Apparatus and method for applying radius filler

Abstract

An apparatus (100) and method for depositing a radius filler (102) into a groove (104), the radius filler being made of a homogeneous material, the groove being formed in a workpiece (106), the apparatus comprising a base frame (110), a first device (120) for extruding the radius filler along an extrusion axis (112), a second device (130) for providing the homogeneous material to the first device, and a third device (140) for compacting the radius filler into the groove. The apparatus also comprises a first sensor (150) configured to provide a first sensor output. The apparatus also comprises a controller (180) operatively coupled to the first device, the second device, and the first sensor. Based on the first sensor output, the controller is configured to determine a first geometric feature of the groove. Furthermore, based on the first geometric feature, the controller is configured to control a second geometric feature of the radius filler extruded by the first device when a tool center point (122) moves relative to the groove.

Description

Technical Field

[0001] The present disclosure relates to systems and methods for filling a groove in a workpiece with a homogenous material. Background Art

[0002] Joints between composite structures, such as spars and / or ribs, typically include grooves filled with radius fillers or "noodles" made of composite material. However, conventional radius filler application techniques are slow and inefficient. Summary of the invention

[0003] Accordingly, an apparatus and method that aims to at least address the above-mentioned problems would be of practical use.

[0004] The following is a non-exhaustive list of embodiments according to the subject matter of the present invention, which embodiments may or may not be claimed.

[0005] One embodiment of the subject matter according to the present invention relates to an apparatus for depositing a radius filler made of a homogeneous material into a groove formed in a workpiece. The apparatus includes a chassis movable relative to the groove. The apparatus also includes a first device for extruding the radius filler along an extrusion axis. The apparatus also includes a tool center point associated with the first device. The apparatus also includes a second device for providing the homogeneous material to the first device. The second device is connected to the chassis and the first device is connected to the second device. The apparatus also includes a third device for compacting the radius filler into the groove. The third device is connected to the chassis. The apparatus also includes a first sensor connected to the chassis and configured to provide a first sensor output, the first sensor output representing a first geometric feature of the groove along at least a portion of the groove length before the radius filler is deposited into the at least a portion of the groove length. The apparatus also includes a controller operably coupled to the first device, the second device, and the first sensor. Based on the first sensor output, the controller is configured to determine a first geometric feature of the groove. Based on the first geometric feature, the controller is also configured to control a second geometric feature of the radius filler extruded by the first device when the tool center point moves relative to the groove.

[0006] The apparatus implements an in-situ radius filler manufacturing and deposition technique that solves the problems associated with excessive manufacturing lead times, high costs, and complex manufacturing, material handling, and large footprint requirements of conventional radius filler installations. The apparatus is used to in-situ produce and install a radius filler having a desired length and cross-sectional shape that is dynamically adjusted to correspond to the cross-sectional shape of the groove into which the radius filler is deposited.

[0007] Another embodiment of the subject matter according to the present invention relates to a method for depositing a radius filler made of a homogeneous material into a groove formed in a workpiece and having a length. The method includes moving a tool center point relative to the groove, the tool center point being associated with a first device for extruding the radius filler along an extrusion axis. The method also includes providing a first sensor output using a first sensor connected to a chassis supporting the first device, the first sensor output representing a first geometric feature of the groove along at least a portion of the groove length before the radius filler is deposited into the at least a portion of the groove length. The method also includes causing the first device to extrude the radius filler along the extrusion axis while controlling a second geometric feature of the radius filler based on the first geometric feature. The method also includes at least partially compacting the radius filler extruded by the first device into the groove.

[0008] The method relates to an in-situ radius filler manufacturing and deposition technique that solves the problems associated with excessive manufacturing lead times, high costs, and complex manufacturing, material handling, and large footprint requirements of conventional radius filler installations. The method is used to in-situ produce and install a radius filler having a desired length and cross-sectional shape that is dynamically adjusted to correspond to the cross-sectional shape of a groove into which the radius filler is deposited. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Having thus generally described one or more embodiments of the present invention, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale and in which like reference numerals represent the same or similar parts throughout the several views, and in which:

[0010] Figure 1 is a block diagram of an apparatus for depositing a radius filler into a groove formed in a workpiece according to one or more embodiments of the present disclosure;

[0011] Figure 2 According to one or more embodiments of the present disclosure Figure 1 A schematic perspective view of a device;

[0012] Figure 3 According to one or more embodiments of the present disclosure Figure 1 A schematic perspective view of a device;

[0013] Figure 4 According to one or more embodiments of the present disclosure Figure 1 A schematic plan view of the equipment;

[0014] Figure 5 According to one or more embodiments of the present disclosure Figure 1 a schematic perspective view of an apparatus for depositing a radius filler into a groove formed in a workpiece;

[0015] Fig. 6A According to one or more embodiments of the present disclosure Figure 1 a schematic perspective view of a portion of an apparatus showing the deposition of a radius filler into a groove formed in a workpiece;

[0016] Figure 6B yes Fig. 6A A schematic perspective view of a portion of a device with radius fillers omitted;

[0017] Figure 7 is a schematic cross-sectional view of a radius filler in a groove according to one or more embodiments of the present disclosure;

[0018] Figure 8 According to one or more embodiments of the present disclosure Figure 1 A schematic perspective view of a device;

[0019] Fig. 9 According to one or more embodiments of the present disclosure Figure 1 A schematic side view of a device;

[0020] Fig. 10A and 10B Taken together, the use of one or more embodiments of the present disclosure Figure 1 A block diagram of a method for depositing a radius filler into a groove formed in a workpiece using an apparatus;

[0021] Fig.11 is a block diagram of the aircraft production and maintenance methods; and

[0022] Fig.12 It is a schematic diagram of an aircraft. DETAILED DESCRIPTION

[0023] exist Figure 1In, as described above, the solid lines (if any) connecting various elements and / or components can represent mechanical, electrical, fluid, optical, electromagnetic and other couplings and / or combinations thereof. As used herein, "coupling" refers to direct and indirect association. For example, member A can be directly associated with member B, or can be indirectly associated with member B, for example, through another member C. It should be understood that not all relationships between various disclosed elements must be represented. Therefore, there may also be couplings other than those depicted in the block diagram. The dotted lines (if any) connecting the boxes indicating various elements and / or components represent couplings similar to those represented by the solid lines in function and purpose; however, couplings represented by dotted lines may be selectively provided, or may involve alternative embodiments of the present disclosure. Similarly, the elements and / or components (if any) represented by dotted lines represent alternative embodiments of the present disclosure. Without departing from the scope of the present disclosure, one or more elements shown in solid and / or dotted lines may be omitted from a particular embodiment. Environmental elements (if any) are represented by dotted lines. For clarity, virtual (imaginary) elements may also be shown. Those skilled in the art will understand that Figure 1 Some of the features shown can be combined in various ways without necessarily including Figure 1 , other features described in other drawings and / or the accompanying disclosure, even if these combinations are not explicitly shown here. Similarly, additional features not limited to the embodiments presented may be combined with some or all of the features shown and described herein.

[0024] In the above mentioned Fig. 10A , 10B In the embodiments of the present invention, boxes may represent operations and / or portions thereof, and the lines connecting the various boxes do not imply any particular order or dependency of the operations or portions thereof. Boxes represented by dashed lines represent alternative operations and / or portions thereof. The dashed lines connecting the various boxes (if any) represent alternative dependencies of the operations or portions thereof. It should be understood that not all dependencies between the various disclosed operations must be represented. Fig. 10A , 10B The accompanying disclosures of 11 and 12 describing the operations of the methods set forth herein should not be construed as necessarily determining the order in which the operations are to be performed. On the contrary, although an illustrative order is shown, it should be understood that the order of operations can be modified when appropriate. Therefore, certain operations can be performed in different orders or simultaneously. In addition, those skilled in the art will appreciate that not all operations described need to be performed.

[0025] In the following description, many specific details are set forth to provide a comprehensive understanding of the disclosed concepts, which can be implemented without some or all of these details. In other cases, details of known equipment and / or processes are omitted to avoid unnecessarily obscuring the present disclosure. Although some concepts will be described in conjunction with specific embodiments, it should be understood that these embodiments are not intended to be limiting.

[0026] Unless otherwise indicated, the terms "first," "second," etc. are used herein merely as labels and are not intended to impose order, position, or hierarchical requirements on the items to which these terms refer. Furthermore, reference to, for example, a "second" item does not require or preclude the presence of, for example, a "first" or lower numbered item and / or, for example, a "third" or higher numbered item.

[0027] References herein to "one embodiment" mean that one or more features, structures, or characteristics described in connection with the embodiment are included in at least one implementation. The phrase "one embodiment" in various places in the specification may or may not refer to the same embodiment.

[0028] As used herein, a system, device, structure, article, element, component, or hardware that is "configured to" perform a specified function is indeed able to perform the specified function without any changes, rather than merely having the potential to perform the specified function after further modification. In other words, a system, device, structure, article, element, component, or hardware that is "configured to" perform a specific function is specifically selected, created, implemented, utilized, programmed, and / or designed to perform a specific function. As used herein, "configured to" represents existing features of a system, device, structure, article, element, component, or hardware that enable the system, device, structure, article, element, component, or hardware to perform a specified function without further modification. For purposes of this disclosure, a system, device, structure, article, element, component, or hardware that is described as "configured to" perform a specific function may be described additionally or alternatively as "suitable for" and / or "operably" perform the function.

[0029] Illustrative, non-exhaustive embodiments of the subject matter in accordance with the present disclosure are provided below, which embodiments may or may not be claimed.

