Abstract: Systems and methods for high-speed non-destructive inspection of a half- or full-barrel-shaped workpiece, such as a barrel-shaped section of an aircraft fuselage. Such workpieces can be scanned externally using a mobile (e.g., translating) arch gantry system comprising a translatable arch frame disposed outside the fuselage section, a carriage that can travel along a curved track carried by the arch frame, a radially inward-extending telescopic arm having a proximal end fixedly coupled to the carriage, and an NDI sensor unit coupled to a distal end of the telescoping arm. The stiffeners of the fuselage sections can be scanned using a mobile scanner platform disposed inside the fuselage section, which platform comprises a radially outward-extending telescopic arm rotatably coupled to a mobile (e.g., holonomic or linear motion) platform and an NDI sensor unit coupled to a distal end of the telescoping arm.

Abstract: A tracking-enabled extended-reach tool system acting upon a workpiece. The tool system includes a gimbal positioned adjacent an opening in a surface, a sensor system, a computer control, and a display. The extended-reach arm has a first end, a second end, an end effector including a tool adjacent the first end. The extended-reach arm engages the gimbal for relative rotational movement and relative slidable movement through the opening positioning the end effector and the tool on a side of the surface opposite the second end. The sensor system is configured to measure a linear position of the extended-reach arm relative to the gimbal. The computer control receives signals from the sensor system indicative of the linear position of the extended-reach arm relative to the gimbal. The display is connected to the computer control and displays a representation of the workpiece and the tool relative to each other in real time.

Abstract: Self-contained, remotely operated, mobile measurement and inspection systems for stand-off inspection of large target objects located at sites distant from an operations center. The systems comprise a mobile platform with on-board instrumentation capable of making dimensional measurements in the local coordinate system of the target object. The systems comprise multiple hardware and software components networked to a control interface that enables the operator at the operations center to teleoperate the equipment. Various embodiments include rough-terrain and floatable mobile measurement and inspection systems.

Abstract: Systems and methods for automating robotic end effector alignment using real-time data from multiple distance sensors to control relative translational and rotational motion. In accordance with one embodiment, the alignment process involves computation of offset distance and rotational angles to guide a robotic end effector to a desired location relative to a target object. The relative alignment process enables the development of robotic motion path planning applications that minimize on-line and off-line motion path script creation, resulting in an easier-to-use robotic application. A relative alignment process with an independent (off-board) method for target object coordinate system registration can be used. One example implementation uses a finite-state machine configuration to control a holonomic motion robotic platform with rotational end effector used for grid-based scan acquisition for non-destructive inspection.

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 that provide a framework for location tracking of a movable target component or device (e.g., an automated device or a hand-operated device) to accurately cover an area of interest along a specified path or in a specified region. Grid patterns are projected onto a surface of a workpiece or a part. The projected grid lines may be straight or curved. Straight grid lines can be parallel or intersecting. The grid pattern may include a path to be followed. The lines of the projected grid pattern are detected by a grid detection sensor which is mounted onboard the movable target component or device. Information from the grid detection sensor is fed to a location mapping program. The systems and methods also enable navigation for use in automated and autonomous manufacturing and maintenance operations, as well as other tracking-based applications.

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: 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 an 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.

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 an 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.

Abstract: An apparatus includes a directional scanner configured to receive signals from at least three RFID tags at a plurality of orientations of the directional scanner. The apparatus includes a pose estimator configured to estimate a pose of a device that includes or is coupled to the directional scanner based on orientation data indicating orientations of the directional scanner associated with determined peak signal strengths associated with the at least three RFID tags.

Abstract: An extended-reach tool system may include a gimbal positioned adjacent a surface opening; an extended-reach arm having a tool and engaging the gimbal; a sensor system for measuring a position of the arm relative to the gimbal and a position and spatial orientation of the tool relative to the opening; a computer control that converts one or both of the rotational and linear measurements from the sensor system into spatial location representations for virtual representations of 3-D models of the workpiece and tool, determines a position and orientation of the tool relative to the opening and workpiece, and adjusts the virtual representations of the 3-D models of the workpiece and tool as the arm and tool move relative to the workpiece, representing a real-time orientation of the tool relative to the workpiece; and a display for displaying the virtual representations of the 3-D models of the workpiece and tool.

