Abstract: Systems and methods for infrared thermographic inspection of large-scale composite structures such as sections of an aircraft fuselage. Optical metrology is used to precisely locate the infrared images relative to a three-dimensional coordinate system of the composite structure. The optical metrology may comprise laser tracking or photogrammetry or both. In some embodiments, the optical metrology comprises laser tracking merged with photogrammetry. Once the infrared images have been precisely located relative to the coordinate system of the composite structure, structural data about the composite structure (e.g., thickness data) can be retrieved from a database containing a three-dimensional model of the composite structure. In the case of thermographic porosity measurements, the infrared imaging data can be correlated with thickness data to determine the porosity of the composite structure in the inspection area.

Abstract: Systems and methods for infrared thermographic inspection of large-scale composite structures such as sections of an aircraft fuselage. Optical metrology is used to precisely locate the infrared images relative to a three-dimensional coordinate system of the composite structure. The optical metrology may comprise laser tracking or photogrammetry or both. In some embodiments, the optical metrology comprises laser tracking merged with photogrammetry. Once the infrared images have been precisely located relative to the coordinate system of the composite structure, structural data about the composite structure (e.g., thickness data) can be retrieved from a database containing a three-dimensional model of the composite structure. In the case of thermographic porosity measurements, the infrared imaging data can be correlated with thickness data to determine the porosity of the composite structure in the inspection area.

Abstract: Systems and methods for providing interactive production illustration information are provided. One system includes a machine vision system configured to attach to a user, wherein the machine vision system when attached to the user is aligned with a line of sight of the user towards a physical location. The machine vision system controllable by the user and configured to acquire an image of an article. The system also includes an interactive production illustration system coupled to the machine vision system, wherein the interactive production illustration system has stored therein interactive production illustration. The interactive production illustration system is configured to select interactive production illustration information for an assembly process for the article at the physical location based at least in part on the acquired image.

Abstract: Systems and methods to calibrate aircraft surfaces are provided. A particular method includes installing a set of laser targets. The set of laser targets includes at least first laser target and a second laser target. The first laser target is installed on a first side of a first aircraft surface and the second laser target is installed on a second side of the first aircraft surface at a known location relative to the first laser target. The method also includes determining a first position of the first laser target with a first laser device. The method further includes determining a second position of the second laser target with a second laser device. The method includes determining a position of the first aircraft surface based on the first position of the first laser target and the second position of the second laser target.

Abstract: Fuselage sections of an aircraft are joined using splice elements that compensate for gaps caused by mismatches between mating surfaces on the fuselage sections. The fuselage sections are virtually assembled using computer models that are based on non-contact measurements of as-built fuselage sections. The virtually assembled fuselage sections are used to map the gaps between the mating surfaces. The mapped gaps are used to produce tool inserts having profiles that reflect the dimensions of the gaps. The tool inserts are used to manufacture splice elements having profiles that fill the gaps when the fuselage sections are assembled and joined, thereby eliminating the need for shims and spaces to fill the gaps.

Abstract: Fuselage sections of an aircraft are joined using splice elements that compensate for gaps caused by mismatches between mating surfaces on the fuselage sections. The fuselage sections are virtually assembled using computer models that are based on non-contact measurements of as-built fuselage sections. The virtually assembled fuselage sections are used to map the gaps between the mating surfaces. The mapped gaps are used to produce tool inserts having profiles that reflect the dimensions of the gaps. The tool inserts are used to manufacture splice elements having profiles that fill the gaps when the fuselage sections are assembled and joined, thereby eliminating the need for shims and spaces to fill the gaps.

Abstract: Fuselage sections of an aircraft are joined using splice elements that compensate for gaps caused by mismatches between mating surfaces on the fuselage sections. The fuselage sections are virtually assembled using computer models that are based on non-contact measurements of as-built fuselage sections. The virtually assembled fuselage sections are used to map the gaps between the mating surfaces. The mapped gaps are used to produce tool inserts having profiles that reflect the dimensions of the gaps. The tool inserts are used to manufacture splice elements having profiles that fill the gaps when the fuselage sections are assembled and joined, thereby eliminating the need for shims and spaces to fill the gaps.

Abstract: A system for measuring a hole of a surface may include at least one light emitting member for emitting varied intensity flashes of light towards the hole of the surface. The system may further include a projector for projecting light beams onto the surface. The system may additionally include at least one camera for taking at least one picture of the hole of the surface each time the at least one light emitting member emits a flash of light towards the hole of the surface, and each time the projector projects light beams onto the surface. The system may also include a computer for determining measurements of the hole of the surface utilizing the at least one picture of the hole and Photogrammetry.

Abstract: Systems and methods to calibrate aircraft surfaces are provided. A particular method includes installing a set of laser targets. The set of laser targets includes at least first laser target and a second laser target. The first laser target is installed on a first side of a first aircraft surface and the second laser target is installed on a second side of the first aircraft surface at a known location relative to the first laser target. The method also includes determining a first position of the first laser target with a first laser device. The method further includes determining a second position of the second laser target with a second laser device. The method includes determining a position of the first aircraft surface based on the first position of the first laser target and the second position of the second laser target.

