Abstract: Embodiments of the presently disclosed system include a thin thermoplastic or thermosetting polymer film loaded with non-polymeric inclusions that are susceptible to heating under a time-varying magnetic field. Insertion of this additional heating layer into a structural or semi-structural heterogeneous laminate provides an “on-demand” de-bonding site for laminate deconstruction. For example, in some embodiments when the heating layer is inserted between a cured Carbon-Fiber Reinforced Plastic (CFRP) layer and a Polymeric/Metallic film stackup layer, the heating layer can be selectively heated above its softening point (e.g., by using energy absorbed from a locally-applied time-varying magnetic field) to allow for ease of applique separation from the CFRP layer.

Abstract: An aircraft lifecycle in which digital data for an aircraft part is automatically collected, retained, and utilized to individualize aircraft inspection and maintenance is described. Several types of data, including non-destructive evaluation and measurement data and structural health monitoring data, are used in a feedback loop having various phases which may automatically receive data in digital format from other phases. In this manner the part being designed, fabricated, tested, and maintained for the aircraft is optimized and processes involved in the lifecycle of the part is made more efficient.

Abstract: An attachment unit is configured to secure to an object, such as cargo. The attachment unit includes one or more portions that are configured to secure to the object. The one or more portions are further configured to one or both of mechanically or magnetically removably couple to a clasp assembly.

Abstract: A deployable clasping system is configured to be deployed from a component and securely clasp and release an object. The deployable clasping system includes a cable that is deployable from the transit vehicle. A clasp assembly is coupled to the cable. The clasp assembly is configured to securely clasp the object. A propulsion sub-system is coupled to one or both of the cable and the clasp assembly. The propulsion sub-system is configured to maneuver the clasp assembly to the object.

Abstract: Composite fabrication system and associated methods. In one embodiment, a composite fabrication system comprises a molding tool that includes a forming surface at least partially disposed within a constrained space, and a foamable material that expands inside of the constrained space to form an expanded material that presses a layup of one or more composite layers against the molding tool. The composite fabrication system further comprises a curing device configured to cure the layup to form a composite part, and a cutting wire embedded in the constrained space that is heated and configured to cut the expanded material into pieces that are removable from the constrained space.

Abstract: A system and method for inspecting an additively manufactured component include an additive manufacturing head configured to form a component layer-by-layer, and an electromagnetic acoustic transducer (EMAT) configured to inspect one or more layers of the component.

Abstract: A manufacturing system includes a printhead, at least one profilometer, and a control system. The printhead extrudes a material onto a substrate and forms a new bead during additive manufacturing of an in-work article. The profilometer moves with the printhead and measures an in-work cross-sectional profile of existing beads of the in-work article. The control system generates in-work profile data including the in-work cross-sectional profile at a plurality of in-work profile locations, and continuously compares the in-work profile data to reference profile data of a reference article. The reference profile data includes a reference cross-sectional profile at a plurality of reference profile locations. The control system adjusts, based on the profile comparison, one or more bead forming parameters and causes the printhead to form the new bead according to the bead forming parameters to reduce or prevent nonconformities associated with forming the new bead.

Abstract: Situational-awareness controllers and methods to increase situational-awareness for an actor associated with a triggering event are described. An example method includes in response to receiving a notification of a triggering event generated by at least one sensor, a computing device accessing information that includes related to an actor associated with the triggering event. The computing device correlates the information to a compilation of historical information by (i) determining whether the actor's location is associated with one or more safety events stored as part of the compilation of historical information and (ii) determining a risk level of the actor based on whether the one or more associated safety events occurred within a predetermined range of time from the time associated with the triggering event. The computing device generates a command based on a result of the correlating and sends the command to at least one controllable device.

Abstract: Methods for performing repair operations using one or more unmanned aerial vehicles (UAVs). First, an unmanned aerial vehicle equipped with a camera is flown to a position in a vicinity of an area of interest on a surface of a structure. Image data representing one or more images of the structure in the area is acquired using the camera. Second, an unmanned aerial vehicle equipped with a non-destructive examination (NDE) sensor unit is flown until the NDE sensor unit is within measurement range of the structure in the area of interest. Then NDE sensor data representing structural characteristics of the structure in the area of interest is acquired. Third, an unmanned aerial vehicle equipped with a repair tool is moved to a location that places the repair tool in contact with the surface in the area of interest. Then the structure in the area is repaired using the repair tool.

Abstract: Apparatus and methods for real-time fusion of data acquired using ultrasonic and eddy current area sensors during nondestructive examination. The ultrasonic data is acquired using an array of ultrasonic transducer elements configured to enable the production and display of a C-scan of a small area. The ultrasonic transducer array may be one- or two-dimensional. The eddy current sensor can be a single pair of induction coils, a multiplicity of coil pairs, or a coil configuration in which the numbers of drive coils and sense coils are not equal. The eddy current sensor is able to provide data about the test material, such as material thickness or conductivity, to complement the ultrasonic data or enable auto-setup of the ultrasonic inspection device.

Abstract: Apparatus and methods for realigning and re-adhering a hanging tool-equipped crawler vehicle with respect to a non-level surface of a target object. When the cable-suspended crawler vehicle with suction devices is adhered to a non-level surface of a target object, it is possible for the crawler vehicle to detach from the surface and be left hanging from the end of the cable in a state. While hanging from the end of the cable in a misaligned state and not in contact with the target object, the crawler vehicle is unable to carry out a planned maintenance operation. Before the maintenance operation is resumed, the crawler vehicle is realigned with the surface of the target object using a turret, a rotating arm or a cam-shaped roll bar provided as equipment on the crawler vehicle and then re-adhered to the surface by activation of the suction devices.