[0030] Overall reference Figure 1 With specific reference to, for example Figure 2-9, discloses an apparatus 100 for depositing a radius filler 102 made of a homogeneous material into a groove 104 formed in a workpiece 106. The apparatus 100 includes a base frame 110 that is movable relative to the groove 104. The apparatus 100 also includes a first device 120 for extruding the radius filler 102 along an extrusion axis 112. The apparatus 100 also includes a tool center point 122 associated with the first device 120. The apparatus 100 also includes a second device 130 for providing the homogeneous material to the first device 120. The second device 130 is connected to the base frame 110, and the first device 120 is connected to the second device 130. In addition, the apparatus 100 includes a third device 140 for pressing the radius filler 102 into the groove 104. The third device 140 is connected to the base frame 110. The apparatus 100 also includes a first sensor 150 coupled to the chassis 110 and configured to provide a first sensor output representing a first geometric characteristic of the groove 104 along at least a portion of the length of the groove 104 before the radius filler 102 is deposited into at least a portion of the length of the groove 104. The apparatus 100 also includes a controller 180 operably coupled to the first device 120, the second device 130, and the first sensor 150. Based on the first sensor output, the controller 180 is configured to determine a first geometric characteristic of the groove 104. Based on the first geometric characteristic, the controller 180 is further configured to control a second geometric characteristic of the radius filler 102 extruded by the first device 120 when the tool center point 122 moves relative to the groove 104. The foregoing subject matter of this paragraph characterizes Embodiment 1 of the present disclosure.

[0031] The apparatus 100 implements an in-situ radius filler manufacturing and deposition technique that solves the problems associated with the excessive manufacturing lead time, high cost, and complex manufacturing, material handling, and large floor space requirements of conventional radius filler installations. The apparatus 100 is used to in-situ produce and install a radius filler 102 having a desired length and cross-sectional shape that is dynamically adjusted to correspond to the cross-sectional shape of a groove 104 into which the radius filler 102 is deposited.

[0032] The chassis 110 supports at least some components of the apparatus 100. In one embodiment, the first device 120 is an adjustable nozzle that extrudes the radius filler 102. The adjustable nozzle is configured to change the size of its opening when the radius filler 102 is extruded to control the cross-sectional area of ​​the radius filler 102. The adjustable nozzle includes a gate that is configured to move over the opening to selectively close the opening when the radius filler 102 is extruded, thereby adjusting the profile of the radius filler 102.

[0033] The tool center point 122 is a reference point that is fixed relative to the first device 120. In one embodiment, the tool center point 122 is located at the outlet of the first device 120 through which the radius filler 102 is extruded. In one embodiment, the second device 130 includes an extruder that heats and / or stores a homogenized material and provides the homogenized material to the first device 120. In one embodiment, the extruder is a VPM-7 powered wedge screw extruder manufactured by Peter Pugger Mfg., Inc. of Ukiah, California. The extruder can be a hydraulic or mechanical screw screw extruder. In one embodiment, the third device 140 includes a roller that rolls along the workpiece 106, trailing the first device 120 and pressing the radius filler 102 into the groove 104. In another embodiment, the third device 140 includes a flat surface that is pulled along the workpiece 106, trailing the first device 120, and sliding on the radius filler 102 to press the radius filler 102 into the groove 104. The first sensor 150 guides the first device 120 as the apparatus 100 moves along the groove 104. The first sensor 150 measures the shape, cross-sectional area, and / or path of the groove 104. The controller 180 is configured to receive and process the first sensor output and control (e.g., maintain or modify a second geometric characteristic of the radius filler 102, which includes a cross-sectional shape of the radius filler 102, a speed at which the radius filler 102 is extruded, etc.). In one embodiment, the controller 180 is a CompactGuardLogix programmable logic controller manufactured by Rockwell Automation, Inc. of Milwaukee, Wisconsin.

[0034] In one embodiment, the radius filler 102 is a truss noodle made of a thermosetting resin reinforced with short fibers. In at least one embodiment, the radius filler 102 is not laminated. In one embodiment, the radius filler 102 has a length as long as the groove 104, which can be up to about 110 feet or even longer. In one embodiment, after the radius filler 102 is deposited into the groove 104, the radius filler 102 and the workpiece 106 are co-cured together.

[0035] The groove 104 can be a uniform groove. For example, the groove 104 can be straight and / or have a constant cross-sectional area along the length of the groove 104. In another embodiment, the groove 104 can be a non-uniform groove. For example, the groove 104 can be curved, twisted, or zigzag in a horizontal or vertical plane, and / or the cross-sectional area can vary along the length of the groove 104.

[0036] In one embodiment, the second device 130 includes a heated barrel that stores and heats the homogenized material to produce the radius filler 102. In one embodiment, the first sensor 150 includes one or more profilometers that provide a signal for measuring the cross-sectional area of ​​the groove 104. In one embodiment, the profilometer is a LJ-V7000 series profilometer produced by Keyence of Itasca, Illinois. In one embodiment, the first device 120 and / or the second device 130 include closed loop thermal control and the temperature is set at approximately 120°F + / - 5°F.

[0037] When the process starts, the device 100 is positioned at a predetermined position so that one end of the groove 104 is within the field of view of the first sensor 150. Once the device 100 is in the starting position, the first sensor output is used to adjust or maintain the position of the device 100 (e.g., the first device 120) relative to the groove 104. More specifically, the first sensor output is used to guide the position of the device 100 by continuously taking X, Y, Z measurements and making adjustments based on the horizontal angle α, the vertical angle β, and the target distance 124 between the first device 120 and the groove 104.

[0038] Overall reference Figure 1 With specific reference to, for example Fig. 6A , 6B and 7, the first geometric characteristic of the groove 104 comprises the cross-sectional area of ​​the groove 104. The foregoing subject matter of this paragraph characterizes Embodiment 2 of the present disclosure, wherein Embodiment 2 also comprises the subject matter of the above-mentioned Embodiment 1.

[0039] In some cases, the cross-sectional area of ​​the groove 104 varies along the groove 104. By monitoring this variation, the second geometric feature of the radius filler 102 can be dynamically adjusted to match the variation in the groove 104. For example, the opening size of the adjustable nozzle (first device 120) is adjusted as the gate moves over the opening to dynamically adjust the second geometric feature of the radius filler 102.

[0040] Overall reference Figure 1 With specific reference to, for example Fig. 6A , 6B and 7, the second geometric characteristic of the radius filler 102 comprises the cross-sectional area of ​​the radius filler 102. The foregoing subject matter of this paragraph characterizes the embodiment 3 of the present disclosure, wherein the embodiment 3 also comprises the subject matter of the above-mentioned embodiment 1 or 2.

[0041] In some cases, the cross-sectional area of ​​the groove 104 varies along the groove 104. By monitoring this variation, the second geometric feature of the radius filler 102 can be dynamically adjusted to match the variation in the groove 104. For example, the opening size of the adjustable nozzle (first device 120) is adjusted as the gate moves over the opening to dynamically adjust the second geometric feature of the radius filler 102.

[0042] Overall reference Figure 1 With specific reference to, for example Figure 3-7 , when the groove 104 observed in the plan view includes a nonlinear portion of the plan view, the controller 180 is further configured to adjust the horizontal angle α between the horizontal projection of the extrusion axis 112 and the vertical plane 181 tangent to the groove 104 based on the first sensor output, so that when the base 110 moves relative to the groove 104, the tool center point 122 follows the groove 104. The aforementioned subject matter of this paragraph characterizes embodiment 4 of the present disclosure, wherein embodiment 4 also includes the subject matter according to any one of the above embodiments 1 to 3.

[0043] Adjusting or maintaining the horizontal angle α allows the radius filler 102 to be located within the groove 104 even if the shape, size and / or orientation of the groove 104 changes. For example, if the groove 104 fluctuates horizontally, the controller 180 adjusts the horizontal angle α so that the tool center point 122 follows the groove 104.

[0044] The first sensor output is also used to calculate an offset (e.g., a change in the angular orientation of the first device 120 to maintain a predetermined optimal target distance 124 and a horizontal angle α between the first device 120 and the groove 104). The horizontal angle α is measured from about 1° to about 5°, about 1° to about 15°, or about 1° to about 30°. In at least one embodiment, the first sensor output is used in conjunction with the second sensor output to achieve this purpose.

[0045] Vertical plane 181 is a virtual reference plane. As used herein, "virtual" means having the attributes of an entity without having its physical form. For example, a virtual reference plane is an invisible or imaginary plane, rather than a physical plane, relative to which, for example, the position and / or orientation of other physical and / or invisible entities can be defined.

[0046] In one embodiment, the tangency point is the intersection of the extrusion axis 112 and the medial (central) longitudinal axis of the groove 104. In another embodiment, the tangency point is the intersection of the extrusion axis 112 and another axis (eg, the central longitudinal axis of the groove 104).

[0047] Overall reference Figure 1 And specifically, for example Figure 3-7and 9, the apparatus 100 further includes a second sensor 160 connected to the chassis 110 and configured to provide a second sensor output representing a third geometric characteristic of the radius filler 102 in the groove 104 along at least a portion of the length of the groove 104 after the third device 140 compacts the radius filler 102 in the groove 104. The foregoing subject matter of this paragraph characterizes embodiment 5 of the present disclosure, wherein embodiment 5 also includes subject matter according to any of embodiments 1 to 4 above.

[0048] The second sensor 160 provides quality assurance for the radius filler 102 in the groove 104 (eg, ensuring that the radius filler 102 properly fills or slightly overfills the groove 104 ).

[0049] The second sensor 160 is used for quality assurance. In one embodiment, the second sensor 160 includes one or more profilometers after the third device 140. In one embodiment, the profilometer is a LJ-V7000 series profilometer produced by Keyence Corporation of Itasca, Illinois. The third geometric feature includes the top height of the radius filler 102 after the radius filler 102 is deposited in the groove 104 (e.g., the height of the radius filler 102 relative to the groove 104). Additionally or alternatively, the third geometric feature includes the width of the radius filler 102 after the radius filler 102 is deposited in the groove 104. Additionally or alternatively, the third geometric feature includes the cross-sectional area of ​​overfill or underfill.

[0050] Overall reference Figure 1 With specific reference to, for example Fig. 6A , 6B and 7, the third geometric characteristic includes at least one of: (1) a maximum width of the radius filler 102 after the third device 140 presses the radius filler 102 against the groove 104; or (2) a difference between a height of the groove 104 and a height of the radius filler 102. The foregoing subject matter of this paragraph characterizes Example 6 of the present disclosure, wherein Example 6 also includes the subject matter of the above-mentioned Example 5.