Abstract: Shims used to join part assemblies are automatically designed and fabricated without the need for fitting part assemblies together in order to determine the exact dimensions of voids filled by the shims. The locations of key features on part assemblies are surveyed using a merged photogrammetry and laser tracking technique that generate the dimensions of a virtual shim. The dimensions of the virtual shim are contained in a digital file that can be used to automatically fabricate the shim using automated fabrication equipment such as a CNC machining center. The automated virtual shim design may be modified to reflect the effect of part assembly fit on performance characteristics of the aircraft.

Abstract: Systems and methods can automatically inspect a workpiece. Non-destructive inspection sensors are mounted on a frame mounted on a transport device. Position of a first predetermined location of a workpiece is measured with a tracking system. The transport device is moved to position the non-destructive inspection sensors proximate the first predetermined location of a workpiece. A first portion of a workpiece proximate the first predetermined location is non-destructively inspected with the non-destructive inspection sensors. Position of a second predetermined location of a workpiece can be measured with the tracking system. The transport device can be moved to position the non-destructive inspection sensors proximate the second predetermined location of a workpiece, and a second portion of a workpiece proximate the second predetermined location can be non-destructively inspected with the non-destructive inspection sensors.

Abstract: The invention relates to the use of one or more targets to measure surfaces. The target may comprise a first portion adapted to reflect a laser beam towards a laser tracking device, a second portion adapted to reflect a light beam towards a photogrammetry device, and a third portion adapted to identify to a computer a unique identifier of the target.

Abstract: The surface of a part is measured using a combination of laser tracking and Photogrammetry processes. Cameras used in the Photogrammetry process are mounted on a carriage for movement to positions along a predetermined path where images of the part surface are recorded and then converted to surface measurements. Laser tracking is used to both measure the part surface and track the position of the cameras. The measurements made by Photogrammetry and laser tracking processes are combined with the camera position to produce highly accurate part surface measurements.

Abstract: Methods and systems for fabricating a composite structure are provided. The method includes receiving data representing a portion of a surface of the structure, measuring a surface of the structure, the measured surface corresponding to the received surface wherein the measuring is performed with the structure in a flexed condition, and determining a difference in a first and a second direction between the measured surface and the received surface at areas that correspond to the measured surface. The method also includes determining a difference in a third direction, transmitting to a morphing algorithm the determined differences in the first, second, and third directions, and determining a position in the first, second, and third directions of a point on the surface in the flexed condition that corresponds to a respective point on the received surface when the structure is placed in the nominal condition.

Abstract: The invention relates to the use of one or more targets in measuring surfaces. Each of the one or more targets may comprise a first portion adapted to reflect a laser beam towards a laser tracking device, and a second portion adapted to reflect a light beam towards a photogrammetry device. Simultaneous photogrammetry and laser tracking measurements may be taken utilizing the one or more targets.

Abstract: Systems and methods can automatically inspect a workpiece. Non-destructive inspection sensors are mounted on a frame mounted on a transport device. Position of a first predetermined location of a workpiece is measured with a tracking system. The transport device is moved to position the non-destructive inspection sensors proximate the first predetermined location of a workpiece. A first portion of a workpiece proximate the first predetermined location is non-destructively inspected with the non-destructive inspection sensors. Position of a second predetermined location of a workpiece can be measured with the tracking system. The transport device can be moved to position the non-destructive inspection sensors proximate the second predetermined location of a workpiece, and a second portion of a workpiece proximate the second predetermined location can be non-destructively inspected with the non-destructive inspection sensors.

Abstract: Methods and systems for fabricating a composite structure are provided. The method includes receiving data representing a portion of a surface of the structure, measuring a surface of the structure, the measured surface corresponding to the received surface wherein the measuring is performed with the structure in a flexed condition, and determining a difference in a first and a second direction between the measured surface and the received surface at areas that correspond to the measured surface. The method also includes determining a difference in a third direction, transmitting to a morphing algorithm the determined differences in the first, second, and third directions, and determining a position in the first, second, and third directions of a point on the surface in the flexed condition that corresponds to a respective point on the received surface when the structure is placed in the nominal condition.

Abstract: The invention relates to processes for measuring one or more surfaces of a part utilizing both Photogrammetry and laser tracking devices. The measured part may comprise the barrel of an airplane. In other embodiments, varying types of surfaces may be measured in both airplane and non-airplane applications. In one embodiment, such a process may comprise measuring at least one surface of a part utilizing Photogrammetry, and simultaneously measuring the at least one surface utilizing laser tracking.

Abstract: Fuselage sections of an aircraft are joined using splice elements that compensate for gaps caused by mismatches between mating surfaces on the fuselage sections. The fuselage sections are virtually assembled using computer models that are based on non-contact measurements of as-built fuselage sections. The virtually assembled fuselage sections are used to map the gaps between the mating surfaces. The mapped gaps are used to produce tool inserts having profiles that reflect the dimensions of the gaps. The tool inserts are used to manufacture splice elements having profiles that fill the gaps when the fuselage sections are assembled and joined, thereby eliminating the need for shims and spaces to fill the gaps.

Abstract: Shims used to join part assemblies are automatically designed and fabricated without the need for fitting part assemblies together in order to determine the exact dimensions of voids filled by the shims. The locations of key features on part assemblies are surveyed using a merged photogrammetry and laser tracking technique that generate the dimensions of a virtual shim. The dimensions of the virtual shim are contained in a digital file that can be used to automatically fabricate the shim using automated fabrication equipment such as a CNC machining center. The automated virtual shim design may be modified to reflect the effect of part assembly fit on performance characteristics of the aircraft.