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: 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: Methods for identifying parts of a target object (e.g., an airplane) using geotagged photographs captured on site by a hand-held imaging device. The geotagged photographs contain GPS location data and camera setting information. The embedded image metadata from two or more photographs is used to estimate the location (i.e., position and orientation) of the imaging device relative to the target object, which location is defined in the coordinate system of the target object. Once the coordinates of the area of interest on the target object are known, the part number and other information associated with the part can be determined when the imaging device viewpoint information is provided to a three-dimensional visualization environment that has access to three-dimensional models of the target object.

Abstract: A method for electronically pairing a plurality of control units with a plurality of objects in an aircraft is provided. The method includes identifying a selected control unit from the plurality of control units that will control a selected object from the plurality of objects, placing a hand-held scanner in close proximity to a first machine-readable tag on the selected control unit to acquire a first unique ID for only the selected control unit, placing the hand-held scanner in close proximity to a second machine-readable tag on the selected object to acquire a second unique ID for only the selected object, and associating the first unique ID with the second unique ID to pair the selected control unit with the selected object.

Abstract: Systems and methods that enable the synchronized display of both “as-built” and “as-designed” representations and automated data updates of a target object of interest (e.g., specific line number aircraft). More specifically, the process allows users to display a panoramic image captured for a reference environment, and then display a visualization of the corresponding 3-D model at the same viewpoint. Interprocess communication between a panoramic image viewer application and a 3-D model visualization application provides the ability to synchronize viewpoints, fields-of-view and other display features.

Abstract: Systems and methods for constructing and saving files containing computer-generated image data with associated virtual camera location data during 3-D visualization of an object (e.g., an aircraft). The process tags computer-generated images with virtual camera location and settings information selected by the user while navigating a 3-D visualization of an object. The virtual camera location data in the saved image file can be used later as a way to return the viewpoint to the virtual camera location in the 3-D environment from where the image was taken. For example, these tagged images can later be drag-and-dropped onto the display screen while the 3-D visualization application is running to activate the process of retrieving and displaying a previously selected image. Multiple images can be loaded and then used to determine the relative viewpoint offset between images.

Abstract: Systems and methods for supplying an open interface (e.g., web pages) for viewpoint navigation control of a three-dimensional (3-D) visualization of an object that is simple to create and fast and easy to use. This viewpoint navigation control application allows users to control the viewpoint in a 3-D environment by interacting with (e.g., clicking on) a 2-D hyperlink layout within a web browser (or other 2-D viewer with hyperlink capability). Position and orientation data for a selected viewpoint are transferred as part of a command message sent to the 3-D visualization application through an application programming interface when users select a hyperlink from a web page displayed by the 2-D layout application. The 3-D visualization application then retrieves data and displays a view of at least a portion of the 3-D model of the object with the predefined viewpoint specified in the command message.

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 self-contained, remotely operated, mobile measurement system for stand-off inspection of large target objects located at sites distant from an operations center of a distributed inspection system. In accordance with one embodiment, the system comprises a mobile platform with on-board instrumentation capable of making dimensional measurements in the local coordinate system of the target object. The system comprises multiple hardware and software components networked to a control interface that enables the operator at the operations center to teleoperate the equipment, including driving the mobile platform to a region of interest, calibrating the on-board local positioning system, acquiring measurement and image data, and communicating with on-site personnel if needed.

Abstract: Methods for identifying parts of a target object (e.g., an airplane) using geotagged photographs captured on site by a hand-held imaging device. The geotagged photographs contain GPS location data and camera setting information. The embedded image metadata from two or more photographs is used to estimate the location (i.e., position and orientation) of the imaging device relative to the target object, which location is defined in the coordinate system of the target object. Once the coordinates of the area of interest on the target object are known, the part number and other information associated with the part can be determined when the imaging device viewpoint information is provided to a three-dimensional visualization environment that has access to three-dimensional models of the target object.