[0051] The image from the first sensor output is compared to the image from the second sensor output to ensure that the radius filler 102 properly fills or slightly overfills the groove 104 .

[0052] The third geometric feature includes a top height of the radius filler 102 after the radius filler 102 is deposited in the groove 104 (e.g., a height of the radius filler 102 relative to the groove 104). Additionally or alternatively, the third geometric feature includes a width of the radius filler 102 after the radius filler 102 is deposited in the groove 104. Additionally or alternatively, the third geometric feature includes an overfilled or underfilled cross-sectional area.

[0053] Overall reference Figure 1 With specific reference to, for example Fig. 6A , 6B and 7, the controller 180 is further configured to determine the amount by which the radius filler 102 overfills or underfills the groove 104 by comparing the first sensor output and the second sensor output. The foregoing subject matter of this paragraph characterizes embodiment 7 of the present disclosure, wherein embodiment 7 also includes the subject matter of embodiment 5 or 6 above.

[0054] The image from the first sensor output is compared to the image from the second sensor output to ensure that the radius filler 102 properly fills or slightly overfills the groove 104 .

[0055] The comparing includes overlaying the second sensor data on the first sensor data. In one embodiment, the desired overfill is from about 1% to about 20% or from about 5% to about 15%.

[0056] Overall reference Figure 1 With specific reference to, for example Figure 5-7 In response to a fault condition corresponding to the radius filler 102 overfilling or underfilling the groove 104 by a predetermined amount and identified by comparing the first sensor output and the second sensor output, the controller 180 is further configured to at least one of: stop movement of the chassis 110 relative to the groove 104 and extrusion of the radius filler 102 along the extrusion axis 112, or store the position of the fault condition along the groove 104. The foregoing subject matter of this paragraph characterizes embodiment 8 of the present disclosure, wherein embodiment 8 also includes the subject matter of embodiment 7 described above.

[0057] If a fault / error is detected, the controller 180 stops part or all of the process so that the fault / error can be analyzed and does not propagate along the length of the groove 104. In one embodiment, the desired overfill is from about 1% to about 20% or from about 5% to about 15%.

[0058] Overall reference Figure 1 With specific reference to, for example Fig. 9 , when the groove 104 observed in the side view includes a nonlinear portion in the side view, the controller 180 is further configured to adjust the vertical angle β between the extrusion axis 112 and the plane 183 based on the first sensor output and the second sensor output, so that when the base 110 moves relative to the groove 104, the tool center point 122 follows the groove 104, and the plane 183 is tangential to the groove 104 and perpendicular to the vertical plane containing the extrusion axis 112. The aforementioned subject matter of this paragraph characterizes embodiment 9 of the present disclosure, wherein embodiment 9 also includes the subject matter according to any one of the above embodiments 5 to 8.

[0059] Adjusting or maintaining vertical angle β allows radius filler 102 to stay within groove 104 even if groove 104 changes shape, size, and / or orientation. For example, if groove 104 undulates vertically, controller 180 adjusts vertical angle β so tool center point 122 follows groove 104.

[0060] The vertical angle β measures about 1° to about 5°, about 1° to about 15°, or about 1° to about 30°. Plane 183 is a virtual reference plane. As used herein, "virtual" means having the attributes of an entity without having its physical form. For example, a virtual reference plane is an invisible or imaginary plane, rather than a physical plane, relative to which, for example, the position and / or orientation of other physical and / or intangible entities can be defined.

[0061] Overall reference Figure 1 With specific reference to, for example Fig. 9 , the controller 180 is further configured to adjust the target distance 124 between the tool center point 122 and the groove 104 based on the first sensor output and the second sensor output, so that when the chassis 110 moves relative to the groove 104, the tool center point 122 follows the groove 104. The foregoing subject matter of this paragraph characterizes embodiment 10 of the present disclosure, wherein embodiment 10 also includes the subject matter of the above-mentioned embodiment 9.

[0062] Adjusting and / or maintaining the target distance 124 allows the radius filler 102 to be located within the groove 104 even if the shape, size, and / or orientation of the groove 104 changes.

[0063] The target distance 124 is measured relative to an axis, such as a central longitudinal axis of the groove 104. The target distance 124 is, for example, about 0.1 cm to about 10 cm, about 0.2 cm to about 8 cm, or about 0.3 cm to about 6 cm.

[0064] Overall reference Figure 1 With specific reference to, for example Figure 4 and Fig. 9, when the groove 104 observed in the plan view includes a plan view nonlinear portion, and when the groove 104 observed in the side view includes a side view nonlinear portion, the controller 180 is further configured to adjust, based on the first sensor output and the second sensor output: a horizontal angle α between a horizontal projection of the extrusion axis 112 and a vertical plane 181 tangent to the groove 104, a vertical angle β between the extrusion axis 112 and a plane 183 (tangent to the groove 104 and perpendicular to the vertical plane containing the extrusion axis 112), and a target distance 124 between the tool center point 122 and the groove 104, so that when the chassis 110 moves relative to the groove 104, the tool center point 122 follows the groove 104. The aforementioned subject matter of this paragraph characterizes Embodiment 11 of the present disclosure, wherein Embodiment 11 also includes subject matter according to any one of Embodiments 5 to 8 described above.

[0065] Adjusting or maintaining the horizontal angle α allows the radius filler 102 to be located within the groove 104 even if the shape, size and / or orientation of the groove 104 changes. For example, if the groove 104 fluctuates horizontally, the controller 180 adjusts the horizontal angle α so that the tool center point 122 follows the groove 104.

[0066] Adjusting or maintaining vertical angle β allows radius filler 102 to stay within groove 104 even if groove 104 changes shape, size, and / or orientation. For example, if groove 104 undulates vertically, controller 180 adjusts vertical angle β so tool center point 122 follows groove 104.

[0067] Adjusting or maintaining the target distance 124 allows the radius filler 102 to be located within the groove 104 even if the shape, size, and / or orientation of the groove 104 changes.

[0068] Planes 181 and 183 are virtual reference planes. As used herein, "virtual" means having the attributes of an entity without having its physical form. For example, a virtual reference plane is an invisible or imaginary plane, rather than a physical plane, relative to which, for example, the position and / or orientation of other physical and / or invisible entities can be defined.

[0069] Overall reference Figure 1 With specific reference to, for example Figure 3-5 , the device 100 further includes a third sensor 170 connected to the chassis 110 and configured to provide a third sensor output, the third sensor output representing a fourth geometric characteristic of the radius filler 102. The foregoing subject matter of this paragraph characterizes embodiment 12 of the present disclosure, wherein embodiment 12 further includes subject matter according to any of the above embodiments 5 to 11.

[0070] The third sensor output verifies the quality of the side surface (eg, the presence of edge and tip tearing of radius filler 102 just prior to deposition into groove 104).

[0071] The third sensor output also verifies the extrusion rate of the radius filler 102. In one example, the third sensor 170 includes one or more profilometers (e.g., one profilometer on either side of the radius filler 102). In one embodiment, the profilometer is a LJ-V7000 series profilometer manufactured by Keyence Corporation of Itasca, Illinois.

[0072] Overall reference Figure 1 With specific reference to, for example Fig. 6A , 6B and 7, a fourth geometric feature of the radius filler 102 includes at least one of a tear, a void, or a protrusion of a predetermined size in a side surface of the radius filler 102 before the radius filler 102 is positioned in the groove 104. The foregoing subject matter of this paragraph characterizes Example 13 of the present disclosure, wherein Example 13 also includes the subject matter of Example 12 described above.

[0073] If the quality of the side surface of the radius filler 102 is below a predetermined threshold, the controller 180 terminates at least a portion of the process to prevent defects from propagating along the length of the groove 104 .

[0074] To determine if an edge tear is present, the profilometer attempts to identify voids or protrusions in / on the radius filler 102. In one embodiment, the profilometer is a LJ-V7000 series profilometer manufactured by Keyence Corporation of Itasca, Illinois. The radius filler 102 can be somewhat stiff because it includes carbon fiber. In some cases, the radius filler 102 can bulge out to the left of the right side. The third sensor helps detect and prevent this.

[0075] Overall reference Figure 1 With specific reference to, for example Figure 3 and Figure 5 , the apparatus 100 further includes a laser sensor 190, which is connected to the chassis 110 and is configured to provide a laser sensor output, the laser sensor output representing the extrusion speed of the radius filler 102 extruded from the first device 120. In one embodiment, the laser sensor 190 is a LaserSpeed ​​Pro4500 sensor manufactured by Beta LaserMike, Inc. of Dayton, Ohio. The foregoing subject matter of this paragraph characterizes embodiment 14 of the present disclosure, wherein embodiment 14 also includes the subject matter of the above-mentioned embodiment 12 or 13.

[0076] The speed at which the radius filler 102 is extruded is compared to the speed of the chassis 110. If the speeds do not match, the speed of the chassis 110 is reduced. It is easier to control the speed of the chassis 110 than to control the speed at which the radius filler 102 is extruded, as the latter can affect the integrity of the radius filler 102. More specifically, changing the extrusion speed can affect the viscosity of the radius filler 102. As the radius filler is extruded, the laser sensor 190 is pointed at the radius filler 102. The laser sensor 190 measures the extrusion speed.

[0077] Overall reference Figure 1 With specific reference to, for example Figure 3 and 5 The controller 180 is further configured to control the movement speed of the chassis 110 relative to the groove 104 based on at least one of the third sensor output or the laser sensor output. The foregoing subject matter of this paragraph characterizes embodiment 15 of the present disclosure, wherein embodiment 15 also includes the subject matter of embodiment 14 described above.

[0078] The laser sensor output is used in conjunction with the third sensor output to synchronize the travel speed of the chassis 110 with the extrusion speed of the radius filler 102. It is easier to control the speed of the chassis 110 than to control the speed at which the radius filler 102 is extruded, as the latter can affect the integrity of the radius filler 102. More specifically, changing the extrusion speed can affect the viscosity of the radius filler 102. As the radius filler is extruded, the laser sensor 190 is directed toward the radius filler 102. The laser sensor 190 measures the extrusion speed.

