Abstract: A method and apparatus for performing an operation on a workpiece. Image information may be received from a camera system at a controller in which the camera system and the controller may be associated with a housing. The workpiece with a number of inconsistencies and a tool system may be moved relative to each other under a control of the controller in which the tool system may be associated with the housing. A number of operations may be performed on the number of inconsistencies on the workpiece holes using the image information under the control of the controller.

Abstract: A method for verifying completion of a task is provided. In various embodiments, the method includes obtaining location coordinates of at least one location sensor within a work cell. The at least one sensor is affixed to a tool used to operate on a feature of a structure to be assembled, fabricated or inspected. The method additionally includes, generating a virtual object locus based on the location coordinates of the at least one location sensor. The virtual object locus corresponds to a computerized schematic of the structure to be assembled and represents of all possible locations of an object end of the tool within the work cell. The method further includes, identifying one of a plurality of candidate features as the most likely to be the feature operated on by the tool. The identification is based on a probability calculation for each of the candidate features that each respective candidate feature is the feature operated on by the tool.

Abstract: According to an embodiment, a numerically controlled (NC) processing system includes materials processing installation having a multi-axis kinematic linkage operable to position a tip portion of the linkage along a predetermined process path. The system also includes a processor having a compensation system operable to detect a singular point in the process path and to improve the accuracy tip portion positioning near the singular point.

Abstract: A method of operating a multi-axis machine. The machine linkage is monitored to detect an approach by linkage joint(s) toward singularity. A degree of the approached singularity is determined. The joint(s) approaching singularity are identified. Virtual joints are used to replace the identified joint(s) in a manipulator matrix to modify the manipulator matrix. The modified matrix is used to determine position changes for the linkage links. This method can provide software-based compensation for a wide range of machine configurations, without a priori knowledge of singularities for a given machine.

Abstract: A system for evaluating optical distortion in an aircraft transparency, such as a windshield, is disclosed. The system utilizes high resolution digital images (a reference image and a test image) of a test grid structure having a pattern of visible index locations. In one embodiment, the test image is taken through the transparency under test, and the reference image is taken without the transparency. The two images are processed and analyzed by a computing device to determine displacement of each index location, relative to the reference image. The displacement data is further processed to obtain vector divergence field data that represents a quantitative measurement of the optical distortion. The optical distortion measurement data is then rendered in a suitable format that allows the transparency to be rated against certain quality criteria.

Abstract: Methods and systems for position sensing are disclosed. In one embodiment, a method includes measuring at least three discrete point positions associated with a first component using at least one transmitter having a known position and orientation and in a line of sight with the three discrete point positions, the three discrete point positions having known distances relative to one another. The method computes a current position and orientation of the first component using data provided by the at least one transmitter and the three discrete point positions, along with position and orientation data from a last known location of the first component assuming that no sudden position changes since the first component has moved from the last known location. The first and second components may be a workpiece and a tool that performs a manufacturing operation on the workpiece.

Abstract: A system for evaluating optical distortion in an aircraft transparency, such as a windshield, is disclosed. The system utilizes high resolution digital images (a reference image and a test image) of a test grid structure having a pattern of visible index locations. In one embodiment, the test image is taken through the transparency under test, and the reference image is taken without the transparency. The two images are processed and analyzed by a computing device to determine displacement of each index location, relative to the reference image. The displacement data is further processed to obtain vector divergence field data that represents a quantitative measurement of the optical distortion. The optical distortion measurement data is then rendered in a suitable format that allows the transparency to be rated against certain quality criteria.

Abstract: A computer implemented method, apparatus and computer usable program product for mapping a position of a physical point on a digital model. The method comprises receiving sensor data for the physical point from a sensor unit and correlating a position of the physical point to the digital model. The computer implemented method calculates an alignment probability for the correlated position and then compares the calculated value to a stored threshold value. If the alignment probability for the correlated position does exceed the predetermined threshold probability, an aligned position is formed. An aligned position of the physical point is stored relative to the digital model, responsive to a store map location command.

Abstract: A computer implemented method, apparatus and computer usable program product for mapping a position of a physical point on a digital model. Sensor data for the physical point is received from a sensor unit and a position of the physical point is correlated to the digital model. An alignment probability for the correlated position is calculated and the calculated value is then compared to a stored threshold value. If the alignment probability for the correlated position does exceed a predetermined threshold probability, an aligned position is formed. An aligned position of the physical point is stored relative to the digital model, responsive to a store map location command.

Abstract: Systems and methods for handling kinematic singular points in a process path are disclosed. In one embodiment, a numerically controlled (NC) processing system includes a materials processing installation having a multi-axis kinematic linkage operable to position a tip portion of the linkage along a predetermined process path. The system also includes a processor having a compensation system operable to detect a singular point in the process path and to improve the accuracy tip portion positioning near the singular point.

Abstract: Systems and methods are provided for evaluating performance of a projector. An imaging screen is configured to produce an image of a pattern projected thereon. A camera is configured to capture and digitize the image of the pattern projected on the imaging screen. An image analyzer is configured to receive the digitized image from the camera and to analyze the received digitized image.