Abstract: Apparatus and methods that can be used to stabilize the distal end of an arm (and an end effector attached thereto) of an automated extended-reach tool-equipped assembly. Stabilization is provided by three or more stabilizers, each comprising a stationary part and a movable part. Each stationary part has a fixed location relative to the end effector; each movable part is translatably coupled to a respective stationary part and comprises a contactor disposed at a distal end of the movable part. When the stabilizers are actuated, the contactors are translated toward and into contact with the surface of the workpiece and then locked in place to stabilize the distal end of the arm and the end effector. During tool operation, the stabilizers reduce oscillation of the end effector (and all structure fixedly coupled thereto).

Abstract: Systems and methods for assessing strain in structural components are disclosed. Structural component may have geometric patterns of grooves, with the grooves in the geometric pattern each having a groove width. The method may include illuminating the geometric pattern of grooves with a first light at a first wavelength that corresponds to the groove width to create diffraction when the first light hits the geometric pattern of grooves and corresponding changes in the wavelength of the light reflected from the geometric pattern of grooves indicating changes in the groove widths due to strain caused when the structural component is exposed to environmental conditions, detecting the wavelength of the light reflected from the geometric pattern of grooves, and correlating the detected wavelength of the light reflected from the geometric pattern of grooves to the strain in the structural components.

Abstract: A method of forming a laminated metallic structure includes steps of: (1) providing a first preformed-metallic sheet having a three-dimensional shape of a first graduated three-dimensional size; (2) providing a second preformed-metallic sheet having the three-dimensional shape of a second graduated three-dimensional size; (3) nesting the second preformed-metallic sheet in the first preformed-metallic sheet; and (4) bonding the first preformed-metallic sheet and the second preformed-metallic sheet together.

Abstract: Systems and methods for an Automated Guided Vehicle (AGV) capable of automatically balancing large and heavy objects for transport through a facility. One embodiment is an Automated Guided Vehicle (AGV) including a balancing plate configured to support a load, load sensors configured to detect a weight distribution of the load, and an actuator configured to shift the balancing plate laterally. The AGV also includes a weight balancing controller configured to determine a center of gravity of the load based on the weight distribution detected by the load sensors, to determine that the center of gravity of the load is vertically misaligned with a center of gravity of the AGV, and to direct the actuator to shift the balancing plate laterally to move the center of gravity of the load toward vertical alignment with the center of gravity of the AGV.

Abstract: Systems and methods for measuring the distance to a target object and acquiring three-dimensional coordinates, scale information, and point-to-point distance information for that target object in an environment using a remotely operated cable-suspended platform. The system uses on-board sensors and processing techniques to provide discrete or continuous measurements of the distances between points on a target object or the scale of the target object. The addition of on-board three-dimensional measurement capabilities to cable-suspended platforms enables these systems to acquire three-dimensional position data defined in the coordinate system of the environment, determine distances between objects or between points on the same object. The system can also be used to determine the scale factors of items in images captured by a camera carried by the cable-suspended platform, in the course of performing metrology-related tasks.

Abstract: Systems and methods for measuring the distance to a target object and acquiring scale and point-to-point distance information for that target object in an environment using a remotely operated flying platform, such as an unmanned aerial vehicle (UAV). The system uses on-board sensors and processing techniques to provide discrete or continuous measurements of the distances between points on a target object or the scale of the target object. The addition of on-board three-dimensional measurement capabilities to UAVs (or other flying platforms) allows the collection of distance data. Having this capability enables these systems to acquire distances between points on a single object, such as determining the true scale factors of items in images captured by the UAV, in the course of performing metrology-related tasks.

Abstract: An improved mechanism for calibrating a local positioning system through the use of passive or retro-reflective markers is described herein. A plurality of imaging targets with the passive or retro-reflective markers may be attached or affixed on a surface of an object. The local positioning system may then capture a first image of the imaging targets in a non-illuminated state and further capture a second image of the imaging targets in an illuminated state. A difference image between the first and second captured images may be computed and then segmented. The local positioning system may then identify the plurality of imaging targets based on the segmented difference image and position itself to extract information. The extracted information may then be used to help calibrate the local positioning system.

Abstract: An extended reach inspection apparatus may include a scanner device and a robotic manipulator arm. The robotic manipulator arm may include a plurality of arm segments including a distal end arm segment and a proximal end arm segment. A movable joint may couple the distal end arm segment to the robotic manipulator arm. A telescoping extension mechanism may be coupled to the distal end arm segment. The scanner device is mounted to the telescoping extension mechanism for moving the scanner device between a retracted position proximate the robotic manipulator arm and an extended position at a distance from the robotic manipulator arm. A control handle may be coupled to the proximal end arm segment of the plurality of arm segments for manipulating the robotic manipulator arm.

Abstract: Systems and methods for increasing situational awareness for a tool operator and an individual approaching a working field of the tool are described. An example method includes activating a first device, where the first device has a working field and has au operational path configured to intersect a barrier. A proximity sensor of the second device then detects a presence of an object in a sensor zone of the second device. The second device transmits a wireless signal to the first device indicating the presence of the object in the sensor zone of the second device. Then at least one of the first device and the second device issues a first alert indicating the presence of the object in the sensor zone of the second device.