Abstract: A method of manufacturing a physical object comprises, during a process of manufacturing the physical object by a machine, capturing image data of at least a portion of the physical object and other sensor data related to the machine or to the at least a portion of the physical object. The method further comprises, during the process of manufacturing the physical object, for each of the plurality of pixels of the image data, coregistering the image data with the other sensor data on a pixel-by-pixel basis, storing the coregistered image data and other sensor data in association with each other in a data structure, and using at least a portion of the coregistered image data and other sensor to detect an anomaly in the physical object or in the process of manufacturing the physical object.

Abstract: In accordance with the present invention, there is provided a technique which may be used in conjunction with an automated Z-pin insertion process to automatically monitor the insertion energy applied to the Z-pins during the initial insertion phase of the automated insertion process, and compare it to an empirically derived value for good insertions, thereafter allowing the insertion process to continue to a predetermined additional insertion depth before terminating the process. The insertion energy is calculated by cumulatively summing the insertion force and multiplying it by the insertion time, thus yielding the cumulative energy. At a specified, predetermined insertion depth, the energy accumulation is stopped and the value at the initial insertion depth is stored and compared to an empirically derived value. If the value is less than the empirical value, the insertion energy is too low, thus indicating that either a partial grid insertion is being encountered or defective Z-pins are being inserted.

Abstract: In accordance with the present invention, there is provided a method of automatically verifying the acceptable insertion of at least one Z-pin into a composite laminate. The method comprises the initial step of positioning at least one Z-pin upon the composite laminate. Thereafter, an insertion force is applied to the Z-pin at a first level which is sufficient to commence an insertion process wherein the Z-pin is driven into the composite laminate at a first insertion speed. The insertion force applied to the Z-pin is continuously monitored, with the first insertion speed being reduced to a second insertion speed in response to a monitored increase in the insertion force from a first level to a second level. The application of the insertion force to the Z-pin is discontinued and the insertion process terminated in response to a monitored increase in the insertion force from the second level to a third level.

Abstract: In accordance with the present invention, there is provided a method of inserting at least one Z-pin into a composite laminate for providing Z direction reinforcement thereto. The method comprises the initial step of positioning at least one Z-pin upon the composite laminate. Thereafter, an insertion force is applied to the Z-pin at a first level which is sufficient to commence an insertion process wherein the Z-pin is driven into the composite laminate at a first insertion speed. The insertion force applied to the Z-pin is continuously monitored, with the first insertion speed being reduced to a second insertion speed in response to a monitored increase in the insertion force from a first level to a second level.

Abstract: A Z-form position detector useful for ascertaining the position of Z-forms with respect to underlying composite structure. The device comprises an oscillating laser that generates a line projected onto the Z-form and composite structure at an angle. The line appears discontinuous due to the topography of the Z-form and composite structure. For example, the line is discontinuous at the edges of the Z-form. The device further comprises a sensor sensitive to the frequency of the laser. The sensor scans along the line until a discontinuity (i.e., a break in the line) is detected. Since the discontinuity corresponds to the edge of the Z-form, detection of the discontinuity allows the device to ascertain precise coordinates of a point on the edge of the Z-form. The device thus allows Z-pins to be driven into composite structure automatically for savings on time and cost.

Abstract: In accordance with the present invention, in an aircraft storage container which is used for the transport of cargo items, defines an enclosed interior compartment and includes a hatch for selectively accessing the interior compartment, there is provided an improvement of the aircraft storage container. The improvement is provided with a high strength flexible bag member disposed about a substantial portion of the interior compartment for distributing force in response to explosive forces emanating from cargo items within the bag member. The bag member includes an opening and is positionable within the interior compartment such that the opening is adjacent the hatch for allowing cargo items to be placed into and removed from within the bag member via the hatch and the opening. The improvement is further provided with a bag opening frame which is attachable to the opening of the bag member and formed to receive cargo items for storage within the bag member therethrough.

Abstract: In accordance with the present invention, in an aircraft storage container which is used for the transport of cargo items, defines an enclosed interior compartment and includes a hatch for selectively accessing the interior compartment, there is provided an improvement of the aircraft storage container. The improvement is provided with a high strength flexible bag member disposed about a substantial portion of the interior compartment for distributing force in response to explosive forces emanating from cargo items within the bag member. The bag member includes an opening and is positionable within the interior compartment such that the opening is adjacent the hatch for allowing cargo items to be placed into and removed from within the bag member via the hatch and the opening. The improvement is further provided with a bag opening frame which is attachable to the opening of the bag member and formed to receive cargo items for storage within the bag member therethrough.