being transmitted (via an electrical cable or wirelessly) to data collection and display hardware at an operations control center.

Abstract: A method and apparatus for evaluating an object having a wrinkle. Energy is sent into the object at a plurality of locations using an array of transmitting elements. Reflected energy is received at an array of receiving elements in response to a portion of the energy being reflected off a plurality of layers in the object. A three-dimensional model of the wrinkle in the object is created based on the reflected energy received at the array of receiving elements.

Abstract: Systems and methods using fluid-filled hollow microspheres to assist in monitoring or indicating high-energy blunt impacts on structures such as aircraft. A multiplicity of microspheres may be adhered to or embedded in a coating applied on a surface of a substrate (e.g., a tape or an appliqué), which substrate in turn can be adhered to a surface of a structure to be monitored. The microspheres are designed to rupture at one or more specified pressure thresholds. In some embodiments, the microspheres are filled with electrically conductive fluid which, if released from ruptured microsphere, changes the electromagnetic state of the substrate. In response to the detection of a sufficiently large change in the electromagnetic state of the substrate, a blunt impact indication is generated. The impact site may then undergo non-destructive inspection.

Abstract: A method and apparatus for inspecting a test object. A sound signal is sent from a first portion of a curved transducer array through the test object in a direction towards a second portion of the curved transducer array. The curved transducer array has a shape that is configured to cover a non-planar surface of the test object. A response signal in response to the sound signal is received at the second portion of the curved transducer array.

Abstract: Systems and methods using fluid-filled hollow microspheres to assist in monitoring or indicating high-energy blunt impacts on structures such as aircraft. A multiplicity of microspheres may be adhered to or embedded in a coating applied on a surface of a substrate (e.g., a tape or an appliqué), which substrate in turn can be adhered to a surface of a structure to be monitored. The microspheres are designed to rupture at one or more specified pressure thresholds. In some embodiments, the microspheres are filled with electrically conductive fluid which, if released from ruptured microsphere, changes the electromagnetic state of the substrate. In response to the detection of a sufficiently large change in the electromagnetic state of the substrate, a blunt impact indication is generated. The impact site may then undergo non-destructive inspection.

Abstract: A mechanism for adjusting the orientation of an end effector (e.g., a non-destructive inspection sensor) during movement over a contoured surface, comprising: (1) a pneumatic or spring-loaded plunger shaft that facilitates positioning of an end effector onto a highly contoured surface by allowing a wide range of vertical motion; (2) a rocker pivotably coupled to a distal end of the plunger shaft, the rocker being pivotable about a horizontal axis to allow a pair of follower wheels coupled to distal ends of the rocker arms to follow the contoured surface and keep the end effector oriented correctly relative to the surface without tipping over; and (3) a hozzle (i.e., an end effector holder) attached to the rocker for rotation therewith, the end effector being coupled to the hozzle by an elastomeric gasket or a plurality of springs which allow the orientation of the end effector relative to the hozzle to change in response to contact forces.

Abstract: In one process, a mechanical stress (quasi-static or dynamic) or thermal stress is introduced into a local area of a structure where damage is suspected. A standard (or high speed for some dynamic stress approaches) video recording is made of the area under test. The video is processed using a motion amplification algorithm which magnifies extremely small motions. The motion amplification can reveal strains (for static or thermal loading) or wave patterns (for dynamic loading) generated on the surface of the part. If there is damage or structural change, the resulting surface strains will indicate it, or the surface waves in that area will change in phase, amplitude, or both, and will be indicated in the video images. In another process, motion magnification is used to highlight local failure events during structural testing.

Abstract: A monitoring system includes a transducer coupled to an outer surface of a tank wall. The transducer is oriented to transmit a first signal through the tank wall. An intermediate reflective surface is positioned within the fuel storage tank. The intermediate reflective surface is oriented to produce a first reflected signal associated with the first signal. A controller is programmed to calculate a fuel level based on at least the first signal and the first reflected signal.

Abstract: A system and method that allow inspection of hollow structures made of composite material, such as an integrally stiffened wing box of an aircraft. A wing box comprises top and bottom skins connected by a plurality of spaced spars. The system employs a plurality of scanners for inspecting different portions of each spar. The system uses dynamically controlled magnetic coupling to connect an external drive tractor to computer-controlled scanners that carry respective sensors, e.g., linear ultrasonic transducer arrays. A system operator can control the various components by means of a graphical user interface comprising multiple interaction regions that represent the individual scanner motion paths and are associated with respective motion script files.

Abstract: A method and apparatus for inspecting a test object. A sound signal is sent from a first portion of a curved transducer array through the test object in a direction towards a second portion of the curved transducer array. The curved transducer array has a shape that is configured to cover a non-planar surface of the test object. A response signal in response to the sound signal is received at the second portion of the curved transducer array.

Abstract: An automated blade crawler capable of scanning a multiplicity of non-destructive inspection sensors over a surface of an airfoil-shaped body such as a blade component. The blade crawler is movable in a spanwise direction, thereby enabling a sensor array to inspect the surface area on one or both sides of the blade component in one pass. The sensors concurrently output scan imaging data which is multiplexed, the multiplexed being transmitted (via an electrical cable or wirelessly) to data collection and display hardware at an operations control center.

Abstract: A mechanism for adjusting the orientation of an end effector (e.g., a non-destructive inspection sensor) during movement over a contoured surface, comprising: (1) a pneumatic or spring-loaded plunger shaft that facilitates positioning of an end effector onto a highly contoured surface by allowing a wide range of vertical motion; (2) a rocker pivotably coupled to a distal end of the plunger shaft, the rocker being pivotable about a horizontal axis to allow a pair of follower wheels coupled to distal ends of the rocker arms to follow the contoured surface and keep the end effector oriented correctly relative to the surface without tipping over; and (3) a hozzle (i.e., an end effector holder) attached to the rocker for rotation therewith, the end effector being coupled to the hozzle by an elastomeric gasket or a plurality of springs which allow the orientation of the end effector relative to the hozzle to change in response to contact forces.

Abstract: A blunt impact indicator tape includes a tape strip, a plurality of rupture-able fluid microspheres carried by the tape strip and a colored indicator fluid in each of the plurality of fluid microspheres.

Abstract: A system and method that allow inspection of hollow structures made of composite material, such as an integrally stiffened wing box of an aircraft. A wing box comprises top and bottom skins connected by a plurality of spaced spars. The system employs a plurality of scanners for inspecting different portions of each spar. The system uses dynamically controlled magnetic coupling to connect an external drive tractor to computer-controlled scanners that carry respective sensors, e.g., linear ultrasonic transducer arrays. A system operator can control the various components by means of a graphical user interface comprising multiple interaction regions that represent the individual scanner motion paths and are associated with respective motion script files.