Abstract: A method, system and devices for autonomous marking of a substrate and for conducting formability measurements. The method, system and devices may be used to apply markings to a substrate, such as panels that are used to construct articles. The panels, for example, may be automobile panels. The markings preferably are applied on the panel autonomously with a laser etching, and with robot device that is controlled to form a precise pattern of indicia (e.g., dots), on the panel surface. An x, y, z, gantry coordinate system may be used to guide the operations of the robot device to position the device for etching at precise locations on the substrate surface. Once etched, the panels may be processed, such as, by stamping or cutting, and the deformation of the dot pattern may be used to determine strain and formability properties.

Abstract: A method and system for determining the quality and configuration of a structure that is constructed from a thermoformable material, such as a thermoplastic or thermoset material, and in particular thermoplastic composite tapes, where heat is applied to cure the thermoformable material. The quality of the build is monitored during the construction of the structure by determining the differential heat flux in the material as it cools from its elevated temperature. The system and method also may determine the location of defects in a structure being constructed so that remedial measures may be taken or production operations halted to address the defect. A transient thermal effect is applied to the structure being monitored, such as the thermoformable material being applied, which may be implemented from the applied heating of the thermoformable construction application process or additional heating.

Abstract: A method and system for determining the quality and configuration of a structure that is constructed from a thermoformable material, such as a thermoplastic or thermoset material, and in particular thermoplastic composite tapes, where heat is applied to cure the thermoformable material. The quality of the build is monitored during the construction of the structure by determining the differential heat flux in the material as it cools from its elevated temperature. The system and method also may determine the location of defects in a structure being constructed so that remedial measures may be taken or production operations halted to address the defect. A transient thermal effect is applied to the structure being monitored, such as the thermoformable material being applied, which may be implemented from the applied heating of the thermoformable construction application process or additional heating.

Abstract: A method, system and devices for autonomous marking of a substrate and for conducting formability measurements. The method, system and devices may be used to apply markings to a substrate, such as panels that are used to construct articles. The panels, for example, may be automobile panels. The markings preferably are applied on the panel autonomously with a laser etching, and with robot device that is controlled to form a precise pattern of indicia (e.g., dots), on the panel surface. An x, y, z, gantry coordinate system may be used to guide the operations of the robot device to position the device for etching at precise locations on the substrate surface. Once etched, the panels may be processed, such as, by stamping or cutting, and the deformation of the dot pattern may be used to determine strain and formability properties.

Abstract: A method, system and devices for optical structural health monitoring that implements digital image correlation (DIC) by applying an invisible pattern comprising a random dot pattern and/or codes, which is applied using a coating containing a dye or substance that is not visible during the normal lighting conditions. The structure is imaged at different time intervals by capturing images of the pattern and codes using a camera and suitable light source. The captured images of the pattern and codes are stored in a CAD file that represents the structure or part to which the pattern and codes are applied, and includes the locations of the pattern and codes. Comparative measurements of the pattern and codes (e.g., using DIC) determine one or more structural health parameters, such as strain, deformation, and other stresses or averse conditions that may be detected from one interval to another (e.g., between measurements).

Abstract: A method, system and devices for autonomous marking of a substrate and for conducting formability measurements. The method, system and devices may be used to apply markings to a substrate, such as panels that are used to construct articles. The panels, for example, may be automobile panels. The markings preferably are applied on the panel autonomously with a laser etching, and with robot device that is controlled to form a precise pattern of indicia (e.g., dots), on the panel surface. An x, y, z, gantry coordinate system may be used to guide the operations of the robot device to position the device for etching at precise locations on the substrate surface. Once etched, the panels may be processed, such as, by stamping or cutting, and the deformation of the dot pattern may be used to determine strain and formability properties.

Abstract: A tracking device that is mountable to a robot, the tracking device has a plurality of faces that contain marking indicia thereon that is used by an imaging apparatus to track the position of a robot. The robot is not required to be at a fixed location, and may have mobility features, such as drives that move the robot along a path of travel, surface, or in space. The tracking devices do not consume or require power to operate. A plurality of tracking devices may be installed on a robot and an imaging apparatus is used to image the field of view in which the robot operates. Discrete locations of the robot in real time or any point in time are ascertained through the positioning of the tracking device. Tracking devices may be installed on robots used for assembly or defect monitoring.

Abstract: Methods, systems and devices for assembling components to form an assembled structure, using virtual or augmented assembly tooling, in real time, real-time virtual assembly tooling (or RVAT). Structures such as vehicles, aircrafts, or other products are produced from assembling a plurality of component parts together, with virtual assembly tooling of the system, method and devices that provides real-time capability for directing and guiding operations and for generating feedback. The structure is built from the CAD, transforming the CAD to imaging representations whose transformations are generated with one or more component scans, projected on a display.

Abstract: Methods, systems and devices for optical structural health monitoring of a subject, including the utilization of pointillism to provide a design or painting of the surface of the structure to be monitored, which also serves as a mechanism for conducting SHM, implementing digital image correlation (DIC) by applying a pattern comprising a random dot pattern and/or codes. The subject is imaged using imaging equipment to capture images of the pattern. For some applications, the captured images of the pattern and codes are stored in a CAD file that represents the subject or portion thereof to which the pattern and codes are applied, and includes the locations of the pattern and codes. Indicia applied to a structure may be applied using a paintjet or inkjet, or robotic mechanism, while some applications implement pre-patterning of a composite sheet that is used to form the structure.

