Abstract: A system and method for detecting an anomaly of an optically transparent or translucent object are disclosed. The system and method include a light source configured to emit light, a light transmission element having a textured surface, and an optical couplant configured to be disposed between the light transmission element and the object. At least a portion of the light emitted by the light source is configured to pass into the light transmission element through the textured surface and pass into the object through the optical couplant. At least a portion of the light that passes into the object internally reflects within the object and impinges on the anomaly to provide an illumination that indicates the location of the anomaly.

Abstract: Systems and methods for automated swapping of a charged replacement battery for a depleted battery onboard an electric vehicle using a battery delivery vehicle (BDV). The BDV may be configured to operate autonomously or under remote control. The electric vehicle which receives the replacement battery from a BDV may be configured to operate autonomously (e.g., an AGV) or non-autonomously (e.g., an electric passenger car). The BDV is loaded with a fully (or partially) charged battery, and then moved to a rendezvous place at which the BDV is underneath and aligned with the electric vehicle. The battery is uploaded to the electric vehicle while the aligned BDV moves in tandem with the electric vehicle. After the replacement battery has been installed, the power distribution system onboard the electric vehicle switches over to draw DC power from the replacement battery (instead of from a depleted battery) without interrupting vehicle operation.

Abstract: A material system including a plurality of expandable pellets or a monolithic flexible carrier is disclosed, each of which may include a polymer matrix configured to hold an expandable core, and a flexible skin configured to encapsulate the polymer matrix, and where the flexible skin is at least partially permeable with respect to the expandable core or a gas released by the expandable core. Implementations of the material system may include where the polymer matrix may include a thermoplastic polymer. The material system may include a charging source configured to introduce blowing agent. A method of curing a composite part is also described.

Abstract: In an example, a method of sealing a bond cavity is described. The method comprises placing an adhesive around a perimeter of a first structure to be joined to a second structure. The method also comprises positioning the first structure relative to the second structure such that the adhesive is disposed between the first structure and the second structure. The method also comprises merging the first structure and the second structure until the first structure and the second structure are separated by a desired gap for bonding. The method also comprises heating the perimeter to at least partially cure the adhesive to form a leak-proof bond cavity perimeter between the first structure and the second structure.

Abstract: An example method of joining a first structure and a second structure is described that includes forming a bond cavity between a first structure and a second structure, placing a semi-permeable breather material at one or more exits of the bond cavity, placing a vacuum bag around the bond cavity and the semi-permeable breather material, evacuating the bond cavity via a vacuum port and forcing adhesive into the bond cavity via an adhesive port while the bond cavity is evacuated, and curing the adhesive via one or more heaters to bond the first structure to the second structure.

Abstract: A method for wirelessly coupling respective transducers of an automated motion platform and a sub-surface sensor node through a skin of a limited-access structure for the purpose of wireless power and data transfer. Coordinates of an as-designed position of the transducer of the sensor node in a local coordinate system of the limited-access structure are retrieved from a non-transitory tangible computer-readable storage medium. Then coordinates of a target position on an external surface of the skin of the limited-access structure are estimated. The target position is calculated to be aligned with the as-designed position of the transducer of the sensor node. The motion platform is moved under computer control so that the transducer onboard the motion platform moves toward the target position. Movement ceases when the transducer onboard the motion platform is at the target position. Then wave energy is transferred between the aligned transducers.

Abstract: Systems and methods for automated swapping of a charged replacement battery for a depleted battery onboard an electric vehicle using a battery delivery vehicle (BDV). The BDV may be configured to operate autonomously or under remote control. The electric vehicle which receives the replacement battery from a BDV may be configured to operate autonomously (e.g., an AGV) or non-autonomously (e.g., an electric passenger car). The BDV is loaded with a fully (or partially) charged battery, and then moved to a rendezvous place at which the BDV is underneath and aligned with the electric vehicle. The battery is uploaded to the electric vehicle while the aligned BDV moves in tandem with the electric vehicle. After the replacement battery has been installed, the power distribution system onboard the electric vehicle switches over to draw DC power from the replacement battery (instead of from a depleted battery) without interrupting vehicle operation.

Abstract: A material system including a plurality of expandable pellets or a monolithic flexible carrier is disclosed, each of which may include a polymer matrix configured to hold an expandable core, and a flexible skin configured to encapsulate the polymer matrix, and where the flexible skin is at least partially permeable with respect to the expandable core or a gas released by the expandable core. Implementations of the material system may include where the polymer matrix may include a thermoplastic polymer. The material system may include a charging source configured to introduce blowing agent. A method of curing a composite part is also described.

Abstract: A method of curing a composite part, including placing an uncured composite part on a mandrel, placing a plurality of expandable pellets on the uncured composite part, expanding the plurality of expandable pellets, applying a positive pressure to the uncured composite part, and curing the uncured composite part.

Abstract: A self-powered sensor node includes a printed wiring board connected to a patch. The printed wiring board includes a microcontroller, a transceiver, an antenna, and a power management module connected to supply electric power to the microcontroller. The patch comprises a metamaterial substrate and a piezoelectric element adhered to the metamaterial substrate. The piezoelectric element is connected to the power management module and to the microcontroller. The power management module is configured to store electric power received from the piezoelectric element. The microcontroller is configured to selectively convert electrical signals received from the piezoelectric element into sensor data and then command the transceiver to transmit the sensor data via the antenna. The metamaterial substrate has an auxetic kirigami honeycomb structure.