[0079] Overall reference Figure 1 With specific reference to, for example Figure 3 and 5 , when the extrusion speed of the radius filler 102 exceeds the movement speed of the chassis 110, the controller 180 increases the movement speed of the chassis 110 relative to the groove 104; and when the movement speed of the chassis 110 exceeds the extrusion speed of the radius filler 102, the controller 180 reduces the movement speed of the chassis 110. The foregoing subject matter of this paragraph characterizes embodiment 16 of the present disclosure, wherein embodiment 16 also includes the subject matter of the above-mentioned embodiment 15.

[0080] This can prevent undesirable bowing in the radius filler 102, which may occur if the radius filler 102 is extruded faster than the chassis 110 moves. It is easier to control the speed of the chassis 110 than to control the speed at which the radius filler 102 is extruded, as the latter can affect the integrity of the radius filler 102. More specifically, varying the extrusion speed can affect the viscosity of the radius filler 102.

[0081] Overall reference Figure 1 With specific reference to, for example Figure 3-5and 8, wherein the apparatus 100 further comprises: a roller 200 connected to the first device 120 and configured to be rotated by the radius filler 102 extruded by the first device 120; and an encoder 202 configured to provide an encoder output in response to the rotation of the roller 200. In one embodiment, the encoder 202 is an RM44 magnetic encoder manufactured by Renishaw of Komenda, Slovenia. The encoder output represents the extrusion speed of the radius filler 102 extruded by the first device 120. The foregoing subject matter of this paragraph characterizes embodiment 17 of the present disclosure, wherein embodiment 17 also includes the subject matter of the above-mentioned embodiment 12 or 13.

[0082] Example 17 concerns an alternative arrangement for determining the extrusion speed of the radius filler 102. Roller-encoder systems are inherently inexpensive and reliable.

[0083] When the radius filler 102 is extruded, the roller 200 contacts the radius filler 102 and rolls in response to the contact with the radius filler 102. The number of revolutions of the roller 200 is used to determine the length and / or speed of the radius filler 102.

[0084] Overall reference Figure 1 With specific reference to, for example Figure 3-5 and 8, the controller 180 is further configured to control the movement speed of the chassis 110 relative to the groove 104 based on at least one of the third sensor output or the encoder output. The foregoing subject matter of this paragraph characterizes embodiment 18 of the present disclosure, wherein embodiment 18 also includes the subject matter of embodiment 17 above.

[0085] It is easier to control the speed of the chassis 110 than to control the speed at which the radius filler 102 is extruded, as the latter may affect the integrity of the radius filler 102. More specifically, varying the extrusion speed may affect the viscosity of the radius filler 102.

[0086] Overall reference Figure 1 With specific reference to, for example Figure 3-5 and 8, when the extrusion speed of the radius filler 102 exceeds the movement speed of the chassis 110, the controller 180 increases the movement speed of the chassis 110 relative to the groove 104; and when the movement speed of the chassis 110 exceeds the extrusion speed of the radius filler 102, the controller 180 reduces the movement speed of the chassis 110. The foregoing subject matter of this paragraph characterizes embodiment 19 of the present disclosure, wherein embodiment 19 also includes the subject matter of the above-mentioned embodiment 18.

[0087] This prevents undesirable bowing in the radius filler 102, which may occur if the radius filler 102 is extruded faster than the chassis 110 moves. It is easier to control the speed of the chassis 110 than to control the speed at which the radius filler 102 is extruded, as the latter can affect the integrity of the radius filler 102. More specifically, varying the extrusion speed can affect the viscosity of the radius filler 102.

[0088] Overall reference Figure 1 With specific reference to, for example Figure 3 , 6A , 6B and 9, the first device 120 includes an opening 121 having an adjustable size and an outlet profile 123 with an adjustable perimeter. The first device 120 is configured to extrude the radius filler 102 through the opening 121. The tool center point 122 is the centroid of a planar shape with adjustable size, which is defined by the outlet profile 123 of the opening 121. The foregoing subject matter of this paragraph characterizes embodiment 20 of the present disclosure, wherein embodiment 20 also includes subject matter according to any of the above embodiments 1 to 19.

[0089] The opening 121 and the outlet profile 123 are part of an adjustable nozzle for changing the shape and / or size of the radius filler 102 as it is extruded. In an alternative embodiment, the outlet profile 123 is part of a movable gate for changing the shape and / or size of the radius filler 102 as it is extruded. A tool center point 122 is defined to provide a reference point for the apparatus 100. This allows the size of the radius filler 102 to match the corresponding size of the groove 104.

[0090] Overall reference Figure 1 With specific reference to, for example Figure 5 The apparatus 100 further comprises a fourth device 145 for clamping and holding one end of the radius filler 102. The foregoing subject matter of this paragraph characterizes the present disclosure

[0091] Embodiment 21, wherein embodiment 21 also includes the subject matter according to any one of the above embodiments 1 to 20.

[0092] The radius filler 102 is clamped to facilitate the introduction of the radius filler 102 into the groove 104 at the beginning of the process. In one embodiment, the fourth device 145 includes a press or a clamp (e.g., a vise with multiple jaws) configured to hold one end of the radius filler 102 relative to the groove 104. In another embodiment, the fourth device 145 is or includes an adhesive. The fourth device 145 operates so that when the device 100 begins to move, one end of the radius filler 102 remains stationary relative to the groove 104. The fourth device 145 is controlled by the controller 180.

[0093] Overall reference Figure 1 With specific reference to, for example Figure 5 , the fourth device 145 is configured to initially clamp one end of the radius filler 102 after the radius filler 102 is extruded from the first device 120 but before the tool center point 122 advances along the groove 104. The foregoing subject matter of this paragraph characterizes embodiment 22 of the present disclosure, wherein embodiment 22 also includes subject matter according to the above-mentioned embodiment 21.

[0094] The radius filler 102 is clamped to facilitate introduction of the radius filler 102 into the groove 104 at the beginning of the process. The fourth device 145 operates so that one end of the radius filler 102 remains stationary relative to the groove 104 when the apparatus 100 begins to move.

[0095] Overall reference Figure 1 With specific reference to, for example Figure 5 , the fourth device 145 is configured to continue to clamp one end of the radius filler 102 as the tool center point 122 advances along the groove 104. The foregoing subject matter of this paragraph characterizes embodiment 23 of the present disclosure, wherein embodiment 23 also includes subject matter according to the above-mentioned embodiment 22.

[0096] The radius filler 102 is clamped to facilitate the introduction of the radius filler 102 into the groove 104 at the beginning of the process. The fourth device 145 continues to clamp the radius filler 102 to prevent the radius filler 102 from sliding within the groove 104.

[0097] Overall reference Figure 1 With specific reference to, for example Figure 5 , before the radius filler 102 is introduced into the groove 104, one end of the radius filler 102 is initially clamped by the fourth device 145. The foregoing subject matter of this paragraph characterizes embodiment 24 of the present disclosure, wherein embodiment 24 also includes subject matter according to any one of the above embodiments 21 to 23.

[0098] The radius filler 102 is clamped to facilitate introduction of the radius filler 102 into the groove 104 at the beginning of the process. The fourth device 145 operates so that one end of the radius filler 102 remains stationary relative to the groove 104 when the apparatus 100 begins to move.

[0099] Overall reference Figure 1 With specific reference to, for example Figure 5 , before the base frame 110 moves relative to the groove 104, the radius filler 102 is clamped by the fourth device 145. The foregoing subject matter of this paragraph characterizes embodiment 25 of the present disclosure, wherein embodiment 25 also includes subject matter according to any of the above embodiments 21 to 24.

[0100] The radius filler 102 is clamped to facilitate introduction of the radius filler 102 into the groove 104 at the beginning of the process. The fourth device 145 operates so that one end of the radius filler 102 remains stationary relative to the groove 104 when the apparatus 100 begins to move.

[0101] Overall reference Figure 1 With specific reference to, for example Figure 2-10B , discloses a method 1000 for depositing a radius filler 102 made of a homogeneous material into a groove 104 formed in a workpiece 106 and having a length. The method 1000 includes (block 1002) moving a tool center point 122 associated with a first device 120 for extruding the radius filler 102 along an extrusion axis 112 relative to the groove 104. The method 1000 also includes (block 1004) using a first sensor 150 connected to a chassis 110 supporting the first device 120 to provide a first sensor output representing a first geometric feature of the groove 104 along at least a portion of the length of the groove 104 before the radius filler 102 is deposited into at least a portion of the length of the groove 104. In addition, the method 1000 also includes (block 1006) causing the first device 120 to extrude the radius filler 102 along the extrusion axis 112 while controlling a second geometric feature of the radius filler 102 based on the first geometric feature. The method 1000 also includes (block 1032) at least partially compacting the radius filler 102 extruded by the first device 120 into the groove 104. The foregoing subject matter of this paragraph characterizes embodiment 26 of the present disclosure.

[0102] The method 1000 relates to an in-situ radius filler manufacturing and deposition technique that solves the problems associated with the excessive manufacturing lead time, high cost, and complex manufacturing, material handling, and large footprint requirements of conventional radius filler installations. The method 1000 is used to in-situ produce and install a radius filler 102 having a desired length and cross-sectional shape that is dynamically adjusted to correspond to the cross-sectional shape of a groove 104 into which the radius filler 102 is deposited.

[0103] In one embodiment, the first device 120 is an adjustable nozzle that extrude the radius filler 102. The adjustable nozzle is configured to change the size of its opening when the radius filler 102 is extruded to control the cross-sectional area of ​​the radius filler 102. The adjustable nozzle includes a gate configured to move over the opening to selectively close the opening when the radius filler 102 is extruded, thereby adjusting the profile of the radius filler 102.

[0104] The tool center point 122 is a reference point that is fixed relative to the first device 120. In one embodiment, the tool center point 122 is located at an outlet of the first device 120 through which the radius filler 102 is extruded. The first sensor 150 guides the first device 120 and measures the shape, cross-sectional area, and / or path of the groove 104. The first sensor output is used to control (e.g., maintain or modify) a second geometric characteristic of the radius filler 102, including a cross-sectional shape of the radius filler 102, a speed at which the radius filler 102 is extruded, and the like.