Abstract: A multi-configuration massive model system. The system comprises a processor unit and a comparator configured to run on the processor unit, a memory, and a configuration manager. The comparator compares sets of parts for two or more configurations of a vehicle to form a list comprising a group of common parts and a group of unique parts. The memory is configured to store a massive model dataset of the configurations of the vehicle with a list of the group of common parts and the group of unique parts for the configurations of the vehicle. The configuration manager, configured to run on the processor unit, receives input of a selected configuration and performs an action relating to the vehicle using the massive model dataset for the selected configuration of the vehicle with the list of the group of common parts and the groups of unique parts stored in the memory.

Abstract: A method and system for managing three-dimensional massive model visualization data sets. The method comprises compiling a vehicle list of vehicles for which the three-dimensional massive model visualization data sets are to be built. The method automatically builds the three-dimensional massive model visualization data sets for vehicles in the vehicle list using a computer system. The method stores the three-dimensional massive model visualization data sets in a group of repositories. The method distributes the three-dimensional massive model visualization data sets for displaying massive model visualizations for the vehicles using the three-dimensional massive model visualization data sets on client devices. The method may selectively update a three-dimensional massive model visualization data set in the three-dimensional massive model visualization data sets when the three-dimensional massive model visualization data set is out-of-date.

Abstract: Systems and methods for automated maintenance of the top and bottom surfaces or skins of an integrally stiffened hollow structure (e.g., a horizontal stabilizer) using surface crawling vehicles. Each system uses dynamically controlled magnetic coupling to couple an external drive tractor to a pair of passive trailers disposed in the interior of the hollow structure on opposite sides of a vertical structural element. The external drive tractor is also coupled to an external maintenance tool, which the tractor pushes or pulls across the surface skin to perform a maintenance function. The systems allow maintenance operations to be performed on both surface skins without turning the hollow structure over. Each system is modular and can be transported to and easily set up in a building or factory.

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: Systems and methods for synchronized display of visualizations of three-dimensional (3-D) models and video images of aircraft for use in assembly of an aircraft. A video display process is configured to process the video image data so that the video images will have a user-selected viewpoint when displayed. In one embodiment, the user selects a virtual view direction and a smaller field-of-view from a full 360-degree field-of-view. A client request process is configured to construct and transmit a command data string containing encoded data specifying parameter values of the viewpoint representation formatted for 3-D model visualization. A server response process is configured to receive and decode the command data string into the specified parameter values representing the user-selected viewpoint for three-dimensional model visualization. A 3-D model visualization process is configured to process the 3-D model data so that 3-D model visualizations will have the user-selected viewpoint when displayed.

Abstract: An automated human personnel fall arresting system including a holonomic base platform, a boom arm movably mounted to and depending from the base platform, at least a portion of the arm being movable in three degrees-of-freedom relative to the base platform, a tether supported by the arm, an operator harness coupled to the tether so as to be dependent from the arm, at least one sensor disposed on the arm and configured to sense movement of the portion of the arm in two degrees-of-freedom of the three degrees-of-freedom, and a controller mounted to the base platform and communicably coupled to the at least one sensor, the controller being configured to automatically control position of the base platform in two orthogonal translational directions and one rotation direction controlled independently from translation, relative to the operator harness, based on signals from the at least one sensor.

Abstract: Provided is a nondestructive inspection (“NDI”) system that includes an unmanned aerial vehicle (“UAV”) comprising a body structure, the body structure comprising one or more support structures where each of the one or more support structures comprise a releasable end structure; and one or more NDI sensors integrated to a respective releasable end structure. The NDI system can also include a location tracking system that can determine a position, an orientation, or both of the UAV and/or one or more NDI sensors relative to a structure being inspected.

Abstract: A method and apparatus for performing an operation on a workpiece using a multi-axis compliant end-effector for attachment to a robotic device. The end-effector is positioned at a nominal location of a workpiece feature on which the operation is to be performed. The end-effector is passively aligned with the workpiece feature by contacting the end-effector with the workpiece feature. The operation is performed on the workpiece feature in response to aligning the end effector with the workpiece feature.

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.