Abstract: A method includes generating, based on first surface data that includes three-dimensional (3D) point positions corresponding to a first portion of a surface of an object, first hole data that indicates first positions of holes in the first portion of the surface. The method includes generating, based on second surface data corresponding to a second portion of the surface of the object, second hole data that indicates second positions of the holes in the second portion of the surface. The method also includes matching the first positions to the second positions to perform an alignment with respect to the first surface data and the second surface data.

Abstract: A system and method for collecting spectral data of a region of interest with a sensor is described. In one embodiment, the method comprises generating a simulated spectral representation of a region of interest, identifying at least one of the plurality of materials as a material of interest within the region of interest, identifying other of the plurality of materials not identified as a material of interest as background materials within the region of interest, selecting a subset spectral portion of the spectral data according to the simulated spectral representation of the material of interest and the simulated spectral representation of the background materials within the region of interest, and configuring the sensor to collect a subset spectral portion of the spectral data.

Abstract: A method of analyzing a curved surface is provided. The method includes obtaining a first data point set including data points representative of a distance between points along the curved surface and a reference axis, determining outlier data points in the first data point set, extracting the outlier data points from the first data point set, thereby defining a second data point set. The method also includes determining a fitted curve for the second data point set, wherein the fitted curve defines an approximate true curve of the curved surface.

Abstract: Systems and methods are provided for verifying the placement of tows by a robot. One embodiment includes a robot that includes an end effector that lays up tows, actuators that reposition the end effector, a memory storing a Numerical Control (NC) program, and a robot controller that directs the actuators to reposition the end effector based on the NC program, and instructs the end effector to lay up tows based on the NC program. The system also includes a sensor system comprising an imaging device that acquires images of the tows as the tows are laid-up, a measuring device that generates input as tows are laid-up by the end effector, and a sensor controller that receives images from the imaging device and the input from the measuring device, and updates stored data to correlate the images with instructions in the NC program, based on the input.

Abstract: A method of developing an automatic control plan for printing on a contoured surface is disclosed. The method includes scanning a contoured surface with a surface scanning device to produce a contoured data set, and creating a multi-dimensional model, with a computing device, of the contoured surface based on the contoured surface data set. Additionally, the method includes inputting a multi-dimensional model of a printing array and an image to be printed onto the contoured surface, into the computing device. The method further includes simulating, on the computing device, a plurality of movements performed by the printing array and a printing by the printing array to apply the image on the contoured surface. Additionally, the method includes, compiling, on the computing device, the automatic control plan which is programmed to execute the plurality of movements of the printing array to apply the image on the contoured surface.

Abstract: Systems and methods are provided for verifying the placement of tows by a robot. One embodiment includes a robot that includes an end effector that lays up tows, actuators that reposition the end effector, a memory storing a Numerical Control (NC) program, and a robot controller that directs the actuators to reposition the end effector based on the NC program, and instructs the end effector to lay up tows based on the NC program. The system also includes a sensor system comprising an imaging device that acquires images of the tows as the tows are laid-up, a measuring device that generates input as tows are laid-up by the end effector, and a sensor controller that receives images from the imaging device and the input from the measuring device, and updates stored data to correlate the images with instructions in the NC program, based on the input.

Abstract: An apparatus and related methods for applying two-dimensional (2D) texture maps onto three-dimensional (3D) objects are described. A computing device can receive differing first and second meshes representing respective first and second 3D objects and a 2D texture associated with the first 3D object. The computing device can determine correspondence points between the first and second meshes and can align the first and second meshes using an alignment transformation based on the correspondence points. The computing device can determine texture portions of the 2D texture associated with first corresponding portions of the first mesh. The computing device can assign the texture portions to second corresponding portions of the aligned second mesh. For each texture portion, the computing device can: project the texture portion onto a 2D plane related to a particular second corresponding portion and fit the projected texture portion to the particular second corresponding portion.

Abstract: A method of collecting a metrology data set of a contoured surface with a metrology system and executing an automatic control plan for printing on a contoured surface is disclosed. The method includes attaching a work piece to a work piece frame and scanning a contoured surface of the work piece to obtain a metrology data set, a three-dimensional point cloud model is generated based on the metrology data set. Additionally, the method includes defining a spatial reference model of the work piece frame, and defining a print path for a print head assembly of a surface treatment assembly. Furthermore, the method includes discretizing the contoured surface into a plurality of regions and the print path is further defined into at least one independent regional print path for each region of the plurality of regions. Moreover, a computer software simulation verifies a control plan for printing on the contoured surface.

Abstract: A method for live metrology of an object includes performing a scanning operation by a plurality of sensors to collect electronic images of an object. The electronic images include 3-D point cloud data for live metrology of the object and the point cloud data from each sensor define a point cloud that represents the object. The method also includes stitching the point clouds from the plurality of sensors to generate a reconstructed model of an as-manufactured object. The method further includes comparing the reconstructed model of the as-manufactured object to an as-designed model of the object to determine that the object is manufactured within an allowable tolerance to the as-designed model of the object.

Abstract: A method of developing an automatic control plan for printing on a contoured surface is disclosed. The method includes scanning a contoured surface with a surface scanning device to produce a contoured data set, and creating a multi-dimensional model, with a computing device, of the contoured surface based on the contoured surface data set. Additionally, the method includes inputting a multi-dimensional model of a printing array and an image to be printed onto the contoured surface, into the computing device. The method further includes simulating, on the computing device, a plurality of movements performed by the printing array and a printing by the printing array to apply the image on the contoured surface. Additionally, the method includes, compiling, on the computing device, the automatic control plan which is programmed to execute the plurality of movements of the printing array to apply the image on the contoured surface.

