Abstract: Systems and methods for tracking the location of a non-destructive inspection (NDI) scanner using images of a target object acquired by the NDI scanner. The system includes a frame, an NDI scanner supported by the frame, a system configured to enable motorized movement of the frame, and a computer system communicatively coupled to receive sensor data from the NDI scanner and track the location of the NDI scanner. The NDI scanner includes a two-dimensional (2-D) array of sensors. Subsurface depth sensor data is repeatedly (recurrently, continually) acquired by and output from the 2-D sensor array while at different locations on a surface of the target object. The resulting 2-D scan image sequence is fed into an image processing and feature point comparison module that is configured to track the location of the scanner relative to the target object using virtual features visible in the acquired scan images.

Abstract: Methods and apparatus for performing repair operations using an unmanned aerial vehicle (UAV). The methods are enabled by equipping the UAV with tools for rapidly repairing a large structure or object (e.g., an aircraft or a wind turbine blade) that is not easily accessible to maintenance personnel. A plurality of tools are available for robotic selection and placement at the repair site. The tools are designed to perform respective repair operations in sequence in accordance with a specified repair plan, which plan may take into account the results of a previously performed UAV-enabled inspection.

Abstract: Embodiments described herein utilize Non-Destructive Inspection (NDI) scan data obtained during a process performed on a surface of a structure to update a location of an NDI scanner on the surface. A subsurface feature within the structure is detected based on the NDI scan data, which are correlated with pre-defined position data for the subsurface feature. A measured location of the NDI scanner on the surface is corrected based on the pre-defined position data for the subsurface feature.

Abstract: A method for navigating a sensor-equipped mobile platform through an through an environment to a destination, the method including: capturing a first image in a first state of illumination; capturing a second image in a second state of illumination; generating a difference image from said first image and said second image; locating an imaging target based on said difference image, said imaging target including a machine-readable code embedded therein, said machine-readable code including navigation vector data; extracting said navigation vector data from said machine-readable code; and using said extracted navigation vector data to direct the navigation of the mobile platform through the environment to a destination.

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 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: An apparatus for retaining a fastener is described. The apparatus includes a base, including a first aperture including a central axis; and a sidewall extending outward from the base and surrounding the central axis, where the sidewall is configured to hold on to a socket; an arm extending outward from the base, including a biasing mechanism connecting a first end of the arm to the base, where the biasing mechanism configured to relieve stress between the base and the arm when the arm is actuated; and a lip disposed at a second end of the arm, where the second end is at an opposite end of the arm than the first end, and where the lip is configured to retain the fastener or a wrenching element of the fastener; and a finger flange configured to actuate the arm, where the finger flange is attached to the arm.

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 computer-automated separation rules compliance method is disclosed. Separation rules that establish separation distance requirements between objects in a three-dimensional (3D) virtual environment are defined. Sample locations associated with at least some of the objects in the 3D virtual environment are specified. One or more of proximity and/or collision analysis is performed on the sample locations to determine separation distances between the objects. The determined separation distances are compared to the separation distance requirements. Objects in the 3D virtual environment that violate the separation rules based on said comparing are identified.

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: A non-destructive inspection system is presented. The non-destructive inspection system comprises a robotic end effector having an extendable actuator and a flange-mounted roller containing an ultrasonic sensor, the flange-mounted roller connected to the extendable actuator by a pivot connection, the extendable actuator configured to extend the flange-mounted roller until the flange-mounted roller contacts an inspection surface.

Abstract: Examples are disclosed that relate to generating an equirectangular image of a three-dimensional (3D) virtual environment in a computer-automated fashion. In one example, a 3D virtual position of a virtual camera in a 3D virtual environment is specified. For each of a plurality of different yaw angles rotated about an axis extending through the 3D virtual position, the virtual camera is used to acquire an image strip of pixels parallel to the axis of rotation. Image strips of pixels of the 3D environment acquired at the different yaw angles are assembled to form an equirectangular image of the 3D virtual environment from the specified 3D virtual position.