[0105] In one embodiment, the radius filler 102 is a truss noodle made of a thermosetting resin reinforced with short fibers. In at least one embodiment, the radius filler 102 is not laminated. The radius filler 102 may have a length as long as the groove 104, which may be up to about 110 feet or even longer. In one embodiment, after the radius filler 102 is deposited into the groove 104, the radius filler 102 and the workpiece 106 are co-cured together.

[0106] The groove 104 can be a uniform groove. For example, the groove 104 can be straight and / or have a constant cross-sectional area along the length of the groove 104. In another embodiment, the groove 104 can be a non-uniform groove. For example, the groove 104 can be curved, twisted, or zigzag in a horizontal or vertical plane, and / or the cross-sectional area can vary along the length of the groove 104.

[0107] When the process starts, the device 100 is positioned at a predetermined position so that one end of the groove 104 is within the field of view of the first sensor 150. Once the device 100 is in the starting position, the first sensor output is used to adjust or maintain the position of the device 100 (e.g., the first device 120) relative to the groove 104. More specifically, the first sensor output is used to guide the position of the device 100 by continuously taking X, Y, Z measurements and making adjustments based on the horizontal angle α, the vertical angle β, and the target distance 124 between the first device 120 and the groove 104.

[0108] Overall reference Figure 1 With specific reference to, for example Fig. 6A , 6B , 7, 10A and 10B, according to method 1000, the first geometric characteristic of groove 104 includes a cross-sectional area of ​​groove 104. The foregoing subject matter of this paragraph characterizes embodiment 27 of the present disclosure, wherein embodiment 27 also includes subject matter according to the above-mentioned embodiment 26.

[0109] In some cases, the cross-sectional area of ​​the groove 104 varies along the groove 104. By monitoring this variation, the second geometric characteristic of the radius filler 102 can be dynamically adjusted to match the variation in the groove 104. For example, the opening size of the adjustable nozzle (first device 120) is adjusted as the gate moves over the opening of the nozzle to dynamically adjust the second geometric characteristic of the radius filler 102.

[0110] Overall reference Figure 1 With specific reference to, for example Fig. 6A , 6B , 7, 10A and 10B, according to method 1000, the second geometric characteristic of radius filler 102 includes a cross-sectional area of ​​radius filler 102. The foregoing subject matter of this paragraph characterizes Example 28 of the present disclosure, wherein Example 28 also includes subject matter according to the above-mentioned Example 26 or 27.

[0111] In some cases, the cross-sectional area of ​​the groove 104 varies along the groove 104. By monitoring this variation, the second geometric characteristic of the radius filler 102 can be dynamically adjusted to match the variation in the groove 104. For example, the opening size of the adjustable nozzle (first device 120) is adjusted as the gate moves over the opening of the nozzle to dynamically adjust the second geometric characteristic of the radius filler 102.

[0112] Overall reference Figure 1 With specific reference to, for example Figure 3 , 6A , 6B, 9, 10A and 10B, according to method 1000 (box 1008), causing the first device 120 to extrude the radius filler 102 includes extruding the radius filler 102 through an opening 121 in the first device 120. The opening 121 has an adjustable size and an outlet profile 123 with an adjustable length. The tool center point 122 is the centroid of a planar shape with adjustable size, which is defined by the outlet profile 123 of the opening 121. The foregoing subject matter of this paragraph characterizes embodiment 29 of the present disclosure, wherein embodiment 29 also includes subject matter according to any of the above embodiments 26 to 28.

[0113] The opening 121 and the outlet profile 123 are part of an adjustable nozzle for changing the shape and / or size of the radius filler 102 as it is extruded. In an alternative embodiment, the outlet profile 123 is part of a movable gate for changing the shape and / or size of the radius filler 102 as it is extruded. A tool center point 122 is defined to provide a reference point for the apparatus 100. This allows the size of the radius filler 102 to match the corresponding size of the groove 104.

[0114] Overall reference Figure 1 With specific reference to, for example Figure 4, 10A and 10B, according to the method 1000, when the groove 104 observed in the plan view includes a nonlinear portion, the method 1000 further includes (block 1016) adjusting the horizontal angle α between the horizontal projection of the extrusion axis 112 and the vertical plane 181 tangent to the groove 104 based on the first sensor output, so that when the chassis 110 moves relative to the groove 104, the tool center point 122 follows the groove 104. The foregoing subject matter of this paragraph characterizes the present disclosure

[0115] Embodiment 30, wherein embodiment 30 also includes the subject matter according to any one of the above embodiments 26 to 29.

[0116] Adjusting or maintaining the horizontal angle α allows the radius filler 102 to be located within the groove 104 even if the shape, size and / or orientation of the groove 104 changes. For example, if the groove 104 fluctuates horizontally, the controller 180 adjusts the horizontal angle α so that the tool center point 122 follows the groove 104.

[0117] The first sensor output is also used to calculate an offset (e.g., a change in angular orientation of the first device 120 to maintain a predetermined optimal target distance 124 and horizontal angle α between the first device 120 and the groove 104). In at least one embodiment, the first sensor output is used in conjunction with the second sensor output to achieve this purpose.

[0118] Vertical plane 181 is a virtual reference plane. As used herein, "virtual" means having the attributes of an entity without having its physical form. For example, a virtual reference plane is an invisible or imaginary plane, rather than a physical plane, relative to which, for example, the position and / or orientation of other physical and / or invisible entities can be defined.

[0119] In one embodiment, the tangency point is the intersection of the extrusion axis 112 and the medial (central) longitudinal axis of the groove 104. In another embodiment, the tangency point is the intersection of the extrusion axis 112 and another axis (eg, the central longitudinal axis of the groove 104).

[0120] Overall reference Figure 1 With particular reference to e.g. Figure 3-7 , 10A and 10B, the method 1000 further includes (block 1034) determining an amount by which the radius filler 102 overfills or underfills the groove 104 based on a second sensor output of a second sensor 160 coupled to the chassis 110. According to the method 1000, the second sensor output represents a third geometric characteristic of the radius filler 102 in the groove 104 along at least a portion of the length of the groove 104. The foregoing subject matter of this paragraph characterizes embodiment 31 of the present disclosure, wherein embodiment 31 further includes subject matter according to any of embodiments 26 to 30 above.

[0121] The image from the first sensor output is compared to the image from the second sensor output to ensure that the radius filler 102 properly fills or slightly overfills the groove 104 .

[0122] The second sensor 160 is used for quality assurance. In one embodiment, the second sensor 160 includes one or more profilometers after the third device 140. In one embodiment, the profilometer is a LJ-V7000 series profilometer produced by Keyence Corporation of Itasca, Illinois. The third geometric feature includes the top height of the radius filler 102 after the radius filler 102 is deposited into the groove 104 (e.g., the height of the radius filler 102 relative to the groove 104). Additionally or alternatively, the third geometric feature includes the width of the radius filler 102 after the radius filler 102 is deposited into the groove 104. Additionally or alternatively, the third geometric feature includes an overfill or underfill cross-sectional area.

[0123] Overall reference Figure 1 With specific reference to, for example Figure 3-7 , 10A and 10B, according to method 1000, determining the amount by which radius filler 102 overfills or underfills groove 104 includes (block 1036) comparing the first sensor output and the second sensor output. The foregoing subject matter of this paragraph characterizes embodiment 32 of the present disclosure, wherein embodiment 32 also includes subject matter according to embodiment 31 above.

[0124] The image from the first sensor output is compared to the image from the second sensor output to ensure that the radius filler 102 properly fills or slightly overfills the groove 104 .

[0125] The comparison includes overlaying the second sensor data on the first sensor data. In one embodiment, the desired overfill is from about 1% to about 20% or from about 5% to about 15%.

[0126] Overall reference Figure 1 With specific reference to, for example Fig. 6A , 6B , 7, 10A and 10B, according to method 1000, the third geometric feature includes at least one of the following: (1) the difference between the maximum width of groove 104 and the maximum width of radius filler 102 after the radius filler 102 is pressed into groove 104; or (2) the difference between the height of groove 104 and the height of radius filler 102 after the radius filler 102 is pressed into groove 104. The foregoing subject matter of this paragraph characterizes embodiment 33 of the present disclosure, wherein embodiment 33 also includes the subject matter according to the above-mentioned embodiment 31 or 32.

[0127] The image from the first sensor output is compared to the image from the second sensor output to ensure that the radius filler 102 properly fills or slightly overfills the groove 104 .

[0128] The third geometric feature includes a top height of the radius filler 102 after the radius filler 102 is deposited into the groove 104 (e.g., a height of the radius filler 102 relative to the groove 104). Additionally or alternatively, the third geometric feature includes a width of the radius filler 102 after the radius filler 102 is deposited into the groove 104. Additionally or alternatively, the third geometric feature includes an overfill or underfill cross-sectional area.

[0129] Overall reference Figure 1 With specific reference to, for example Figure 5-7 , 10A and 10B, the method 1000 further includes (block 1038) stopping movement of the chassis 110 based on the second sensor output, thereby preventing the radius filler 102 from being squeezed out, or stopping movement of the chassis 110 and preventing the radius filler 102 from being squeezed out in response to detecting a defect in at least one of the workpiece 106, the groove 104, or the radius filler 102. The foregoing subject matter of this paragraph characterizes embodiment 34 of the present disclosure, wherein embodiment 34 also includes subject matter according to any of the above embodiments 31 to 33.

[0130] If a defect is detected, the controller 180 stops at least a portion of the process so that the defect can be analyzed and / or does not propagate along the length of the groove 104 .

