Abstract: According to an embodiment, a testing system for a satellite payload includes a built-in testing component configured at a satellite, the built-in testing component comprising a built-in testing component input and a built-in testing component output, and a payload component configured at the satellite, the payload component comprising a payload component input communicatively connected to the built-in testing component output and a payload component output communicatively connected to the built-in testing component input, wherein the built-in testing component is configured to transmit a digital test signal from the built-in testing component output to the payload component input and receive a digital output signal at the built-in testing component input from the payload component output.

Abstract: A method and apparatus for fastening structures. A first end of a body is placed into a hole on a first side of the structures. The body has an outer surface with a noncircular cross-section. A nut element is positioned on a flange at a second end of the body. A bolt is moved into a channel at the first end of the body towards the nut element on the flange on the second end of the body on the first side the structures. The bolt and the nut element are fastened to each other.

Abstract: Provided are assemblies having composite structures interlocked with shape memory alloy structures and methods of fabricating such assemblies. Interlocking may involve inserting an interlocking protrusion of a shape memory alloy structure into an interlocking opening of a composite structure and heating at least this protrusion of the shape memory alloy structure to activate the alloy and change the shape of the protrusion. This shape change engages the protrusion in the opening such that the protrusion cannot be removed from the opening. The shape memory alloy structure may be specifically trained prior to forming an assembly using a combination of thermal cycling and deformation to achieve specific pre-activation and post-activation shapes. The pre-activation shape allows inserting the interlocking protrusion into the opening, while the post-activation shape engages the interlocking protrusion within the opening. As such, activation of the shape memory alloy interlocks the two structures.

Abstract: Apparatus and method for applying pre-molded seal caps to fasteners. The apparatus includes an installation tool and a disposable cap holding fixture. The installation tool includes a body and a handle. A plunger can pass through the body and handle. A disposable cap holding fixture can be connected to an end of the body of the installation tool. The disposable cap holding fixture can grip a surface of a pre-molded seal cap. The pre-molded seal cap can then be placed on a fastener and the disposable cap holding fixture can be rotated to rotate the cap to cover the fastener with uncured sealant in the cap. The body and handle can be rotated by an operator or the body can rotate about the handle and actuation of the plunger can cause the body and the cap holding fixture to rotate. The plunger can then dislodge the cap from the fixture.

Abstract: Manufacturing a thermoplastic composite tubular structure embedded with a first load fitting comprising the steps of braiding a first plurality of inner layers of thermoplastic composite material around a soluble, expandable mandrel. A first load fitting is positioned on the first plurality of inner layers of thermoplastic composite material. A second plurality of outer layers of thermoplastic composite material is braided around the first load fitting and the mandrel so as to form an overbraided mandrel embedded with the first load fitting. The overbraided mandrel is installed into a matched tooling assembly and heated at a specified heating profile in order to consolidate the first plurality of inner layers of thermoplastic composite material and the second plurality of outer layers of thermoplastic composite material with the first load fitting so as to form a thermoplastic composite tubular structure embedded with the first load fitting.

Abstract: A gimbal mechanism for a turret includes a support member and a pair of opposing yoke arms extending from the support member. The pair of opposing yoke arms define a first axis. A sphere is rotatably mounted between the opposing yoke arms for rotation about the first axis. A disk is rotatably mounted within the sphere for rotation about a second axis perpendicular to the first axis. The disk is sized for rotation within the sphere. The second axis may be offset from the first axis. An aperture is provided in the disk. The sphere includes a slot within which the aperture is moveable in response to rotation of the disk about the second axis. The aperture is movable to define a field of coverage in response to rotation of the sphere about the first axis and the disk about the second axis.

Abstract: The present invention relates to a structural health monitoring system, for example a system used in the non-destructive evaluation of an aircraft structure. The present invention provides a method and apparatus for evaluating one or more anomalies within a structure using a structural health monitoring system that includes at least three transducers arranged in operative contact with the structure such that no two transducers are aligned to be parallel. A transducer excites an elastic wave that propagates through the structure, and reflections from any anomalies within the structure are collected by the three transducers. These collected signals are analyzed to identify an anomaly within the structure. Time of flight techniques are used to determine the location of the anomaly.

Abstract: Software is prepared for deployment across an enterprise system. The software initially included a base package and now includes an extended package. The extended package includes duplicate files and new files with respect to the base package. A method comprises using a computer to create indices of files for each of the base and extended packages, the indices identifying properties of the files; compare the properties of the files listed in the indices to identify the duplicate files and the new files in the extended package; and create a deployment package that includes only the new files.

Abstract: A highly doped layer for interconnecting tunnel junctions in multijunction solar cells is presented. The highly doped layer is a delta doped layer in one or both layers of a tunnel diode junction used to connect two or more p-on-n or n-on-p solar cells in a multijunction solar cell. A delta doped layer is made by interrupting the epitaxial growth of one of the layers of the tunnel diode, depositing a delta dopant at a concentration substantially greater than the concentration used in growing the layer of the tunnel diode, and then continuing to epitaxially grow the remaining tunnel diode.

Abstract: A guide and safety guard for a table saw, of the type having a table top and a powered saw blade with an exposed saw blade portion projecting above the table top and a movable guide fence positionable on the table top on a far side of the saw blade, has a support rail having opposite ends coupled to support members in a desired spaced relation to the guide fence of the table saw, a guard block mounted by a sleeve portion so as to be slidable on the support rail in axial directions thereon, and rotatable on the support rail so that it can be moved out of and into operative position, wherein the guard block has a height projecting above the table top in the operative position that is greater than the height of the exposed saw blade portion for protecting the hand of the user, and a guard extension fixed to a trailing side of the guard block for protecting the wrist and lower arm area of the user.