Abstract: A method and system for determining the quality and configuration of a structure that is constructed from a thermoformable material, such as a thermoplastic or thermoset material, and in particular thermoplastic composite tapes, where heat is applied to cure the thermoformable material. The quality of the build is monitored during the construction of the structure by determining the differential heat flux in the material as it cools from its elevated temperature. The system and method also may determine the location of defects in a structure being constructed so that remedial measures may be taken or production operations halted to address the defect. A transient thermal effect is applied to the structure being monitored, such as the thermoformable material being applied, which may be implemented from the applied heating of the thermoformable construction application process or additional heating.

Abstract: This invention detects leaks in small, hermetically sealed packages, especially microchips or other packages of electronic circuits. The invention includes a procedure for detecting fine leaks, and a somewhat different procedure for finding gross leaks. To detect gross leaks, one places the package in a chamber, and varies the pressure in the chamber slightly. If the leak is not too big, one wall of the package, such as its lid, initially becomes deformed, but quickly returns to its original position, due to the leak. If the leak is very large, the wall of the package may not move at all. The position of the wall is monitored with an interferometer, such as an electronic shearography apparatus. The movements of the wall show whether there is a gross leak. In the fine leak test, the package is placed in the chamber and the pressure is changed substantially, thus causing the walls of the package to deform. If there is a fine leak, a deformed wall gradually returns to its initial position.

Abstract: This invention tests a vehicle, such as an aircraft, using nondestructive interferometry. An interferometer detects movements in the vehicle surface due to stress. One applies such stress by pressurizing the vehicle. In one embodiment, a hood housing the interferometer attaches to the vehicle surface with the aid of a vacuum. One can vary the pressure in the vehicle in various ways, while monitoring the interferometer for signs of defects in the structure behind the surface. The invention also includes an arrangement for substantially automating the analysis. For example, one can automatically position the interferometer according to position information received from appropriate sensors, in combination with stored information about the structure of the vehicle. One preferably uses a real-time interferometer, such as an electronic shearography camera, in the present invention. One can quickly determine the location of defects by observing fringes on a video monitor.

Abstract: Two laterally-displaced images of a test object interfere with each other to form a shearogram. Two shearograms, taken while the object is unstressed and stressed, respectively, are compared electronically to yield a composite interference pattern. According to the invention, each shearogram is formed by the interference of pairs of distinct rays of coherent light, reflected from different points on the object. The first ray of each pair is reflected from the object, strikes a mirror spaced from the object, and is reflected from the mirror. At the same time, the second ray of each pair is reflected from the object and strikes a beam splitter positioned beside the mirror. The beam splitter directs a portion of the second ray in the same direction as the reflected first ray, and a portion of the first ray passes through the beam splitter without being reflected. Since the two rays have the same polarization angle, and are mutually parallel, the rays interfere.

Abstract: The purpose of the present invention is to improve the quality of a video signal generated by the method of nondestructive testing known as electronic shearography. In electronic shearography, two laterally-displaced images of a test object are made to interfere, and the interference pattern is stored. Another such interference pattern is obtained while the object is stressed. The two patterns are compared by computer, such as by subtracting one pattern from the other, and the resulting composite pattern is displayed on a video monitor or equivalent. According to the present invention, the subtracted signal is connected to a rectifier circuit which causes both positive-going and negative-going variations in the video signal to become positive-going variations. Thus, any changes in the intensity of the signal, due to phase changes resulting from deformation of the object, are displayed as increases in brightness of a pixel on the final display.

Abstract: This invention detects leaks in small, hermetically sealed packages, especially microchips or other packages of electronic circuits. The invention includes a procedure for detecting fine leaks, and a somewhat different procedure for finding gross leaks. To detect gross leaks, one places the package in a chamber, and varies the pressure in the chamber slightly. If the leak is not too big, one wall of the package, such as its lid, initially becomes deformed, but quickly returns to its original position, due to the leak. If the leak is very large, the wall of the package may not move at all. The position of the wall is monitored with an interferometer, preferably an electronic shearography apparatus. The movements of the wall show whether there is a gross leak. In the fine leak test, the package is placed in the chamber and the pressure is changed substantially, thus causing the walls of the package to deform. If there is a fine leak, a deformed wall gradually returns to its initial position.

Abstract: The present invention is a system for monitoring and displaying a measured parameter in each of a series of similar modules. In one embodiment, the invention can be used to monitor a parameter or condition, such as the amount of fuel in a tank, in each of a plurality of coupled locomotives. The parameter is measured by an analog or digital sensor, the output of which is connected to a microprocessor. Each locomotive in the train has such a microprocessor, and each microprocessor is programmed in substantially the same way. The microprocessors in the several locomotives are programmed to communicate with each other, and to determine which one is in the lead locomotive, and what signals are being received from which microprocessor. The value of the measured parameters for any of the locomotives of the train can therefore be displayed by the microprocessor in the lead locomotive. The programming of the microprocessors is such that the system will work regardless of the arrangement of the locomotives.