[0131] Overall reference Figure 1 With specific reference to, for example Fig. 9 , 10A and 10B, when the groove 104 observed in the side view includes a nonlinear portion, the method 1000 further includes (block 1018), based on the first sensor output and the second sensor output, adjusting the vertical angle β between the extrusion axis 112 and the plane 183 so that the tool center point 122 follows the groove 104 when the chassis 110 moves relative to the groove 104, and the plane 183 is tangential to the groove 104 and perpendicular to the vertical plane containing the extrusion axis 112. The foregoing subject matter of this paragraph characterizes embodiment 35 of the present disclosure, wherein embodiment 35 also includes subject matter according to any one of embodiments 31 to 34 above.

[0132] Adjusting or maintaining vertical angle β allows radius filler 102 to stay within groove 104 even if groove 104 changes shape, size, and / or orientation. For example, if groove 104 undulates vertically, controller 180 adjusts vertical angle β so tool center point 122 follows groove 104.

[0133] Plane 183 is a virtual reference plane. As used herein, "virtual" means having the attributes of an entity without having its physical form. For example, a virtual reference plane is an invisible or imaginary plane, rather than a physical plane, relative to which, for example, the position and / or orientation of other physical and / or invisible entities can be defined.

[0134] Overall reference Figure 1 With specific reference to, for example Fig. 9 , 10A and 10B, the method 1000 further includes (block 1020) adjusting the target distance 124 between the tool center point 122 and the groove 104 based on the first sensor output and the second sensor output so that the tool center point 122 follows the groove 104 when the chassis 110 moves relative to the groove 104. The foregoing subject matter of this paragraph characterizes embodiment 36 of the present disclosure, wherein embodiment 36 also includes subject matter according to embodiment 35 above.

[0135] Adjusting or maintaining the target distance 124 allows the radius filler 102 to be located within the groove 104 even if the shape, size, and / or orientation of the groove 104 changes.

[0136] The target distance 124 is measured relative to an axis, such as a central longitudinal axis of the groove 104 .

[0137] Overall reference Figure 1 With specific reference to, for example Figure 4 , 9 , 10A and 10B, when the groove 104 observed in the plan view includes a nonlinear portion, and when the groove 104 observed in the side view includes a nonlinear portion, the method further includes, based on the first sensor output and the second sensor output: (box 1016) adjusting a horizontal angle α between a horizontal projection of the extrusion axis 112 and a vertical plane 181 tangent to the groove 104; (box 1018) adjusting a vertical angle β between the extrusion axis 112 and a plane 183 tangent to the groove 104 and perpendicular to the vertical plane 181 containing the extrusion axis 112; and (box 1020) adjusting a target distance 124 between the tool center point 122 and the groove 104 so that when the base 110 moves relative to the groove 104, the tool center point 122 follows the groove 104. The foregoing subject matter of this paragraph characterizes embodiment 37 of the present disclosure, wherein embodiment 37 also includes subject matter according to the above-mentioned embodiment 31.

[0138] Adjusting or maintaining the horizontal angle α allows the radius filler 102 to be located within the groove 104 even if the shape, size and / or orientation of the groove 104 changes. For example, if the groove 104 fluctuates horizontally, the controller 180 adjusts the horizontal angle α so that the tool center point 122 follows the groove 104.

[0139] Adjusting or maintaining vertical angle β allows radius filler 102 to stay within groove 104 even if groove 104 changes shape, size, and / or orientation. For example, if groove 104 undulates vertically, controller 180 adjusts vertical angle β so tool center point 122 follows groove 104.

[0140] Adjusting or maintaining the target distance 124 allows the radius filler 102 to be located within the groove 104 even if the shape, size, and / or orientation of the groove 104 changes.

[0141] Planes 181 and 183 are virtual reference planes. As used herein, "virtual" means having the attributes of an entity without having its physical form. For example, a virtual reference plane is an invisible or imaginary plane, rather than a physical plane, relative to which, for example, the position and / or orientation of other physical and / or invisible entities can be defined.

[0142] Overall reference Figure 1 With specific reference to, for example Figure 3-7 , 10A and 10B, the method 1000 further includes (block 1022) determining a quality of a side surface of the radius filler 102 before the radius filler 102 is positioned in the groove 104 based on a third sensor output from a third sensor 170 coupled to the chassis 110, and wherein the third sensor output represents a fourth geometric characteristic of the radius filler 102. The foregoing subject matter of this paragraph characterizes embodiment 38 of the present disclosure, wherein embodiment 38 further includes subject matter according to any of embodiments 31 to 37 above.

[0143] If the quality of the side surface is below a predetermined threshold, the controller 180 stops part or all of the process so that the quality can be analyzed and defects do not propagate along the length of the groove 104 .

[0144] The third sensor output also verifies the extrusion rate of the radius filler 102. The third sensor 170 includes one or more profilometers (e.g., profilometers on either side of the radius filler 102). In one embodiment, the profilometer is a LJ-V7000 series profilometer manufactured by Keyence Corporation of Itasca, Illinois.

[0145] Overall reference Figure 1 With specific reference to, for example Fig. 6A , 6B , 7, 10A and 10B, according to method 1000, the fourth geometric feature of radius filler 102 includes at least one of a tear, a void or a protrusion in the side surface of radius filler 102 before radius filler 102 is positioned in groove 104. The foregoing subject matter of this paragraph characterizes embodiment 39 of the present disclosure, wherein embodiment 39 also includes subject matter according to embodiment 38 above.

[0146] If the quality of the side surface is below a predetermined threshold, the controller 180 stops part or all of the process so that the quality can be analyzed and defects do not propagate along the length of the groove 104 .

[0147] To determine if an edge tear is present, the profiler attempts to identify voids or protrusions in / on the radius filler 102. The radius filler 102 can be somewhat stiff because it includes carbon fiber. In some cases, the radius filler 102 can bulge to the left or right. The third sensor helps detect and prevent this.

[0148] Overall reference Figure 1 With specific reference to, for example Figure 3 , 5 , 10A and 10B, the method 1000 further includes (block 1024) determining an extrusion speed at which the radius filler 102 is extruded from the first device 120 along the extrusion axis 112 based on a laser sensor output of the laser sensor 190 connected to the chassis 110. The foregoing subject matter of this paragraph characterizes embodiment 40 of the present disclosure, wherein embodiment 40 also includes subject matter according to embodiment 38 or 39 above.

[0149] The speed at which the radius filler 102 is extruded is compared to the speed of the chassis 110. If the speeds do not match, the speed of the chassis 110 is reduced. It is easier to control the speed of the chassis 110 than to control the speed at which the radius filler 102 is extruded, as the latter can affect the integrity of the radius filler 102. More specifically, changing the extrusion speed can affect the viscosity of the radius filler 102. As the radius filler is extruded, the laser sensor 190 is pointed at the radius filler 102. The laser sensor 190 measures the extrusion speed.

[0150] Overall reference Figure 1 With specific reference to, for example Figure 3 , 5 , 10A and 10B, the method 1000 further includes (block 1026) changing the speed of movement of the chassis 110 relative to the groove 104 based on at least one of the third sensor output or the laser sensor output. The foregoing subject matter of this paragraph characterizes embodiment 41 of the present disclosure, wherein embodiment 41 also includes subject matter according to the above-mentioned embodiment 40.

[0151] The speed at which the radius filler 102 is extruded is compared to the speed of the chassis 110. If the speeds do not match, the speed of the chassis 110 is reduced. It is easier to control the speed of the chassis 110 than to control the speed at which the radius filler 102 is extruded, as the latter can affect the integrity of the radius filler 102. More specifically, changing the extrusion speed can affect the viscosity of the radius filler 102. As the radius filler is extruded, the laser sensor 190 is pointed at the radius filler 102. The laser sensor 190 measures the extrusion speed.

[0152] Overall reference Figure 1 With specific reference to, for example Figure 5 , 8 , 10A and 10B, according to method 1000, (block 1028) a roller 200 connected to the first device 120 is configured to rotationally contact the radius filler 102 when the radius filler 102 is extruded from the first device 120 along the extrusion axis 112. In response to the rotation of the roller 200, an encoder output is generated, which represents the extrusion speed of the radius filler 102 extruded from the first device 120 along the extrusion axis 112. The foregoing subject matter of this paragraph characterizes embodiment 42 of the present disclosure, wherein embodiment 42 also includes subject matter according to any of the above embodiments 38 to 41.

[0153] Example 42 is directed to an alternative arrangement for determining the extrusion speed of the radius filler 102. Roller-encoder systems are inherently inexpensive and reliable.

[0154] When the radius filler 102 is extruded, the roller 200 contacts the radius filler 102 and rolls in response to the contact with the radius filler 102. The number of revolutions of the roller 200 is used to determine the length and / or speed of the radius filler 102.

[0155] Overall reference Figure 1 With specific reference to, for example Figure 5 , 8 , 10A and 10B, the method 1000 further includes (block 1030) changing the speed of movement of the chassis 110 relative to the groove 104 based on at least one of the third sensor output or the encoder output. The foregoing subject matter of this paragraph characterizes embodiment 43 of the present disclosure, wherein embodiment 43 also includes subject matter according to the above-mentioned embodiment 42.

[0156] The speed at which the radius filler 102 is extruded is compared to the speed of the chassis 110. If the speeds do not match, the speed of the chassis 110 is reduced. It is easier to control the speed of the chassis 110 than to control the speed at which the radius filler 102 is extruded, as the latter can affect the integrity of the radius filler 102. More specifically, changing the extrusion speed can affect the viscosity of the radius filler 102.

[0157] Overall reference Figure 1With specific reference to, for example Figure 5 , 10A and 10B, the method 1000 further includes (block 1010) clamping and holding one end of the radius filler 102. The foregoing subject matter of this paragraph characterizes embodiment 44 of the present disclosure, wherein embodiment 44 further includes subject matter according to any one of embodiments 26 to 43 above.

[0158] The radius filler 102 is clamped to facilitate the introduction of the radius filler 102 into the groove 104 at the beginning of the process. In one embodiment, the fourth device 145 includes a press or a clamp (e.g., a vise with multiple jaws) configured to hold one end of the radius filler 102 relative to the groove 104. In another embodiment, the fourth device 145 is or includes an adhesive. The fourth device 145 operates so that when the device 100 starts to move, one end of the radius filler 102 remains stationary relative to the groove 104. The fourth device 145 is controlled by the controller 180.

