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: Automated apparatus for performing maintenance functions on airfoil-shaped bodies having short chord lengths, the apparatus being movable in a spanwise direction along the airfoil-shaped body. In accordance with various embodiments, the apparatus comprises a blade crawler capable of supporting any one of a plurality of end effectors for performing a set of maintenance functions on an airfoil-shaped body, such as a blade component. Included in these functions are multiple options for nondestructive inspection, drilling, grinding, fastening, appliqué application, scarfing, ply mapping, depainting, cleaning, and painting devices that are attached as the end effector for the blade crawler. As a whole, the blade crawler reduces maintenance time, labor hours and human errors when robotic maintenance functions are performed on blade components.

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: 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: Automated apparatus for performing maintenance functions on airfoil-shaped bodies having short chord lengths, the apparatus being movable in a spanwise direction along the airfoil-shaped body. In accordance with various embodiments, the apparatus comprises a blade crawler capable of supporting any one of a plurality of end effectors for performing a set of maintenance functions on an airfoil-shaped body, such as a blade component. Included in these functions are multiple options for nondestructive inspection, drilling, grinding, fastening, appliqué application, scarfing, ply mapping, depainting, cleaning, and painting devices that are attached as the end effector for the blade crawler. As a whole, the blade crawler reduces maintenance time, labor hours and human errors when robotic maintenance functions are performed on blade components.

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.

Abstract: A self-contained, holonomic motion tracking solution for supplementing the acquisition of inspection information on the surface of a structure, thereby enabling the real-time production of two-dimensional images from hand-held and automated scanning by holonomic-motion of non-destructive inspection (NDI) sensor units (e.g., NDI probes). The systems and methods disclosed enable precise tracking of the position and orientation of a holonomic-motion NDI sensor unit (hand-held or automated) and conversion of the acquired tracking data into encoder pulse signals for processing by a NDI scanning system.

Abstract: A system comprising a multi-functional boom subsystem integrated with a holonomic-motion boom base platform. The boom base platform may comprise: Mecanum wheels with independently controlled motors; a pair of sub-platforms coupled by a roll-axis pivot to maintain four-wheel contact with the ground surface; and twist reduction mechanisms to minimize any yaw-axis twisting torque exerted on the roll-axis pivot. A computer with motion control software may be embedded on the boom base platform. The motion control function can be integrated with a real-time tracking system. The motion control computer may have multiple platform motion control modes: (1) a path following mode in which the boom base platform matches the motion path of the surface crawler (i.e.

Abstract: A system comprising a multi-functional boom subsystem integrated with a holonomic-motion boom base platform. The boom base platform may comprise: Mecanum wheels with independently controlled motors; a pair of sub-platforms coupled by a roll-axis pivot to maintain four-wheel contact with the ground surface; and twist reduction mechanisms to minimize any yaw-axis twisting torque exerted on the roll-axis pivot. A computer with motion control software may be embedded on the boom base platform. The motion control function can be integrated with a real-time tracking system. The motion control computer may have multiple platform motion control modes: (1) a path following mode in which the boom base platform matches the motion path of the surface crawler (i.e.

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: 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 system comprising a multi-functional boom subsystem integrated with a holonomic-motion boom base platform. The boom base platform may comprise: Mecanum wheels with independently controlled motors; a pair of sub-platforms coupled by a roll-axis pivot to maintain four-wheel contact with the ground surface; and twist reduction mechanisms to minimize any yaw-axis twisting torque exerted on the roll-axis pivot. A computer with motion control software may be embedded on the boom base platform. The motion control function can be integrated with a real-time tracking system. The motion control computer may have multiple platform motion control modes: (1) a path following mode in which the boom base platform matches the motion path of the surface crawler (i.e.

