Abstract: Position determining systems and methods are provided. A particular portable device includes a calibration component to communicate with a local positioning system to determine an initial position and orientation of the portable device within a local coordinate system associated with a target structure. The portable device also includes at least one movement sensor to detect movement of the portable device. The portable device further includes a processor to determine a measured position and orientation of the portable device based on the initial position and orientation of the portable device within the local coordinate system and based on the detected movement of the portable device.

Abstract: A system and method for correlating data is provided. Generally, the system contains a scanning system having at least one inspection emitter. The scanning system situated to scan a structure and produce a quantity of inspection information. A local positioning system is in communication with the scanning system and situated to detect a location of the quantity of inspection information in relation to the structure. A quantity of computer-aided design data corresponding to the quantity of inspection information is included. An imaging system is in communication with the scanning system and the local positioning system, the imaging system situated to produce an overlay image of at least two of an image based from the structure, an image based from the quantity of inspection information and an image formed from at least a portion of the quantity of computer-aided design data.

Abstract: A first method determines a position of a point of interest on a target object surface in a target object coordinate system using orientation and distance measurements of a pointing instrument in an instrument coordinate system. A second method determines an orientation of a pointing instrument in an instrument coordinate system for the instrument to be aligned with a point of interest on a target object surface having a target object coordinate system, wherein a position of the point of interest in the target object coordinate system is known. A third method controls orientation of a laser beam of a laser in an instrument coordinate system for the laser beam to trace an image on a target object surface having a target object coordinate system, wherein positions of points for the image on the surface of the target object in the target object coordinate system are known.

Abstract: A method of removing an out-of-tolerance area in a composite structure comprises determining the location of the out-of-tolerance area and selecting a volume of the composite structure to be removed based on the location of the out-of-tolerance area. The method may further include programming a machine tool to remove the volume and to pause after removal of each one of a quantity of layers of the volume. The method may additionally include removing one of the layers using the programmed machine tool. The method may further include restoring the volume removed using the programmed area removal digital definition.

Abstract: A composite structure containing an out-of-tolerance area is restored using an automated material removal method. The location of an out-of-tolerance area within the structure is determined by non-destructive inspection and a volume of the structure to be removed is selected based on the location of the out-of-tolerance area. An automatic material removal tool is programmed and used to remove the selected volume of material. The volume of removed material may be is replaced by an integrated patch.

Abstract: Optical metrology methods, apparatuses, and systems for detecting seal integrity. These comprise changing an air pressure inside a chamber to an excitation pressure level when the chamber is placed over a segment of a surface of a structure having one or more seal features and determining whether the integrity of any of the one or more seal features has been compromised by determining, using an optical system, whether any of the one or more seal features have been deformed by the changing of the air pressure.

Abstract: A first method locates a component positioned underneath a surface of a target object using a pointing instrument, wherein a position of the component in the target object coordinate system is known. The first method includes calculating an orientation of the aim point axis of the instrument in the instrument coordinate system for the aim point axis of the instrument to be aligned with the component using at least an inverse calibration matrix, the position of the component in the target object coordinate system, and inverse kinematics of the instrument. The first method also includes rotating the aim point axis of the instrument to the calculated orientation. Second and third methods also are described for locating an access panel for accessing the component and/or maintenance zones in which the component resides.

Abstract: Methods are described for controlling orientation of an aim point axis of a video camera having an instrument coordinate system to track a point of interest on a movable target object and calculating positions of the point of interest in a local coordinate system in which the target object is moving. The methods include measuring pan and tilt angles of the aim point axis and distance substantially along the aim point axis and calculating a calibration matrix which transforms a position defined in the instrument coordinate system to a position defined in the local coordinate system. A system is described including an instrument and at least one computer, wherein the instrument includes a video camera and a range finder, and wherein the video camera includes an aim point axis having an adjustable orientation. In one example, the target object is adapted to move on and inspect an airplane surface.

Abstract: A method and apparatus are used to fit a metallic or composite doubler on an uneven surface. A three dimensional digital map of the gap between the doubler and the uneven surface is generated by digitally scanning the uneven surface. The digital map is then used to fabricate a stack of adhesive plies tailored to substantially fill the gap between the doubler and the uneven surface.

Abstract: A first method determines a position of a point of interest on a target object surface in a target object coordinate system using orientation and distance measurements of a pointing instrument in an instrument coordinate system. A second method determines an orientation of a pointing instrument in an instrument coordinate system for the instrument to be aligned with a point of interest on a target object surface having a target object coordinate system, wherein a position of the point of interest in the target object coordinate system is known. A third method controls orientation of a laser beam of a laser in an instrument coordinate system for the laser beam to trace an image on a target object surface having a target object coordinate system, wherein positions of points for the image on the surface of the target object in the target object coordinate system are known.

Abstract: Methods and systems are disclosed for drilling counter sink fastener holes in composite materials with conductive foil lightning strike protection systems. Initially a non-destructive depth detector is scanned over a prospective fastener hole location. Then the depth of a conductive foil below a surface is detected. When the detected depth is less than a predetermined depth, a signal that indicates that a countersink fastener hole may be drilled is output. When the detected depth is greater than a predetermined depth, a signal that indicates that a countersink fastener hole may not be drilled is output.

Abstract: Optical metrology methods, apparatuses, and systems for detecting seal integrity. These comprise changing an air pressure inside a chamber to an excitation pressure level when the chamber is placed over a segment of a surface of a structure having one or more seal features and determining whether the integrity of any of the one or more seal features has been compromised by determining, using an optical system, whether any of the one or more seal features have been deformed by the changing of the air pressure.

Abstract: The apparatus, method and system for inspecting a fastener installed in a structure includes the illumination of a fastener and a portion of the structure surrounding the fastener, the detection of the light reflected from the fastener and the portion of the structure surrounding the fastener, the analysis of the reflected light, and the definition of at least one inspection criteria. The structure has a coating that reflects light of a predefined wavelength differently than the fastener. As such, the light that illuminates the fastener and the structure surrounding the fastener has a wavelength within the predefined range. The light reflected from the fastener and the portion of the structure surrounding the fastener is then detected and analyzed to determine an interface between exposed surfaces of the fastener and the coating. Based upon the detected interface, at least one inspection criteria may then be defined.

Abstract: The apparatus, method and system for inspecting a fastener installed in a structure includes the illumination of a fastener and a portion of the structure surrounding the fastener, the detection of the light reflected from the fastener and the portion of the structure surrounding the fastener, the analysis of the reflected light, and the definition of at least one inspection criteria. The structure has a coating that reflects light of a predefined wavelength differently than the fastener. As such, the light that illuminates the fastener and the structure surrounding the fastener has a wavelength within the predefined range. The light reflected from the fastener and the portion of the structure surrounding the fastener is then detected and analyzed to determine an interface between exposed surfaces of the fastener and the coating. Based upon the detected interface, at least one inspection criteria may then be defined.

Abstract: A damage detection device is used to detect damage in bonded and laminated composite structures. A tap hammer or tap coin containing an acceleration sensor is connected to a circuit that can measure the width of an impact signal and then display the result. The result correlates to local stiffness of a structure. A method of determining the desired signal width and the method of using the damage detection device, includes tapping a known good region and then tapping a suspect region. Readings from the two areas are used to determine whether the suspect region is within an acceptable range. The circuit determines the desired signal width by measuring from the time the impact signal exceeds a threshold to the time it falls below the threshold.