Abstract: An example method includes determining first classification rule(s) based on first data that classifies pixel groups of first reference image(s) as types of objects. The first reference image(s) are captured by a first sensor. The method further includes determining second classification rule(s) based on second data that classifies pixel groups of second reference image(s) as types of objects. The second reference image(s) are captured by a second sensor. The method includes classifying, as respective first objects, pixel group(s) of a first image of a scene based on the first classification rule(s). The method includes classifying, as respective second objects, pixel group(s) of a second image of the scene based on the second classification rule(s). The method further includes determining whether a change occurred in the scene based on the object classification of the first image(s) and the second image(s).

Abstract: Systems and methods are provided for verifying the placement of tows by a robot. One embodiment includes a robot that includes an end effector that lays up tows, actuators that reposition the end effector, a memory storing a Numerical Control (NC) program, and a robot controller that directs the actuators to reposition the end effector based on the NC program, and instructs the end effector to lay up tows based on the NC program. The system also includes a sensor system comprising an imaging device that acquires images of the tows as the tows are laid-up, a measuring device that generates input as tows are laid-up by the end effector, and a sensor controller that receives images from the imaging device and the input from the measuring device, and updates stored data to correlate the images with instructions in the NC program, based on the input.

Abstract: Provided are methods and systems for inspecting surfaces of various components, such as evaluating height deviations on these surfaces. A method involves aggregating inspection data from multiple line scanners into a combined data set. This combined data set represents a portion of the surface that is larger than the field of measurement any one of the scanners. Furthermore, each pair of adjacent scanners operate at different periods of time to avoid interference. Because operating periods are offset, surface portions scanned by the pair of adjacent scanners can overlap without interference. This overlap of the scanned portions ensures that the entire surface is analyzed. The position of scanners relative to the inspection surface may be changed in between the scans and, in some embodiments, even during the scan. This approach allows precise scanning of large surfaces.

Abstract: Provided are methods and systems for inspecting surfaces of various components, such as evaluating height deviations on these surfaces. A method involves aggregating inspection data from multiple line scanners into a combined data set. This combined data set represents a portion of the surface that is larger than the field of measurement any one of the scanners. Furthermore, each pair of adjacent scanners operate at different periods of time to avoid interference. Because operating periods are offset, surface portions scanned by the pair of adjacent scanners can overlap without interference. This overlap of the scanned portions ensures that the entire surface is analyzed. The position of scanners relative to the inspection surface may be changed in between the scans and, in some embodiments, even during the scan. This approach allows precise scanning of large surfaces.

Abstract: An example method includes determining first classification rule(s) based on first data that classifies pixel groups of first reference image(s) as types of objects. The first reference image(s) are captured by a first sensor. The method further includes determining second classification rule(s) based on second data that classifies pixel groups of second reference image(s) as types of objects. The second reference image(s) are captured by a second sensor. The method includes classifying, as respective first objects, pixel group(s) of a first image of a scene based on the first classification rule(s). The method includes classifying, as respective second objects, pixel group(s) of a second image of the scene based on the second classification rule(s). The method further includes determining whether a change occurred in the scene based on the object classification of the first image(s) and the second image(s).

Abstract: A system and method for collecting spectral data of a region of interest with a sensor is described. In one embodiment, the method comprises generating a simulated spectral representation of a region of interest, identifying at least one of the plurality of materials as a material of interest within the region of interest, identifying other of the plurality of materials not identified as a material of interest as background materials within the region of interest, selecting a subset spectral portion of the spectral data according to the simulated spectral representation of the material of interest and the simulated spectral representation of the background materials within the region of interest, and configuring the sensor to collect a subset spectral portion of the spectral data.

Abstract: Systems and methods are provided for verifying the placement of tows by a robot. One embodiment includes a robot that includes an end effector that lays up tows, actuators that reposition the end effector, a memory storing a Numerical Control (NC) program, and a robot controller that directs the actuators to reposition the end effector based on the NC program, and instructs the end effector to lay up tows based on the NC program. The system also includes a sensor system comprising an imaging device that acquires images of the tows as the tows are laid-up, a measuring device that generates input as tows are laid-up by the end effector, and a sensor controller that receives images from the imaging device and the input from the measuring device, and updates stored data to correlate the images with instructions in the NC program, based on the input.

Abstract: A method for registering existing vector data associated with a first image of a location to a second image of the location is provided. Typically the images are separated by an increment of time. The method is implemented by at least one computing device including at least one processor in communication with a memory. The method includes receiving, by the at least one computing device, the existing vector data associated with the first image of the location, receiving, by the at least one computing device, a plurality of controls for registering the first image to the second image, applying, by the at least one computing device, the plurality of controls to the existing vector data to generate updated vector data, and storing, in the memory, the updated vector data associated with the second image.

Abstract: A method for registering existing vector data associated with a first image of a location to a second image of the location is provided. Typically the images are separated by an increment of time. The method is implemented by at least one computing device including at least one processor in communication with a memory. The method includes receiving, by the at least one computing device, the existing vector data associated with the first image of the location, receiving, by the at least one computing device, a plurality of controls for registering the first image to the second image, applying, by the at least one computing device, the plurality of controls to the existing vector data to generate updated vector data, and storing, in the memory, the updated vector data associated with the second image.

Abstract: A method of analyzing a curved surface is provided. The method includes obtaining a first data point set including data points representative of a distance between points along the curved surface and a reference axis, determining outlier data points in the first data point set, extracting the outlier data points from the first data point set, thereby defining a second data point set. The method also includes determining a fitted curve for the second data point set, wherein the fitted curve defines an approximate true curve of the curved surface.