Abstract: A method, system, and apparatus for visually presenting a virtual environment relative to a physical workspace. An output device visually presents a view of the virtual environment to guide a human operator in performing a number of operations within the physical workspace. A mounting structure holds the output device and is movable with at least one degree of freedom relative to the physical workspace. A sensor system measures movement of the output device relative to the physical workspace to generate sensor data. A controller computes a transformation matrix and the set of scale factors to align the virtual environment and the physical workspace. The controller changes the view of virtual environment based on the sensor data to thereby change the view of the virtual environment in correspondence with the movement of the output device relative to the physical workspace.

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 detection system including a target object having a target object coordinate system, a tracking unit configured to monitor a position and/or an orientation of the target object and generate a target object position signal indicative of the position and/or the orientation of the target object, a camera positioned to capture an image of the target object, an orienting mechanism connected to the camera to control an orientation of the camera relative to the target object, and a processor configured to analyze the image to detect a discrepancy in the image and, when the discrepancy is present in the image, determine a location of the discrepancy relative to the target object coordinate system based at least upon the target object position signal and the orientation of the camera, and then orient the camera and laser to aim at and point out the discrepancy.

Abstract: Systems and methods for automated maintenance of the top and bottom surfaces or skins of an integrally stiffened hollow structure (e.g., a horizontal stabilizer) using surface crawling vehicles. Each system uses dynamically controlled magnetic coupling to couple an external drive tractor to a pair of passive trailers disposed in the interior of the hollow structure on opposite sides of a vertical structural element. The external drive tractor is also coupled to an external maintenance tool, which the tractor pushes or pulls across the surface skin to perform a maintenance function. The systems allow maintenance operations to be performed on both surface skins without turning the hollow structure over. Each system is modular and can be transported to and easily set up in a building or factory.

Abstract: A system for stand-off inspection comprising local positioning system hardware and a nondestructive evaluation instrument supported by a pan-tilt mechanism. The system further comprises a computer system that is programmed to perform the following operations: (a) directing the local positioning system hardware toward an area of a surface on a target object by control of the pan-tilt mechanism; (b) activating the local positioning system hardware to acquire an image; (c) processing the image to determine whether an anomaly is present in the area; (d) if an anomaly is present, determining coordinates of a position of the anomaly in a coordinate system of the target object; and (e) directing the nondestructive evaluation instrument toward a position corresponding to the coordinates. Optionally, the computer system is further programmed to measure one or more characteristics of the anomaly.

Abstract: Systems and methods for automated non-destructive inspection scanning of the top and bottom aerodynamic surfaces or skins of an integrally stiffened wing box (e.g., a horizontal stabilizer) using surface crawling vehicles. Each system uses dynamically controlled magnetic coupling to couple an external drive tractor to a pair of passive trailers disposed in the interior of the wing box on opposite sides of a spar. The external drive tractor is also coupled to an external NDI scanner, which the tractor pushes or pulls across the surface skin being inspected. The systems allow scanning of both surface skins without turning the wing box over. Each system is modular and can be transported to and easily set up in a building or factory.

Abstract: An apparatus for removing for removing an out-of-tolerance area in a composite structure may include a machine tool having a machine head movable along at least one axis over the composite structure. The machine tool may include at least one of a video camera and a non-destructive inspection (NDI) scanner mounted to the machine head for scanning the composite structure and locating the out-of-tolerance area. The machine tool may also include a cutting tool movable along a tool path for removing a volume containing the out-of-tolerance area. The machine tool may additionally include a controller that may be programmable with a quantity of layers of the volume for which the cutting tool is paused following removal of each one of the layers.

Abstract: A system in accordance with one embodiment comprises a marking device attached to a holonomic-motion crawler vehicle capable of movement on non-horizontal surfaces. Modular attachment and motion control interfaces on the platform allow attachment of various types of marking and non-destructive inspection (NDI) sensor modules. The crawling vehicle marks the location of sub-surface features on an aircraft skin or overlaid patch (doubler) using a pen or sticker or tape applicator that is guided based on either a 3-D CAD model or NDI data collected as the vehicle crawls. A second embodiment utilizes an automated NDI scanner to collect 2-D image data of the substructure to enable manual or automated feature/edge selection for marking. Location tracking of the marking device can be implemented using a local positioning system or a motion capture system.