[0159] Overall reference Figure 1 With specific reference to, for example Figure 5 , 10A and 10B, the method 1000 further includes (block 1012) clamping and holding an end of the radius filler 102 after the radius filler 102 is extruded from the first device 120 but before the tool center point 122 advances along the groove 104. The foregoing subject matter of this paragraph characterizes embodiment 45 of the present disclosure, wherein embodiment 45 also includes subject matter according to any of embodiments 26 to 43 above.

[0160] The radius filler 102 is clamped to facilitate introduction of the radius filler 102 into the groove 104 at the beginning of the process. The fourth device 145 operates so that one end of the radius filler 102 remains stationary relative to the groove 104 when the apparatus 100 begins to move.

[0161] Overall reference Figure 1 With specific reference to, for example Figure 5 , 10A and 10B, method 1000 further includes (block 1014) continuing to clamp an end of radius filler 102 while tool center point 122 advances along groove 104. The foregoing subject matter of this paragraph characterizes embodiment 46 of the present disclosure, wherein embodiment 46 also includes subject matter according to embodiment 45 above.

[0162] The radius filler 102 is clamped to facilitate introduction of the radius filler 102 into the groove 104 at the beginning of the process. The fourth device 145 operates so that one end of the radius filler 102 remains stationary relative to the groove 104 when the apparatus 100 begins to move.

[0163] Overall reference Figure 1With specific reference to, for example Figure 5 , 10A and 10B, according to method 1000, clamping radius filler 102 before introducing radius filler 102 into groove 104. The foregoing subject matter of this paragraph characterizes embodiment 47 of the present disclosure, wherein embodiment 47 also includes subject matter according to embodiment 45 or 46 above.

[0164] The radius filler 102 is clamped to facilitate introduction of the radius filler 102 into the groove 104 at the beginning of the process. The fourth device 145 operates so that one end of the radius filler 102 remains stationary relative to the groove 104 when the apparatus 100 begins to move.

[0165] Overall reference Figure 1 With specific reference to, for example Figure 5 , 10A and 10B, according to method 1000, clamping radius filler 102 before chassis 110 is moved relative to groove 104. The foregoing subject matter of this paragraph characterizes embodiment 48 of the present disclosure, wherein embodiment 48 also includes subject matter according to any of embodiments 45 to 47 above.

[0166] The radius filler 102 is clamped to facilitate introduction of the radius filler 102 into the groove 104 at the beginning of the process. The fourth device 145 operates so that one end of the radius filler 102 remains stationary relative to the groove 104 when the apparatus 100 begins to move.

[0167] The embodiments of the present disclosure may be Fig.11 Aircraft manufacturing and service method 1100 and the like are shown Fig.12 1102. During pre-production, the illustrative method 1100 may include specification and design of the aircraft 1102 (block 1104) and material procurement (block 1106). During production, component and subassembly manufacturing (block 1108) and system integration (block 1110) of the aircraft 1102 may be performed. Thereafter, the aircraft 1102 may be certified and delivered (block 1112) to be placed in service (block 1114). While in service, the aircraft 1102 may be scheduled for routine maintenance and service (block 1116). Routine maintenance and service may include modification, reconfiguration, refurbishment, etc. of one or more systems of the aircraft 1102.

[0168] Each process of the illustrative method 1100 may be performed or carried out by a system integrator, a third party, and / or an operator (e.g., a customer). For the purposes of this description, a system integrator may include, but is not limited to, any number of aircraft manufacturers and major system subcontractors; a third party may include, but is not limited to, any number of suppliers, subcontractors, and vendors; an operator may be an airline, a leasing company, a military entity, a service organization, etc.

[0169] like Fig.12 As shown, an aircraft 1102 produced by an illustrative method 1100 may include a fuselage 1118 having a plurality of high-level systems 1120 and an interior 1122. Embodiments of the high-level systems 1120 include one or more of a propulsion system 1124, an electrical system 1126, a hydraulic system 1128, and an environmental system 1130. Any number of other systems may be included. Although an aerospace embodiment is shown, the principles disclosed herein may be applied to other industries, such as the automotive industry. Therefore, in addition to the aircraft 1102, the principles disclosed herein may be applied to other vehicles, such as land vehicles, marine vehicles, space vehicles, etc.

[0170] During any one or more stages of the manufacturing and service method 1100, the apparatus and methods shown or described herein may be employed. For example, components or subassemblies corresponding to component and subassembly manufacturing (block 1108) may be constructed or manufactured in a manner similar to components or subassemblies produced while the aircraft 1102 is in service (block 1114). In addition, one or more embodiments of the apparatus, method, or combination thereof may be utilized during the production stages 1108 and 1110, for example, by significantly speeding up the assembly of the aircraft 1102 or reducing the cost of the aircraft 1102. Similarly, for example, but not limited to, one or more embodiments of the apparatus or method implementation or combination thereof may be utilized while the aircraft 1102 is in service (block 1114) and / or during maintenance and service (block 1116).

[0171] The different embodiments of the apparatus and methods disclosed herein include various components, features and functions. It should be understood that the various embodiments of the apparatus and methods disclosed herein may include any components, features and functions of any other embodiments of the apparatus and methods disclosed herein in any combination, and all of these possibilities are intended to fall within the scope of the present disclosure.

[0172] Many modifications of the examples set forth herein will come to mind to one skilled in the art to which this disclosure pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings.

[0173] Therefore, it should be understood that the present disclosure is not limited to the specific embodiments shown, and modifications and other embodiments are intended to be included within the scope of the appended claims. In addition, although the foregoing description and associated drawings describe examples of embodiments of the present disclosure in the context of certain illustrative combinations of elements and / or functions, it should be understood that different combinations of elements and / or functions may be provided by alternative implementations without departing from the scope of the appended claims. Accordingly, parenthetical reference numerals in the appended claims are for illustrative purposes only and are not intended to limit the scope of the claimed subject matter to the specific embodiments provided in the present disclosure.

Claims

1. An apparatus (100) for depositing a radius filler (102) made of a homogeneous material into a groove (104) formed in a workpiece (106) and having a length, the apparatus (100) comprising: A base frame (110) capable of moving relative to the groove (104); a first device (120) for extruding the radius filler (102) along an extrusion axis (112); a tool center point (122) associated with the first device (120); a second device (130) for providing the homogenous material to the first device (120), wherein the second device (130) is connected to the base frame (110), and the first device (120) is connected to the second device (130); a third device (140) for compacting the radius filler (102) into the groove (104), wherein the third device (140) is connected to the chassis (110); a first sensor (150) coupled to the chassis (110) and configured to provide a first sensor output representative of a first geometric characteristic of the groove (104) along at least a portion of the length of the groove (104) prior to the radius filler (102) being deposited into the at least a portion of the length of the groove (104); as well as a controller (180) operatively coupled to the first device (120), the second device (130), and the first sensor (150), and wherein: based on the first sensor output, the controller (180) is configured to determine the first geometric characteristic of the groove (104); and based on the first geometric characteristic, the controller (180) is configured to control a second geometric characteristic of the radius filler (102) extruded by the first device (120) when the tool center point (122) moves relative to the groove (104); The apparatus further comprises a second sensor (160) coupled to the chassis (110) and configured to provide a second sensor output, the second sensor output representing a third geometric characteristic of the radius filler (102) in the groove (104) along at least a portion of the length of the groove (104) after the third device (140) compacts the radius filler (102) into the groove (104); The controller (180) is further configured to determine an amount by which the radius filler (102) overfills or underfills the groove (104) by comparing the first sensor output and the second sensor output.

2. The device (100) according to claim 1, wherein The first geometric characteristic of the groove (104) includes a cross-sectional area of ​​the groove (104).

3. The device (100) according to claim 1 or 2, wherein: The second geometric characteristic of the radius filler (102) includes a cross-sectional area of ​​the radius filler (102).

4. The device (100) according to claim 1, wherein When the groove (104) observed in a plan view includes a nonlinear portion of the plan view, the controller (180) is also configured to adjust a horizontal angle (α) between a horizontal projection of the extrusion axis (112) and a vertical plane (181) tangent to the groove (104) based on the first sensor output, so that when the base (110) moves relative to the groove (104), the tool center point (122) follows the groove (104).

5. The device (100) according to claim 1 or 2, wherein: The third geometric feature includes at least one of the following: a maximum width of the radius filler (102) after the third device (140) compacts the radius filler (102) into the groove (104); and The difference between the height of the groove (104) and the height of the radius filler (102).

6. The device (100) according to claim 1 or 2, wherein: In response to a fault condition, the controller (180) is further configured to at least one of: stopping movement of the chassis (110) relative to the groove (104) and extrusion of the radius filler (102) along the extrusion axis (112); or storing a location of the fault condition along the groove (104), wherein the fault condition corresponds to the radius filler (102) overfilling or underfilling the groove (104) by a predetermined amount and is identified by a comparison between the first sensor output and the second sensor output.

7. The device (100) according to claim 1 or 2, wherein: When the groove (104) observed in the side view includes a nonlinear portion of the side view, the controller (180) is also configured to adjust the vertical angle (β) between the extrusion axis (112) and the plane (183) based on the first sensor output and the second sensor output, so that when the base (110) moves relative to the groove (104), the tool center point (122) follows the groove (104), wherein the plane is tangential to the groove (104) and perpendicular to the vertical plane containing the extrusion axis (112).

8. The device (100) according to claim 7, wherein The controller (180) is also configured to adjust a target distance (124) between the tool center point (122) and the groove (104) based on the first sensor output and the second sensor output so that the tool center point (122) follows the groove (104) when the base (110) moves relative to the groove (104).

