An autonomous or semi-autonomous cell for inspecting composite parts, verifying repairs made to such parts, and facilitating repairs to composite parts. The cell employs automated inspection, damage assessment, and repair systems. An industrial robot automatically attaches to a set of interchangeable inspection and repair end effectors to carry out the inspection, verification, and repair processes. The cell can be equipped with fixtures for supporting a rotorcraft blade and rotating the blade within the cell so that the robot can access the entire blade. Processes are provided for performing inspections, tracking the inspection data for parts in a database, and carrying out repairs. Over time, a software applicant can use the inspection data to train a machine learning model for recognizing damage to the composite part based on inspection images.

An autonomous or semi-autonomous cell for inspecting composite parts, verifying repairs made to such parts, and facilitating repairs to composite parts. The cell employs automated inspection, damage assessment, and repair systems. An industrial robot automatically attaches to a set of interchangeable inspection and repair end effectors to carry out the inspection, verification, and repair processes. The cell can be equipped with fixtures for supporting a rotorcraft blade and rotating the blade within the cell so that the robot can access the entire blade. Processes are provided for performing inspections, tracking the inspection data for parts in a database, and carrying out repairs. Over time, a software applicant can use the inspection data to train a machine learning model for recognizing damage to the composite part based on inspection images.

A method of and system for removing a portion of a thermoplastic component is provided. The component includes a thermoplastic material having a melting temperature. The method includes: a) providing a glider that includes an electrically conductive material operable to produce thermal energy resulting from electrical resistance; b) heating a portion of the glider with electrical energy to a glider operating temperature that is equal or greater than the melting temperature; and c) removing the portion by engaging the component with the glider and translating one of the glider or the component relative to the other. The engagement of the glider and the component causes an amount of the thermoplastic material to melt, and the translation of the one of the glider or the component relative to the other removes the portion from the thermoplastic component.

To reduce the processing time in the case of repairing of excessively countersunk bolt openings or surface damage in fiber composite workpieces, it is proposed to countersink the corresponding surface spot to produce a contact surface and a depression for a fiber composite insert body. The fiber composite insert body is placed onto the contact surface and is fixed on the fiber composite workpiece in the depression. In the case of an excessively countersunk bolt opening, a new bolt opening is drilled into the fiber composite insert body, which new bolt opening is subsequently countersunk to the correct countersunk bore depth. In the case of the method, a three-legged application tool can be used which positions and orients the fiber composite insert body correctly and presses it onto the fiber composite workpiece during the curing of the adhesive.

A method for repairing a tire is provided that includes: (a) providing a reamer, a knife, an insertion tool forming a receiving opening, a plugging strip, and vulcanizing fluid; (b) inserting the reamer into a puncture hole of a tire to clear debris; (c) applying the vulcanizing fluid; (d) inserting the plugging strip into the insertion tool; (e) inserting the insertion tool with the plugging strip into the puncture hole to cause the plugging strip to fold into the puncture hole mixed with the vulcanizing fluid to bond the plugging strip and the tire; (f) removing the insertion tool from the puncture hole causing a middle portion of the plugging strip to fold internally forming a four-layer seal within the puncture hole; and (g) cutting the plugging strip from the insertion tool and the excess portions of the plugging strip with the knife.

A method for repairing a tire is provided that includes: (a) providing a reamer, a knife, an insertion tool forming a receiving opening, a plugging strip, and vulcanizing fluid; (b) inserting the reamer into a puncture hole of a tire to clear debris; (c) applying the vulcanizing fluid; (d) inserting the plugging strip into the insertion tool; (e) inserting the insertion tool with the plugging strip into the puncture hole to cause the plugging strip to fold into the puncture hole mixed with the vulcanizing fluid to bond the plugging strip and the tire; (f) removing the insertion tool from the puncture hole causing a middle portion of the plugging strip to fold internally forming a four-layer seal within the puncture hole; and (g) cutting the plugging strip from the insertion tool and the excess portions of the plugging strip with the knife.

Methods and apparatus for performing repair operations using an unmanned aerial vehicle (UAV). A UAV carries a repair patch ensemble containing all repair materials (including a repair patch, a heating blanket and other ensemble materials) in a prepackaged form to the repair area. During flight of the UAV, the repair patch is vacuum adhered to the heating blanket. Vacuum pressure is also used to hold the repair patch ensemble in position on the composite surface of the structure. Then the hot bond process is enacted to bond the repair patch to the repair area. In accordance with one embodiment, the hot bond process involves heating the repair patch to adhesively bond the repair patch while applying vacuum pressure to consolidate the composite material. Then the repair patch is released from the ensemble and residual ensemble materials (heating blanket, bleeder material, and release films) are removed by the UAV.

Disclosed herein are a repair apparatus, system, and method for structurally reinforcing an abnormal composite structural member. The repair is suited for reinforcing a cured composite structure that defines a strength tolerance and has an abnormality that reduces the structural strength relative to the strength tolerance of the cured composite. The structural reinforcement repairs the abnormality in the cured composite and provides the repair strength so that the repaired composite has a structural strength that meets or exceeds the strength tolerance. The structural reinforcement has a composite patch that is coupled to the cured composite over the abnormality and is covered by pressure-sensitive tape.

Disclosed herein are a repair apparatus, system, and method for a composite sandwich structure. The repair is suited for reinforcing a sandwich panel having a first sheet and a second sheet opposite the first sheet. A core is interposed between and coupled to the first sheet and the second sheet. The repair uses a potting compound packed into an abnormality of the core and located on the outer surface of the first sheet. A patch is coupled to the outer surface of the first sheet over the abnormality of the core and cured. The cured potting compound is interposed between and bonded to the patch and the abnormality of the core and bonded to the patch and the outer surface of the first sheet to form a structural reinforcement.

Disclosed herein are a repair apparatus, system, and method for a composite sandwich structure. The repair is suited for reinforcing a sandwich panel having a first sheet and a second sheet opposite the first sheet. A core is interposed between and coupled to the first sheet and the second sheet. The repair uses a potting compound packed into an abnormality of the core and located on the outer surface of the first sheet. A patch is coupled to the outer surface of the first sheet over the abnormality of the core and cured. The cured potting compound is interposed between and bonded to the patch and the abnormality of the core and bonded to the patch and the outer surface of the first sheet to form a structural reinforcement.