Abstract: A robotic manufacturing system and method include a robot including a control unit in communication with an operative member. The control unit is configured to operate the operative member in relation to a workpiece within a working area according to a control plan. A presence sensor is configured to detect presence of a human within the working area. An imaging device is configured to acquire an image of at least a portion of the workpiece in response to the presence sensor detecting the presence of the human within the working area.

Abstract: Robots for moving relative to a surface, robotic systems including the same, and associated methods are disclosed. A robot includes a body, at least two legs, and at least two feet. Each leg has a proximal end region operatively coupled to the body at a respective body joint with one rotational degree of freedom and a distal end region operatively coupled to a respective foot at a respective foot joint comprising two rotational degrees of freedom. Each foot is configured to be translated relative to the surface with two degrees of translational freedom. Robotic systems include one or more robots and a surface along which the one or more robots are positioned to move. Methods of operating robots and of operating robotic systems include translating at least one foot of a robot to operatively move the body of the robot with six degrees of freedom.

Abstract: Resin permeation of a dry preform having one or more reinforcement plies is locally influenced during resin infusion using a selectively permeable veil applied to at least one of the reinforcement plies.

Abstract: Systems and methods for retuning a surface to a nominal geometry using local reference points are disclosed. The system can include an imaging device for detecting the location of local features on an object. The system can use the location of local features, as opposed to an absolute reference frame, to determine one or more reference areas and one or more surface defects on an object. The system can then determine a nominal geometry for the surface (i.e., a surface that is substantially free of surface defects) and calculate the tool path necessary to create a nominal geometry. The system can machine the surface and, in some cases, rescan the surface to ensure the operation has machined the part to the nominal geometry.

Abstract: A system and method is disclosed for performing matched drilling operations on mating first and second workpieces. A microscopic camera is mounted on a movable spindle holding a tool. A micro-adjustment mechanism on the spindle controllable moves the tool. A template is provided that is mounted to the first workpiece and to the second workpiece. A controller receives images of the template from the microscopic camera at each of the predetermined positions on the first workpiece and identifies microscopic features on the template associated with each of the predetermined positions on the first workpiece. The controller compares microscopic features within received images of the template at each of the predetermined positions on the second workpiece associated with microscopic features of a corresponding image of the first workpiece to calculate a necessary offset adjustment that is applied to the micro-adjustment mechanism before each operation on the second workpiece.

Abstract: A robotic system includes a robot and a processor configured to autonomously generate a master plan for movement of an end effector of the robot for operating on an operating surface of a workpiece in a physical environment. The master plan is based on a computer aided design (CAD) model of the workpiece and defines movement paths of the end effector based on a reach distance of a robotic arm of the robot at each of a plurality of working waypoints defined in the master plan and corresponding to fiducial markers on the workpiece. The processor registers the robot to the workpiece, iteratively adjusts an approximate workpiece position in a world map until matching an actual workpiece position in the physical environment, and constructs and executes a robotic arm trajectory causing the end effector to operate on the operating surface along the movement paths defined in the master plan.

Abstract: A method and apparatus for establishing a pathway for performing an automated validation of a condition of assembly. A sensor system coupled to an automated guided vehicle is moved into test positions relative to the structure. Image data is generated at each test position, using the sensor system, to build test images. Each test image is registered to a computer model of the structure to form registered images that are added to a collection of registered images. An optimal set of positions that will allow an entirety of an area of interest to be captured using a fewest number of registered images from the collection of registered images is determined. A pathway is generated for moving the automated guided vehicle to each optimal position in a least amount of time. A computer file identifying the pathway is generated for use in performing the automated validation of the condition of assembly.

Abstract: A method and apparatus for performing an automated validation of a condition of assembly for a structure. A plurality of images of the structure are registered to a computer model of the structure in which an image in the plurality of images captures a portion of the structure. Each image in the plurality of images is segmented based on registration of the plurality of images to the computer model to form a plurality of image sections. A final score is generated for the condition of assembly of the structure based on whether each image section in the plurality of image sections meets a corresponding condition in which the final score indicates whether the condition of assembly is valid.

Abstract: A robotic system includes a robot and a processor configured to autonomously generate a master plan for movement of an end effector of the robot for operating on an operating surface of a workpiece in a physical environment. The master plan is based on a computer aided design (CAD) model of the workpiece and defines movement paths of the end effector based on a reach distance of a robotic arm of the robot at each of a plurality of working waypoints defined in the master plan and corresponding to fiducial markers on the workpiece. The processor registers the robot to the workpiece, iteratively adjusts an approximate workpiece position in a world map until matching an actual workpiece position in the physical environment, and constructs and executes a robotic arm trajectory causing the end effector to operate on the operating surface along the movement paths defined in the master plan.

Abstract: Robots for moving relative to a surface, robotic systems including the same, and associated methods are disclosed. A robot includes a body, at least two legs, and at least two feet. Each leg has a proximal end region operatively coupled to the body at a respective body joint with one rotational degree of freedom and a distal end region operatively coupled to a respective foot at a respective foot joint comprising two rotational degrees of freedom. Each foot is configured to be translated relative to the surface with two degrees of translational freedom. Robotic systems include one or more robots and a surface along which the one or more robots are positioned to move. Methods of operating robots and of operating robotic systems include translating at least one foot of a robot to operatively move the body of the robot with six degrees of freedom.

