Abstract: A manufacturing system includes a stator base, a plurality of movers, one or more end effectors, and a controller. The stator base has a planar stator surface covering an array of electrical coils configured to generate an electromagnetic field. The movers each contain multiple permanent magnets configured to cause the movers to levitate and move relative to the stator surface in response to the electromagnetic field. The end effectors are coupled to the movers, and each end effector perform one or more functions in relation to a material sheet. The controller activates the electrical coils in a manner causing independent, coordinated movement of the movers over the stator surface, and causing the end effectors to engage with and operate on the material sheet.

Abstract: A method, apparatus, system, and computer program product for processing a composite ply. An image of the composite ply is received. Natural features in the image of the composite ply are detected. Feature data for the natural features detected in association is saved with a ply identifier for the composite ply in a repository. The feature data is used to position the composite ply during manufacturing of a composite part using the composite ply.

Abstract: A method, apparatus, and system for manufacturing a composite part. A set of reference locations is identified for a set of fiducial markers on a composite ply from a ply shape model for the composite part. The set of fiducial markers is created at the set of reference locations on the composite ply. The composite ply is cut to have a shape defined by the ply shape model.

Abstract: A method of analyzing ergonomics includes calculating a three-dimensional skeletal model. The method further includes scoring the three-dimensional skeletal model. The method further includes storing the score with the skeletal identifier.

Abstract: Systems and methods are provided for characterizing a ply of fiber having a thermoplastic veil. One method includes acquiring an image of a fiber material comprising strands of fiber and further comprising a veil of filaments of thermoplastic, subdividing the image into slices, determining an amount of melted filaments depicted within each of the slices, and determining an amount of unmelted filaments depicted within each of the slices.

Abstract: Systems and methods are provided for characterizing a ply of fiber having a thermoplastic veil. One method includes acquiring an image of a fiber material comprising strands of fiber and further comprising a veil of filaments of thermoplastic, subdividing the image into slices, determining an amount of melted filaments depicted within each of the slices, and determining an amount of unmelted filaments depicted within each of the slices.

Abstract: A method and apparatus for laying composite tape. The method may comprise driving a plurality of robots, each having a respective movement system across a movement surface, in which the movement surface faces a workpiece, and laying composite tape from the plurality of robots in a coordinated manner on the workpiece.

Abstract: A method and apparatus for a robot self-locating on a movement surface. The method may comprise moving a first robot across the movement surface and relative to a workpiece, in which the movement surface faces the workpiece. The method may also form sensor data using a first number of sensors on the first robot as the first robot moves across the movement surface, in which the sensor data represents identifying characteristics of a portion of the movement surface. The method may also determine a location of the first robot on the movement surface using the sensor data. The method may further determine a location of a functional component of the first robot relative to the workpiece using the location of the first robot on the movement surface.

Abstract: A method and apparatus for managing a rework of a composite structure. Boundary geometries are identified for the layer boundaries in an image of a rework area. The image includes layer boundaries for exposed layers in the rework area. Layer orientations are identified for the exposed layers. A description of a patch for installation in the rework area is generated using the boundary geometries and layer orientations. The patch has plies having ply boundaries with the boundary geometries corresponding to the layer boundaries and ply orientations corresponding to the layer orientations. An operation of a ply cutting system is controlled using the group of files describing the patch, enabling fabricating the patch for the rework area using the group of files describing the patch.

Abstract: A method and apparatus for customizing tool paths. A reference tool path is identified for a tool based on an expected shape for a surface of an object. Offset data is generated for a plurality of sample points identified for use in evaluating the surface of the object. The offset data identifies a difference between the expected shape for the surface of the object and an actual shape of the surface of the object. The reference tool path is modified using the offset data to form a modified tool path for the tool.

Abstract: A method and apparatus for managing a rework of a composite structure. Boundary geometries are identified for the layer boundaries in an image of a rework area. The image includes layer boundaries for exposed layers in the rework area. Layer orientations are identified for the exposed layers. A description of a patch for installation in the rework area is generated using the boundary geometries and layer orientations. The patch has plies having ply boundaries with the boundary geometries corresponding to the layer boundaries and ply orientations corresponding to the layer orientations. An operation of a ply cutting system is controlled using the group of files describing the patch, enabling fabricating the patch for the rework area using the group of files describing the patch.

Abstract: A method and apparatus for a robot self-locating on a movement surface. The method may comprise moving a first robot across the movement surface and relative to a workpiece, in which the movement surface faces the workpiece. The method may also form sensor data using a first number of sensors on the first robot as the first robot moves across the movement surface, in which the sensor data represents identifying characteristics of a portion of the movement surface. The method may also determine a location of the first robot on the movement surface using the sensor data. The method may further determine a location of a functional component of the first robot relative to the workpiece using the location of the first robot on the movement surface.

Abstract: A method and apparatus for laying composite tape. The method may comprise driving a plurality of robots, each having a respective movement system across a movement surface, in which the movement surface faces a workpiece, and laying composite tape from the plurality of robots in a coordinated manner on the workpiece.

Abstract: A method and apparatus for customizing tool paths. A reference tool path is identified for a tool based on an expected shape for a surface of an object. Offset data is generated for a plurality of sample points identified for use in evaluating the surface of the object. The offset data identifies a difference between the expected shape for the surface of the object and an actual shape of the surface of the object. The reference tool path is modified using the offset data to form a modified tool path for the tool.