Abstract: Non-destructive testing apparatuses, systems, and methods for assessing strain in structural components are disclosed. Structural components include induced predetermined regions having materials of varying density, including induced geometric patterns of differing densities within the structural component that can be a composite material structural component. The method includes projecting waves of energy, that can be beams of electromagnetic (EM) energy and/or waves of ultrasonic (UT) energy, into or through the structural component to evaluate the predetermined induced pattern region of varying density and determining existing strain within a structural component based on the detected energy response.

Abstract: A material system including a plurality of expandable pellets or a monolithic flexible carrier is disclosed, each of which may include a polymer matrix configured to hold an expandable core, and a flexible skin configured to encapsulate the polymer matrix, and where the flexible skin is at least partially permeable with respect to the expandable core or a gas released by the expandable core. Implementations of the material system may include where the polymer matrix may include a thermoplastic polymer. The material system may include a charging source configured to introduce blowing agent. A method of curing a composite part is also described.

Abstract: A foam sheet core, including a plurality of foam sheet walls defining an array of hollow cells, wherein the plurality of foam sheet walls are bonded together to form the array of hollow cells, each of the plurality of foam sheet walls has a thickness from about 0.002 inches to about 0.08 inches, and each of the plurality of foam sheet walls has an average height from about 0.05 inches to about 5 inches.

Abstract: A method for repairing a composite structure, includes creating a repair cavity in a composite structure, placing foamable media in the repair cavity, placing a replacement skin over the repair cavity, and expanding the foamable media placed in the repair cavity.

Abstract: Skinned cell structures and methods of producing the same are disclosed. A disclosed example apparatus includes a placer to place foamable structures together to define a bundle, a restrainer to restrain the bundle, an activator to activate the foamable structures to expand and form a cell structure within the restrainer, a trimmer to trim the cell structure to define a core, and an assembler to couple a skin to the core to define the skinned cell structure.

Abstract: A method includes obtaining, at an unmanned aerial vehicle, a flight plan for the unmanned aerial vehicle. The flight plan is based on an aircraft type of an aircraft to be inspected. The method also includes coordinating, with a control device onboard the aircraft, an operation of a particular device of the aircraft based on the flight plan such that a state of the particular device changes when a particular sensor of the one or more sensors is located (i.e., positioned and oriented) to perform a sensing operation on the particular exterior light. The method further includes performing the sensing operation on the particular device using the particular sensor. The method also includes determining a functionality metric associated with the particular device based on the sensing operation.

Abstract: Systems and methods for tracking the location of a non-destructive inspection (NDI) scanner using scan data converted into images of a target object. Scan images are formed by aggregating successive scan strips acquired using one or two one-dimensional sensor arrays. An image processor computes a change in location of the NDI scanner relative to a previous location based on the respective positions of common features in partially overlapping scan images. The performance of the NDI scanner tracking system is enhanced by: (1) using depth and intensity filtering of the scan image data to differentiate features for improved landmark identification during real-time motion control; and (2) applying a loop-closure technique using scan image data to correct for drift in computed location. The enhancements are used to improve localization, which enables better motion control and coordinate accuracy for NDI scan data.

Abstract: A system for inspecting a structure includes a laser ultrasound device configured to direct laser light onto a surface of the structure that generates ultrasonic waves within the structure and to generate an array of ultrasound data representative of the ultrasonic waves. The system includes a robotic arm configured to move the laser light across the surface. The system includes a multiplex controller configured to trigger generation of the ultrasonic waves within the structure at an inspection location and to receive the array of ultrasound data for the inspection location. The system includes a computer system that includes a motion-control module configured to control movement of the laser light relative to the surface of the structure, a motion-tracking module configured determine when the laser light is at the inspection location, and an inspection module configured to process the array of ultrasound data to inspect the structure at the inspection location.

Abstract: An end effector, for adhesively attaching a first part to a second part, comprises a support, a first nozzle, movable relative to the support, and a second nozzle, movable relative to the support. The first nozzle comprises a first-nozzle-body outlet port and a first-nozzle separator plate. The second nozzle comprises a second-nozzle-body outlet port and a second-nozzle separator plate. The end effector additionally comprises a first ultrasonic-sensor roller that is rotatable relative to the support and located between the first nozzle and the second nozzle. The end effector also comprises a second ultrasonic-sensor roller that is rotatable relative to the support and located between the first ultrasonic-sensor roller and the second nozzle.

Abstract: An end effector, for adhesively attaching a first part to a second part, comprises a support, a first nozzle, movable relative to the support, and a second nozzle, movable relative to the support. The first nozzle comprises a first-nozzle-body outlet port and a first-nozzle separator plate. The second nozzle comprises a second-nozzle-body outlet port and a second-nozzle separator plate. The end effector additionally comprises a first ultrasonic-sensor roller that is rotatable relative to the support, translationally fixed relative to support, and located between the first nozzle and the second nozzle. The end effector also comprises a second ultrasonic-sensor roller that is rotatable relative to the support, translationally fixed relative to support, and located between the first ultrasonic-sensor roller and the second nozzle.