9. The device (100) according to claim 1 or 2, wherein: When the groove (104) observed in a plan view includes a nonlinear portion in the plan view, and when the groove (104) observed in a side view includes a nonlinear portion in the side view, the controller (180) is also configured to adjust a horizontal angle (α) between a horizontal projection of the extrusion axis (112) and a vertical plane (181) tangent to the groove (104), adjust a vertical angle (β) between the extrusion axis (112) and a plane (183) tangent to the groove (104) and perpendicular to the vertical plane containing the extrusion axis (112), and adjust a target distance (124) between the tool center point (122) and the groove (104) based on the first sensor output and the second sensor output, so that when the base (110) moves relative to the groove (104), the tool center point (122) follows the groove (104).

10. The apparatus (100) of claim 1, further comprising a third sensor (170) coupled to the chassis (110) and configured to provide a third sensor output, the third sensor output representing a fourth geometric characteristic of the radius filler (102).

11. The device (100) according to claim 10, wherein The fourth geometric feature of the radius filler (102) includes at least one of a tear, a void, and a protrusion of a predetermined size in a side surface of the radius filler (102) before the radius filler (102) is positioned in the groove (104).

12. The apparatus (100) of claim 10 or 11, further comprising a laser sensor (190) connected to the chassis (110) and configured to provide a laser sensor output, the laser sensor output representing an extrusion speed at which the radius filler (102) is extruded from the first device (120).

13. The device (100) according to claim 12, wherein The controller (180) is further configured to control a speed of movement of the chassis (110) relative to the groove (104) based on at least one of the third sensor output and the laser sensor output.

14. The device (100) according to claim 13, wherein When the extrusion speed of the radius filler (102) exceeds the movement speed of the base frame (110), the controller (180) increases the movement speed of the base frame (110) relative to the groove (104), and when the movement speed of the base frame (110) exceeds the extrusion speed of the radius filler (102), the controller reduces the movement speed of the base frame (110).

15. The device (100) according to claim 10 or 11, further comprising: a roller (200) connected to the first device (120) and configured to be rotated by the radius filler (102) extruded by the first device (120); and an encoder (202) configured to provide an encoder output in response to rotation of the roller (200), and The encoder output represents an extrusion rate at which the radius filler (102) is extruded by the first device (120).

16. The device (100) according to claim 15, wherein The controller (180) is further configured to control a speed of movement of the chassis (110) relative to the groove (104) based on at least one of the third sensor output and the encoder output.

17. The device (100) according to claim 16, wherein When the extrusion speed of the radius filler (102) exceeds the movement speed of the base frame (110), the controller (180) increases the movement speed of the base frame (110) relative to the groove (104), and when the movement speed of the base frame (110) exceeds the extrusion speed of the radius filler (102), the controller reduces the movement speed of the base frame (110).

18. The apparatus (100) of claim 1, wherein: The first device (120) comprises an opening (121) having an adjustable size and an outlet profile (123) with an adjustable perimeter; The first device (120) is configured to extrude the radius filler (102) through the opening (121); The tool center point (122) is the centroid of a dimensionally adjustable planar shape defined by the outlet contour (123) of the opening (121).

19. The apparatus (100) according to claim 1, further comprising a fourth device (145) for clamping and holding one end of the radius filler (102).

20. The device (100) according to claim 19, wherein The fourth device (145) is configured to initially clamp an end of the radius filler (102) after the radius filler (102) is extruded from the first device (120) but before the tool center point (122) advances along the groove (104).

21. The device (100) according to claim 20, wherein The fourth device (145) is configured to continue to clamp an end of the radius filler (102) as the tool center point (122) advances along the groove (104).

22. The device (100) according to any one of claims 19 to 21, wherein: Prior to introducing the radius filler (102) into the groove (104), one end of the radius filler (102) is initially clamped by the fourth device (145).

23. The device (100) according to any one of claims 19 to 21, wherein: The radius filler (102) is clamped by the fourth device (145) before the base (110) moves relative to the groove (104).

24. A method (1000) for depositing a radius filler (102) made of a homogeneous material into a groove (104) formed in a workpiece (106) and having a length, the method (1000) comprising the steps of: moving a tool center point (122) relative to the groove (104), the tool center point being associated with a first means (120) for extruding the radius filler (102) along an extrusion axis (112); providing a first sensor output using a first sensor (150) coupled to a chassis (110) supporting the first device (120), the first sensor output representing a first geometric characteristic of the groove (104) along at least a portion of the length of the groove (104) before the radius filler (102) is deposited into the at least a portion of the length of the groove (104); causing the first device (120) to extrude the radius filler (102) along the extrusion axis (112) while controlling a second geometric characteristic of the radius filler (102) based on the first geometric characteristic; and at least partially compacting the radius filler (102) extruded by the first device (120) into the groove (104); Characterized in that the method also includes the step of determining an amount by which the radius filler (102) overfills or underfills the groove (104) based on a second sensor output of a second sensor (160) connected to the base frame (110), and wherein the second sensor output represents a third geometric characteristic of the radius filler (102) in the groove (104) along at least a portion of the length of the groove (104).

25. The method (1000) of claim 24, wherein: The first geometric characteristic of the groove (104) includes a cross-sectional area of ​​the groove (104).

26. The method (1000) according to claim 24 or 25, wherein: The second geometric characteristic of the radius filler (102) includes a cross-sectional area of ​​the radius filler (102).

27. The method (1000) of claim 24, wherein: The step of causing the first device (120) to extrude the radius filler (102) comprises extruding the radius filler (102) through an opening (121) in the first device (120), The opening (121) has an adjustable size and has an outlet profile (123) with an adjustable length, and The tool center point (122) is the centroid of a dimensionally adjustable planar shape defined by the outlet contour (123) of the opening (121).

28. The method (1000) according to claim 24 or 27, wherein: When the groove (104) observed in a plan view includes a nonlinear portion, the method (1000) further includes adjusting a horizontal angle (α) between a horizontal projection of the extrusion axis (112) and a vertical plane (181) tangential to the groove (104) based on the first sensor output, so that when the base (110) moves relative to the groove (104), the tool center point (122) follows the groove (104).

29. The method (1000) of claim 24, the step of determining an amount by which the radius filler (102) overfills or underfills the groove (104) comprising comparing the first sensor output to the second sensor output.

30. The method (1000) of claim 24, wherein: The third geometric feature includes at least one of the following: a difference between a maximum width of the groove (104) and a maximum width of the radius filler (102) after compacting the radius filler (102) into the groove (104); as well as The difference between the height of the groove (104) and the height of the radius filler (102) after compacting the radius filler (102) into the groove (104).

31. The method (1000) according to claim 24 further includes stopping the movement of the base frame (110) based on the output of the second sensor to prevent the radius filler (102) from being extruded, or stopping the movement of the base frame (110) and preventing the radius filler (102) from being extruded in response to detecting a defect in at least one of the workpiece (106), the groove (104) and the radius filler (102).

32. The method (1000) of claim 24, wherein: When the groove (104) observed in the side view includes a nonlinear portion, the method (1000) also includes adjusting the vertical angle (β) between the extrusion axis (112) and the plane (183) based on the first sensor output and the second sensor output, so that when the base (110) moves relative to the groove (104), the tool center point (122) follows the groove (104), and the plane (183) is tangent to the groove (104) and perpendicular to the vertical plane containing the extrusion axis (112).

33. The method (1000) according to claim 32 further includes adjusting a target distance (124) between the tool center point (122) and the groove (104) based on the first sensor output and the second sensor output, so that when the base (110) moves relative to the groove (104), the tool center point (122) follows the groove (104).

34. The method (1000) of claim 24, wherein: When the groove (104) observed in a plan view includes a nonlinear portion, and when the groove (104) observed in a side view includes a nonlinear portion, the method (1000) further includes, based on the first sensor output and the second sensor output: Adjusting a horizontal angle (α) between a horizontal projection of the extrusion axis (112) and a vertical plane (181) tangent to the groove (104); adjusting a vertical angle (β) between the extrusion axis (112) and a plane (183) that is tangential to the groove (104) and perpendicular to a vertical plane (181) containing the extrusion axis (112); and A target distance (124) between the tool center point (122) and the groove (104) is adjusted so that the tool center point (122) follows the groove (104) when the base (110) moves relative to the groove (104).

35. The method (1000) according to claim 24 further includes determining a quality of a side surface of the radius filler (102) before the radius filler (102) is positioned in the groove (104) based on a third sensor output from a third sensor (170) connected to the base frame (110), and wherein the third sensor output represents a fourth geometric feature of the radius filler (102).

36. The method (1000) of claim 35, wherein: The fourth geometric feature of the radius filler (102) includes at least one of a tear, a void, and a protrusion in a side surface of the radius filler (102) before the radius filler (102) is positioned in the groove (104).

37. The method (1000) according to claim 35 or 36, further comprising determining an extrusion speed at which the radius filler (102) is extruded from the first device (120) along the extrusion axis (112) based on a laser sensor output of a laser sensor (190) connected to the base frame (110).

38. The method (1000) of claim 37, further comprising varying a speed of movement of the chassis (110) relative to the groove (104) based on at least one of the third sensor output and the laser sensor output.

39. The method (1000) of claim 35 or 36, wherein: a roller (200) connected to the first device (120) configured to rotationally contact the radius filler (102) as the radius filler (102) is extruded from the first device (120) along the extrusion axis (112), and In response to the rotation of the roller (200), an encoder output is generated, the encoder output representing an extrusion velocity at which the radius filler (102) is extruded from the first device (120) along the extrusion axis (112).

40. The method (1000) of claim 39, further comprising changing a speed of movement of the chassis (110) relative to the groove (104) based on at least one of the third sensor output and the encoder output.

41. The method (1000) of claim 24, further comprising clamping and holding an end of the radius filler (102).

42. The method (1000) of claim 24, further comprising clamping and holding one end of the radius filler (102) after the radius filler (102) is extruded from the first device (120) but before the tool center point (122) advances along the groove (104).

43. The method (1000) of claim 42, further comprising continuing to clamp an end of the radius filler (102) while the tool center point (122) advances along the groove (104).

44. The method (1000) according to claim 42 or 43, wherein: Prior to introducing the radius filler (102) into the groove (104), the radius filler (102) is clamped.

45. The method (1000) of claim 42 or 43, wherein: The radius filler (102) is clamped before the base (110) is moved relative to the groove (104).

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