Abstract: An aircraft inspection system is configured to inspect one or more components of an aircraft before a flight. The aircraft inspection system includes an inspection robot that is configured to inspect the component(s) of the aircraft. The inspection robot includes a conveying sub-system that is configured to efficiently move the inspection robot to different locations, and a sensing sub-system including one or more sensors that are configured to sense one or more characteristics of the component(s) during an inspection. The sensing sub-system is configured to record the characteristic(s) as inspection data.

Abstract: The system includes a drive vehicle configured to attach to the platform at a pivot point and to move the platform relative to the target object. One or more distance sensors are positioned to sense the target object, and one or more rotation angle sensors acquire an angular position of the drive vehicle relative to the platform. A processing circuit is configured to calculate one or more distances between the platform and the target object based on inputs from the one or more distance sensors. The processing circuit receives a command to move the drive vehicle in one or more forward, reverse, or rotational directions. The processing circuit allows motion in one or more directions in which the platform will not contact the target object and prevents motion in one or more directions that would cause the platform to contact the target object.

Abstract: An aircraft inspection system is configured to inspect one or more components of an aircraft before a flight. The aircraft inspection system includes an inspection robot that is configured to inspect the component(s) of the aircraft. The inspection robot includes a conveying sub-system that is configured to efficiently move the inspection robot to different locations, and a sensing sub-system including one or more sensors that are configured to sense one or more characteristics of the component(s) during an inspection. The sensing sub-system is configured to record the characteristic(s) as inspection data.

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 constructs and then compares successive partially overlapping scan images that include common features corresponding to respective structural features of the target object. The image processor is further configured to compute a change in location of the NDI scanner relative to a previous location based on the respective positions of those common features in the partially overlapping scan images. This relative physical distance is then added to the previous (old) absolute location estimate to obtain the current (new) absolute location of the NDI scanner.

Abstract: A ground-based visual-inspection system includes a ground-based visual-inspection apparatus and a control system. The ground-based visual-inspection apparatus includes a mobile base, an actuatable arm coupled to the mobile base, and an effector coupled to the actuatable arm. The actuatable arm is locatable in a three dimensional space. The end effector includes a camera configured to capture images of a structure, such as an aircraft. The control system is configured to determine location information of the camera relative to a reference location and associate the location information with the images.

Abstract: Provided is a nondestructive inspection (“NDI”) system that includes an unmanned aerial vehicle (“UAV”) comprising a body structure and at least one support arm. The support arm includes a first arm portion having a first end coupled to the body structure and a second end coupled to a second arm portion. The second arm portion includes a first end coupled to the second end of the first arm portion and a second end coupled to an NDI scanning device. The support arm also includes a compliant member disposed between the first arm portion and the second arm portion. The NDI scanning device includes one or more NDI sensors.

Abstract: Methods and apparatus for UAV-enabled marking of surfaces during manufacture, inspection, or repair of limited-access structures and objects. A UAV is equipped with a marking module that is configured to apply marking patterns (e.g., alignment features) of known dimensions to surfaces. The marking module may include a 2-D plotter that enables free-form drawing capability. The marking process may involve depositing material on the surface. The marking material may be either permanent or removable. A “clean-up” module may be attached to the UAV platform instead of the marking module, and may include solvents and oscillating or vibrating pads to remove the marks via scrubbing. The clean-up module can also be used for initial surface preparation.

Abstract: Methods and apparatus for performing repair operations using an unmanned aerial vehicle. The methods are enabled by equipping the UAV with tools for rapidly repairing a large structure or object (e.g., an aircraft or a wind turbine blade) that is not easily accessible to maintenance personnel. In accordance with various embodiments disclosed below, the unmanned aerial vehicle may be equipped with an easily attachable/removable module that includes an additive repair tool. The additive repair tool is configured to add material to a body of material. For example, the additive repair tool may be configured to apply a sealant or other coating material in liquid form to a damage site on a surface of a structure or object (e.g., by spraying liquid or launching liquid-filled capsules onto the surface). In alternative embodiments, the additive repair tool is configured to adhere a tape to the damage site.