Abstract: Kinematic singular points in a process system are handled. In one embodiment, a numerically controlled (NC) processing system includes materials processing installation having a multi-axis kinematic linkage operable to position a tip portion of the linkage along a predetermined process path. The system also includes a processor having a compensation system operable to detect a singular point in the process path and to improve the accuracy tip portion positioning near the singular point.

Abstract: A self-locating feature for a pi-joint assembly is provided. The pi-joint assembly includes a substructure, a member coupled to the substructure. The substructure includes one or more land extending above one of a front side and a back side of the substructure. The land includes an outer surface, a depth location control surface and an edge location control surface. The member includes a base, a pair of axially elongated leg extending from the base to define a channel therebetween, and one or more notch located in one of the pair of axially elongated leg.

Abstract: An image shifting apparatus may capture multiple frames of an image, with each frame offset by a sub-pixel offset distance. After capture, the various sub-pixel offset images may be registered together and analyzed using known resolution enhancement algorithms. Super resolution algorithms, for example. may take the various frames and perform edge identification and peak extraction routines to improve the resolution of high frequency data within an image. The image shifting apparatus may include an actuation controlled optical compensator within the imaging system that may be adjusted to create a sub-pixel offset image of an original reference image. The optical compensator may be an image-stabilizing element, for example, capable of forming sub-pixel shifts in an image plane.

Abstract: A computer implemented method, apparatus and computer usable program product for mapping a position of a physical point on a digital model. The method comprises receiving sensor data for the physical point from a sensor unit and correlating a position of the physical point to the digital model. The computer implemented method calculates an alignment probability for the correlated position and then compares the calculated value to a stored threshold value. If the alignment probability for the correlated position does exceed the predetermined threshold probability, an aligned position is formed. An aligned position of the physical point is stored relative to the digital model, responsive to a store map location command.

Abstract: Methods and systems for position sensing are disclosed. In one embodiment, a method includes measuring at least three discrete point positions associated with a first component by using at least one transmitter having a known position and orientation and in a line of sight with the three discrete point positions, the three discrete point positions having known distances relative to one another. The method computes a current position and orientation of the first component using data provided by the at least one transmitter and the three discrete point positions, along with position and orientation data from a last known location of the first component assuming that no sudden position changes since the first component has moved from the last known location. The first and second components may be a workpiece and a tool that performs a manufacturing operation on the workpiece.

Abstract: The apparatus and method of the present invention provide a quick, simple and accurate manner in which to measure the dimensions or characteristics of a hole without contacting the hole. The apparatus and method of the present invention also automatically detect different materials defining the hole and, therefore, the location of the interface where the materials meet. To measure the characteristics of the hole, the apparatus and method measure the intensities of the light reflected off the hole wall. In addition, the light directed toward the hole wall by the optical fiber may be of the type, such as collimated or focused, to provide distinct reflections that are received and measured by the optical receiver to supply accurate measurements of the hole characteristics.

Abstract: A system and method for improving gage calibration in a manufacturing environment. The system includes a gage calibration apparatus that provides remote gage calibration. The apparatus includes a gage measuring apparatus, a processor, a user interface, a scanner, and a printer. The gage measuring apparatus receives a gage and generates measurement information of the received gage. The processor is electrically coupled to the gage measuring apparatus and includes a communication component for communicating with a remotely located metrology system, and a component for determining calibration status of the gage based on the generated measurement information and predefined gage calibration information. The user interface presents the determined calibration status. The scanner scans a tag previously affixed to the gage for information pertaining to the gage and sends the gage information to the processor. The printer prints a label based on the determined calibration status and the communication component.

Abstract: A system and method for improving gage calibration in a manufacturing environment. The system includes a gage calibration apparatus that provides remote gage calibration. The apparatus includes a gage measuring apparatus, a processor, a user interface, a scanner, and a printer. The gage measuring apparatus receives a gage and generates measurement information of the received gage. The processor is electrically coupled to the gage measuring apparatus and includes a communication component for communicating with a remotely located metrology system, and a component for determining calibration status of the gage based on the generated measurement information and predefined gage calibration information. The user interface presents the determined calibration status. The scanner scans a tag previously affixed to the gage for information pertaining to the gage and sends the gage information to the processor. The printer prints a label based on the determined calibration status and the communication component.

Abstract: The apparatus and method of the present invention provide a quick, simple and accurate manner in which to measure the dimensions or characteristics of a hole without contacting the hole. The apparatus and method of the present invention also automatically detect different materials defining the hole and, therefore, the location of the interface where the materials meet. To measure the characteristics of the hole, the apparatus and method measure the intensities of the light reflected off the hole wall. In addition, the light directed toward the hole wall by the optical fiber may be of the type, such as collimated or focused, to provide distinct reflections that are received and measured by the optical receiver to supply accurate measurements of the hole characteristics.