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: Methods of performing a plurality of operations within a region of a part utilizing an end effector of a robot and robots that perform the methods are disclosed herein. The methods include collecting a spatial representation of the part and aligning a predetermined raster scan pattern for movement of the end effector relative to the part with the spatial representation of the part. The methods also include defining a plurality of normality vectors for the part at a plurality of predetermined operation locations for operation of the end effector. The methods further include moving the end effector relative to the part and along the predetermined raster scan pattern. The methods also include orienting the end effector such that an operation device of the end effector faces toward each operation location along a corresponding normality vector and executing a corresponding operation of the plurality of operations with the operation device.

Abstract: Certain aspects of the present disclosure provide techniques for a method, including: receiving multi-dimensional event data associated with a vehicle event; determining, based on the multi-dimensional event data, an inspection classification for the vehicle event; receiving multi-dimensional analysis data associated with the inspection classification for the vehicle event; determining, based on the multi-dimensional analysis data, a repair classification for the vehicle event; receiving multi-dimensional action data associated with the repair classification for the vehicle event; and determining, based on the multi-dimensional action data, a monitoring classification for the vehicle event.

Abstract: Methods and apparatus for performing repair operations using an unmanned aerial vehicle (UAV). A UAV carries a repair patch ensemble containing all repair materials (including a repair patch, a heating blanket and other ensemble materials) in a prepackaged form to the repair area. During flight of the UAV, the repair patch is vacuum adhered to the heating blanket. Vacuum pressure is also used to hold the repair patch ensemble in position on the composite surface of the structure. Then the hot bond process is enacted to bond the repair patch to the repair area. In accordance with one embodiment, the hot bond process involves heating the repair patch to adhesively bond the repair patch while applying vacuum pressure to consolidate the composite material. Then the repair patch is released from the ensemble and residual ensemble materials (heating blanket, bleeder material, and release films) are removed by the UAV.

Abstract: A piezoelectric sensor includes a substrate, a meta-membrane adhered to the substrate, and a piezoelectric element adhered to the meta-membrane. The substrate includes a support frame which laterally surrounds and partly defines a recess and a cover film which overlies and partly defines the recess. The support frame supports the cover film along an entire periphery of the cover film. The meta-membrane is adhered to the cover film of the substrate. In accordance with one embodiment, the meta-membrane has an auxetic bi-axial kirigami honeycomb structure. In accordance with another embodiment, the meta-membrane has an auxetic hexagonal honeycomb structure. The meta-membrane is adhered to the substrate and to the piezoelectric element using elastic glue. In one proposed implementation, the substrate and meta-membrane are made of polycarbonate and the piezoelectric element comprises a piezoelectric substrate made of polyvinylidene fluoride.

Abstract: Method, apparatus, system, and computer program product for inspecting a joining feature on an object. A portable housing with an x-ray system is moved along the joining feature on the object. The x-ray system is controlled to direct an x-ray beam through an opening in the portable housing to scan an area of the object containing the joining feature as the portable housing moves along the joining feature on the object. Sensor data generated from a backscatter detected by a sensor system is received. The backscatter is generated in response to the x-ray beam encountering the area of the object including the joining feature. A determination is made as to whether an inconsistency is present in the area of the object including the joining feature using the sensor data.

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: Rotation hoists are disclosed. A disclosed example rotation hoist to support a component includes a platform having a first end and a second end opposite the first end, a body supported by the platform, a rotator supported by the body, the rotator couplable to the component at a first position of the component, and an arm extending from the rotator, the arm couplable to the component at a second position of the component different from the first position, the rotator to rotate the arm to rotate the component.

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: Methods, systems and apparatuses are disclosed for non-destructively a substrate using ultrasound waves, and enhancing resolution of imaging created from ultrasound signals that are back reflected from a substrate surface second, or back surface by maintaining the incident angles of the ultrasonic beams at the substrate second surface such that the ultrasonic beams strike the substrate second surface at an angle that is substantially perpendicular to the complex geometric profile of the substrate second surface by supplying known spatial coordinates to the system to maintain the incident angles of the ultrasonic beams at a predetermined angle relative to the substrate second surface.