Abstract: An EMI filter network may be used to provide interference filtering for multiple loads (referred to collectively as a dynamic load). In one aspect, the EMI filter network includes electrical switches that establish different configurations or arrangements of passive circuit elements (e.g., inductors and capacitors) where each configuration generates a different filter value. The EMI filter network may be communicatively coupled to a controller which changes the configuration of the EMI filter network using the switches in response to the dynamic load changing operational states. For example, each configuration of the EMI filter network may correspond to one of the operational states of the dynamic load. Thus, as the operational state of the dynamic load changes—e.g., different motors become operational—the controller alters the configuration of the EMI filter network to provide a filter value that corresponds to the current operational state of the dynamic load.

Abstract: A cooling system for a fuel tank of an aircraft includes a temperature sensor, a cooling system, and a control module. The temperature sensor detects a fuel temperature within the fuel tank. The cooling system maintains the fuel temperature below a control temperature. The phase change cooling system includes a heat exchanger. A cooling fluid flows through the heat exchanger and is in thermal communication with a surface of the fuel tank. The control module is in signal communication with the temperature sensor and the cooling system. The control module includes control logic for monitoring the temperature sensor, determining if the fuel temperature is above the control temperature, and generating an activation signal.

Abstract: Systems and methods provide for a guided lift system utilized for maneuvering payloads. According to aspects of the disclosure, a guided lift system may include a lift unit attached to a payload, at least two control tethers attached to the lift unit, and at least two control units fixed in positions and capable of adjusting the lengths of the control tethers. Coordinated length adjustments of the control tethers pulls the lift unit and payload in a desired direction to a desired delivery location.

Abstract: A method of forming a workpiece having an initial heat treatment and made of a naturally aging alloy to a final shape using an incremental sheet forming (ISF) machine having a coordinate system and a tool path corresponding to the final shape of the workpiece is disclosed. The method comprises positioning the workpiece in the ISF machine; performing an initial forming operation on the workpiece using the ISF machine; performing a final heat treatment on the workpiece; repositioning the workpiece in the ISF machine; and, with the workpiece in a final workpiece orientation in the ISF machine and the tool path of the ISF machine in a final tool-path orientation in the ISF machine, performing a final forming operation on the workpiece using the ISF machine to achieve the final shape of the workpiece. Intermediate heat treatments and intermediate forming operations in the ISF machine may also be performed.

Abstract: Methods for identifying and quantifying wrinkles in a composite structure by processing infrared image data. The intensity and first and second time derivatives thereof at a particular time can be displayed as thermography line profiles on a graph in which the horizontal axis represents the pixel number across the field of view of an infrared camera. The spatial derivatives of the foregoing thermography line profiles can also be calculated and displayed as a graph. The maximum amplitude (i.e., height) of an out-of-plane wrinkle can be determined using a correlation/calibration curve that is constructed by correlating infrared image data with optical measurement data. In addition, the wavelength and maximum amplitude of an in-plane wrinkle can be measured directly from the thermography line profiles.

Abstract: A combination of liquid-to-air and air-to-liquid heat exchangers is employed in an aircraft anti-icing system configured to avoid ice buildup on exterior leading edges of wings and engine inlets of aircraft during flight under known or anticipated icing conditions. The anti-icing system may be utilized in lieu of traditionally employed air-to-air heat exchangers. In one embodiment, a heated anti-icing liquid is conveyed through tubes juxtaposed against interior surfaces of the leading edges of the wings and engine inlets. The liquid is heated by engine core bleed air, and the tubes are arranged to optimize heat flux directly from the tubes into the leading edges of the wings and the engine inlets, respectively, to avoid ice accumulation. In one configuration, spring clips retain the tubes directly against the leading edge interiors of the wings and engine inlets, and thermal grease and insulation are used to enhance heat flux.

Abstract: A component-removal tool assembly is configured to remove a component from a mandrel assembly, and may include a main frame, and a plurality of rotational input devices extending from the main frame. Each rotational input device may be operatively coupled to a respective plunger that is configured to be actuated against a portion of the mandrel assembly. A synchronizing link synchronously couples the rotational input devices together. The synchronizing link operates to synchronize movement of the plurality of rotational input devices. Movement of one or more of the rotational input devices causes the plungers coupled thereto to exert a uniform and consistent disconnecting force against the mandrel assembly.

Abstract: A part analysis tool is used to analyze aspects of a composite part. The part analysis tool includes a verification control unit that compares numerical control data used to control operation of a forming system that is used to form the composite part to computer-aided design (CAD) data that includes an authoritative part definition for the composite part. The verification control unit determines whether the numerical control data is within one or more conformance thresholds related to the CAD data. The part analysis tool may also include an inspection control unit that compares inspection data of one or more plies of the composite part to the CAD data. The inspection control unit determines whether the inspection data is within the conformance threshold(s) related to the CAD data.

Abstract: A camera on a robotic arm end effector is used to locate a workpiece coordinate system transformation in rotation and translation with respect to the end effector coordinate system by successively measuring an offset between a target affixed to the workpiece and its expected location. The target reflects energy from a light beam provided by a light beam source. A beam splitter is used to align the light beam with a line of sight of the camera.

Abstract: Stepped sabots for projectiles are provided. One sabot includes a cylindrical tubular body and at least one stepped surface within the cylindrical tubular body. The stepped surface is configured for engaging at least one complementary surface on a projectile and the stepped surface forms a progressively narrower inner diameter of the cylindrical tubular body.