Abstract: Robots for moving relative to a surface, robotic systems including the same, and associated methods are disclosed. A robot includes a body, at least two legs, and at least two feet. Each leg has a proximal end region operatively coupled to the body at a respective body joint with one rotational degree of freedom and a distal end region operatively coupled to a respective foot at a respective foot joint comprising two rotational degrees of freedom. Each foot is configured to be translated relative to the surface with two degrees of translational freedom. Robotic systems include one or more robots and a surface along which the one or more robots are positioned to move. Methods of operating robots and of operating robotic systems include translating at least one foot of a robot to operatively move the body of the robot with six degrees of freedom.

Abstract: A system includes a robotic device for moving an inspection tool, a scanner coupleable to the robotic device such that the robotic device is configured to automatically move the scanner to collect data associated with a surface of the object, and a computer system configured to determine a surface profile associated with the surface of the object based on the data, and generate a tool path for inspecting the object using the inspection tool based on the surface profile.

Abstract: Disclosed herein are methods and systems for generating a fingerprint for verification of a reference object, such as a layer or ply during a composite laminate layup procedure. An exemplary method includes generating a plurality of images of the reference object from a plurality of angles, removing at least one lighting effect from at least one reference image to generate at least one processed image, generating a reference fingerprint for the reference object based on the at least one processed image, generating at least one candidate image of a candidate object, generating a candidate fingerprint for the candidate object based on the at least one candidate image, comparing the candidate fingerprint and the reference fingerprint to determine whether a correlation exists between the candidate fingerprint and the reference fingerprint, and generating an alert based on the comparison of the candidate fingerprint and the reference fingerprint.

Abstract: A method for drawing a flexible sleeve over an elongated mandrel includes placing a ring within a lumen of the sleeve. A first end of the sleeve is fixed against movement relative to a first end of the mandrel. A first end portion of the sleeve is inverted over a first end portion of the mandrel so as to define a circumferential cuff in the sleeve, and the ring is positioned concentrically within the circumferential cuff. Using, e.g., a magnet, the ring is then urged longitudinally along the mandrel and toward an opposite, second end thereof, such that the sleeve is inverted over at least an outer surface of the mandrel.

Abstract: Systems and methods for generating a coordinate transformation are disclosed. The system can include a non-destructive imaging (NDI) device for detecting the location of local surface and subsurface features in an object (e.g., an aircraft). The system can compare the location of these local features to the location of features from engineering drawings (e.g., CAD files) to generate a coordinate transformation from a machine coordinate system, for example, to an absolute coordinate system. The system can then accurately locate a work piece to perform repairs or replacements, as necessary. The system can also include a robotic arm to enable repairs to be performed at reduced cost and with increased accuracy. The system can also compare two or more NDI scans to locate or relocate a machine that has been moved. This can enable the machine to be repositioned for repairs, maintenance, or to perform a two part repair.

Abstract: A method of repairing a structure is provided. The method includes inspecting the structure with a robotic device to identify a structural defect in the structure, generating a tool path for repairing the structural defect, and transmitting the tool path to the robotic device from a location remote from the robotic device.

Abstract: Disclosed herein are methods and systems for generating a fingerprint for verification of a reference object, such as a layer or ply during a composite laminate layup procedure. An exemplary method includes generating a plurality of images of the reference object from a plurality of angles, removing at least one lighting effect from at least one reference image to generate at least one processed image, generating a reference fingerprint for the reference object based on the at least one processed image, generating at least one candidate image of a candidate object, generating a candidate fingerprint for the candidate object based on the at least one candidate image, comparing the candidate fingerprint and the reference fingerprint to determine whether a correlation exists between the candidate fingerprint and the reference fingerprint, and generating an alert based on the comparison of the candidate fingerprint and the reference fingerprint.

Abstract: A system for manufacturing a composite structure includes a tool with a surface for supporting component elements of the composite structure. The surface is divided into a multi-dimensional array of thermal zones for in-process control of the temperature of a component element (e.g. resin) of the composite structure. The sensors sense a characteristic of the component element and provide sensor data, which is applied to a machine-learning algorithm configured to generate control data to achieve a defined quality goal. A controller then independently controls the thermal zones to locally heat, cool or maintain the temperature of the component element according to the control data to advance the component element or composite structure to the defined quality goal. This may be performed over a plurality of instances during which the machine-learning algorithm learns to increase advancement of the component element or composite structure to the defined quality goal.

Abstract: A method and apparatus for performing an automated validation of a condition of assembly for a structure. A plurality of images of the structure are registered to a computer model of the structure in which an image in the plurality of images captures a portion of the structure. Each image in the plurality of images is segmented based on registration of the plurality of images to the computer model to form a plurality of image sections. A final score is generated for the condition of assembly of the structure based on whether each image section in the plurality of image sections meets a corresponding condition in which the final score indicates whether the condition of assembly is valid.

Abstract: A method and apparatus for establishing a pathway for performing an automated validation of a condition of assembly. A sensor system coupled to an automated guided vehicle is moved into test positions relative to the structure. Image data is generated at each test position, using the sensor system, to build test images. Each test image is registered to a computer model of the structure to form registered images that are added to a collection of registered images. An optimal set of positions that will allow an entirety of an area of interest to be captured using a fewest number of registered images from the collection of registered images is determined. A pathway is generated for moving the automated guided vehicle to each optimal position in a least amount of time. A computer file identifying the pathway is generated for use in performing the automated validation of the condition of assembly.