Abstract: A seam tracking robotic drilling machine (10) is disclosed which is capable of moving a drill head along the seam (12) between abutting skin panels (16, 18) to drill a plurality of precisely positioned holes (18) through the panel. The machine (10) includes a perimeter support frame (20) which mounts a platform (36) for rotation about an axis (38) generally perpendicular the panels to be drilled. The platform supports a carriage (48) for movement along an axis 50 parallel the surface of the panels and in the direction of the seam while the carriage (48) supports an inner carriage (62) for movement along axis 60 perpendicular thereto. A drill head (74) is mounted on the inner carriage (62). A series of variable height vacuum cup assemblies (22-28) support the perimeter support frame (20). A similar series of variable height vacuum cup assemblies (66-72) support the inner carriage (62).

Abstract: Sensor assemblies, comprising one or more sensors for use in high-temperature environments such as an aircraft wing, include a thermally conductive retaining member in thermal communication with either the sensor or the environment surrounding the sensor. A housing assembly placed proximate to, and in thermal communication with, the retaining member defines a fluid passageway. During operation, fluid circulates through the housing to enhance the transfer of heat away from the sensor. Such heat transfer facilitates maintaining a sensor environment within the tolerance range of the sensor, thereby facilitating monitoring of the pressure fluctuation (or other sensor parameter) during operation of the aircraft.

Abstract: An electronic bubble level display is provided for determining surface normality when coupled with three sensors (18, 20, 22) sensing distance to the surface. The signals from the sensors are provided to an electronic processor (34) for computing the surface angularity and translating the angularity to specific positions on an LED dot matrix display chip (38).

Abstract: A manually positioned computer controlled drilling machine (10) is disclosed for drilling a hole (12) through a surface (14). The machine includes a base (16) which is supported on a counterbalanced suspension so that an operator can manually move and shift the machine on the surface to be drilled. Automatic adjustable legs (20-26) are biased outwardly from the base by low pressure air cylinders which allows the operator to tilt and move the base (16) relative to the surface (14). This allows the operator to position the drill bit (18) over the position where the hole is to be drilled and orient the drill bit perpendicular to the surface. Caliper brakes (38) are then activated to lock the legs in place. A number of suction cup assemblies (42-52) are then sequentially moved outward into contact with the surface. A suction foot (56) on each of the suction cup assemblies is adhered to the surface by a vacuum.

Abstract: Ultrasonic inspection of composite products such as curved components of airplane engine nacelles utilizes guide wheels and rollers to support and control the nacelle component or panel and permit rotation of the nacelle panel about its longitudinal axis. The nacelle panel is passed through an inspection zone which contains an ultrasonic inspection assembly comprising ultrasonic transmitting transducers and ultrasonic receiving transducers mounted on opposite sides of the nacelle panel. The ultrasonic inspection assembly is mounted to be moved along a frame by a drive assembly whereby the ultrasonic inspection assembly is translated across the width of the nacelle panel. The nacelle panel is rotated about its axis in small incremental rotational steps by a cable driven by a motor drive assembly. After each incremental rotational movement of the nacelle panel, the ultrasonic inspection assembly is translated across the width of the nacelle panel to inspect the portion aligned with the frame.

Abstract: A machine for processing a workpiece is disclosed. Preferably, the machine includes a circular saw blade that may be positionable about multiple axes with respect to the workpiece. The machine is particularly suited for processing an elongated workpiece. The machine includes two gripping mechanisms and three vises that cooperate with one another to move an elongated workpiece into position, hold the workpiece while it is being processed, and remove the workpiece from the machine. The machine also includes a computer system that controls the orientation of the saw blade and the movements of the vises and gripping mechanisms.

Abstract: A self-indexing vise 10 for clamping an angled workpiece 47 includes a pair of jaws 20, 32 capable of relative movement, a semi-cylindrical jaw insert 54 received in a recess 52 in one of the jaws 20, 32 and capable of pivoting to automatically conform to the contour of an angled workpiece 47. The jaw insert 54 is sized slightly larger than the recess 52 in which it pivots such that when the vise 10 is loaded, a press fit forms between recess 52 and jaw insert 54 which locks the insert 54 into position.

Abstract: A method of processing a composite structure in an autoclave involves producing a layup (10) with a low density honeycomb core (12) covered by resin impregnated composite face plies (14). The layup is sealed to a mold (18) under a vacuum bag (20). The layup is then cured in an autoclave under high temperatures and pressures. A vacuum is applied between the layup (10) and the vacuum bag (20) via a vacuum port (22), thus creating a pressure differential across the bag (20). This creates a compressive consolidating force on the composite face plies (14). Volatiles emitted during curing are drawn away through the vacuum port (22). The core (12) communicates with the autoclave by means of a pressurization tube (26) which penetrates the mold (18) and into the core (12), thus eliminating the pressure differential between the core (12) and the autoclave. Autoclave pressure is communicated throughout the entire core via perforations (13) in the honeycomb core (12).

Abstract: A structurally-embedded electronics assembly is disclosed and includes an outer skin member which is lightly loaded structurally, a primary load-carrying member positioned inboard from the outer skin member, a core member positioned between the primary load-carrying member and the outer skin member, an intermediate skin member positioned between the outer skin member and the core member and an electronics structure positioned between a predetermined two of the members or intermingled with a predetermined number of the members set forth above which are adjacent each other. In another embodiment, a thermally conductive baseplate member is positioned inboard from the primary load-carrying member. In another embodiment, a vibration damping member is positioned inboard from the primary load-carrying member.