Abstract: Systems and methods are provided for utilizing pellet-loaded bladders to consolidate and/or harden composite parts. One embodiment is a method for fabricating a composite part. The method includes laying up a preform that is made of fiber reinforced material and that includes a cavity, inserting one or more bladders that are loaded with expandable pellets into the cavity, inflating the bladders in response to a triggering condition, consolidating the preform while the bladders are inflated, deflating the bladders, and removing the bladders from the cavity.

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 tool for detecting a covered edge of a structural member through sealant material of a fillet seal includes an edge detection probe mounted to a fixture. The probe outputs an interrogation signal toward the covered edge and receives a return signal indicative of a location of the covered edge. The tool includes an electronic control unit (“ECU”) in communication with the edge detection probe and a display screen. The ECU is configured to generate, from the return signal, one or more XY coordinates indicative of the edge location, and to display the edge location on the display screen. Additionally, the tool includes a seal measurement device. In response to the edge location, the device measures a predetermined dimension of the fillet seal, including a thickness and/or a shape of the fillet seal. A method includes detecting the covered edge using the tool.

Abstract: Methods, apparatus, systems, and articles of manufacture are disclosed for high-traffic density air transportation. An example system includes a land vehicle having a first location and a transit carrier having a movement system, first stacking couplers, a first and second magnetic coupler, and a transit pod having second stacking couplers configured to couple to the first stacking couplers, a UAV having UAV couplers and a second location, and a controller to, in response to obtaining a request to direct the land vehicle to move from the first location to a third location, invoke the UAV to move to the third location, and in response to the land vehicle and the UAV arriving at the third location, invoke the UAV to couple to the transit pod to facilitate transport of the transit pod from the third location to a fourth location by coupling the UAV couplers to the second stacking couplers.

Abstract: A non-destructive inspection apparatus includes a robotic device, an end effector coupled to the robotic device, and a controller coupled to the robotic device and the end effector. The controller is configured to determine, based on an amount of linear actuator extension of a sensor of the end effector and an amount of rotation of the sensor about a first axis of rotation and a second axis of rotation, a displacement of the sensor relative to a center point of the end effector surface so as to determine location information of the sensor, wherein sensor data for a location on a surface of a test article is sensed and correlated with the determined location information of the sensor. The robotic device controls movement of the end effector and is configured to determine, during the movement of the end effector, positional information for the center point of the end effector surface.

Abstract: An apparatus for automated maintenance of limited-access areas on large structures. The apparatus is a rolling or sliding tool-equipped mobile platform that is adhered to a surface by operation of one or more adherence fans and then propelled across the surface by operation of one or more propulsion fans. The adherence and propulsion fans are coupled to a base made of semi-rigid material. The adherence fans produce suction forces in one or more suction zones to adhere the mobile platform to the surface. The propulsion fans produce thrust to propel the surface-adhered mobile platform in a desired direction across the surface. The tool-equipped mobile platform is capable of adhering to and moving over a non-level surface on a large structure while keeping standoff contact elements in contact with the surface regardless of surface contour. The propulsion fans, adherence fans and maintenance tool (e.g., an NDI sensor unit) are controlled by a computer system.

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: 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: In an example, a method is described. The method comprises forming a single hole into a bond gap repair area. The method also comprises evacuating, via an adhesive injection apparatus attached to the single hole, the bond gap repair area and an injection channel of the adhesive injection apparatus. The method also comprises forcing adhesive through the evacuated injection channel and into the evacuated bond gap repair area.

Abstract: In an example, a method is described. The method comprises placing a repair patch over a repair area of a structure, the repair patch comprising a repair-patch hole. The method also comprises sealing the repair patch and repair area with a vacuum bag having a seal ring around a periphery of the vacuum bag. The method also comprises evacuating, via an adhesive injection apparatus attached to the repair-patch hole and the seal ring of the vacuum bag, the repair area and an injection channel of the adhesive injection apparatus. The method also comprises forcing adhesive through the evacuated injection channel and into the evacuated repair area.