Abstract: Systems and methods for calibrating the location of an end effector-carrying apparatus relative to successive workpieces before the start of a production manufacturing operation. The location calibration is performed using a positioning system. These disclosed methodologies allow an operator to program (or teach) the robot motion path once and reuse that path for subsequent structures by using relative location feedback from a measurement system to adjust the position and orientation offset of the robot relative to the workpiece. When each subsequent workpiece comes into the robotic workcell, its location (i.e., position and orientation) relative to the robot may be different than the first workpiece that was used when developing the initial program. The disclosed systems and methods can also be used to compensate for structural differences between workpieces intended to have identical structures.

Abstract: A method is provided that includes rendering for display, a digital three-dimensional (3D) model of a structural product composed of a plurality of parts, with the digital 3D model being observed from a home viewpoint. Input is received to navigate the digital 3D model to a part of the plurality of parts, observation of the digital 3D model being moved from the home viewpoint to a navigated viewpoint. A digital label is generated that includes information specifying the navigated viewpoint and includes information for the part. The digital label may be output to a label recorder configured to record the digital label on a physical medium and thereby produce a corresponding physical label. At least the navigated viewpoint of the digital 3D model in the digital label and corresponding physical label are in a machine-readable format and capable of being machine-read to automatically restore the digital 3D model at the navigated viewpoint.

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: A system is provided that includes a scanner movable relative to seat units and controllable devices each having RFID tags, the scanner configured to obtain a continuum of received signals, a distance sensor configured to determine a relative position of the scanner, a filter configured to disregard outliers and smooth the continuum into respective sets of received signal data, wherein each set of received signal data includes data points having a unique ID and a received signal strength, and wherein a relative time and a relative position are determined for each data point, and a processor configured to determine a relative location of each RFID tag, based on the relative position associated with maximum received signal strength within the set of received signal data, and generate a data file including pairings of seat units and associated controllable devices based on similar relative positions of 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: Systems and methods for inspecting a surface are disclosed. A source, detector, a base, a controller, and a processing device are used to collect image data related to the surface and information relating to the location of the image data on the surface. The image data and information relating to location are correlated and stored in a processing device to create a map of surface condition.

Abstract: A system is provided that includes a scanner movable relative to seat units and controllable devices each having RFID tags, the scanner configured to obtain a continuum of received signals, a distance sensor configured to determine a relative position of the scanner, a filter configured to disregard outliers and smooth the continuum into respective sets of received signal data, wherein each set of received signal data includes data points having a unique ID and a received signal strength, and wherein a relative time and a relative position are determined for each data point, and a processor configured to determine a relative location of each RFID tag, based on the relative position associated with maximum received signal strength within the set of received signal data, and generate a data file including pairings of seat units and associated controllable devices based on similar relative positions of RFID tags.

Abstract: An apparatus and method for attaching a crawler vehicle to the surface of an object. The crawler vehicle may comprise a frame, a number of moveable surface-engaging components attached to the frame, a number of actuators, and an electro-permanent magnet. The number of actuators is operable to move the frame with respect to the object when the number of moveable surface-engaging components is in contact with the surface of the object. The electro-permanent magnet is operable to hold the number of moveable surface-engaging components in contact with the surface of the object by a magnetic force between the electro-permanent magnet and the object when the electro-permanent magnet is activated and to remove the magnetic force when the electro-permanent magnet is deactivated to release the number of moveable surface-engaging components from the surface of the object.

Abstract: A multi-axis tool may include, in some embodiments, a gimbal adapted to be positioned adjacent an opening in a wall; an extended-reach device having first and second ends and an end effector adjacent the first end, the extended-reach device engaging the gimbal for relative rotational movement and relative slidable movement through the opening such that the end effector is positioned on a side of the wall opposite the second end; a sensor system configured to measure a linear position of the extended-reach device relative to the gimbal, and a position and spatial orientation of the end effector relative to the opening; and a computer control connected to receive signals from the sensor system to determine at least one of a position and an orientation of the end effector relative to the opening.

Abstract: Systems and methods for mapping a damaged region on an object. An exemplary system captures an image of the damaged region with a camera, selects target points around a boundary of the damaged region on the image, and determines 2D image coordinates for the target points on the image. The system further determines angles for aiming a laser ranging device at each of the target points based on the image coordinates, and measures a distance to each of the target points with the laser ranging device based on the aiming angles. The system then calculates 3D coordinates for each of the target points in the coordinate system of the object based on the distance measurement and the 2D image coordinates for each of the target points.