Dynamic indexing for moving components in a manufacturing environment

Abstract

This relates to dynamic indexing for moving parts in a manufacturing environment. Specifically, systems and methods for indexing a laminating mandrel are provided. One embodiment is a method for indexing a laminating mandrel of a composite part. The method includes the steps of: identifying a first side surface of a laminating mandrel traveling in a process direction during the manufacturing of the composite part; placing a laminating head in contact with said surface; traversing the surface of the laminating mandrel using the laminating head; acquiring a 3D coordinate flow of the laminating head as it traverses the surface; characterizing the laminating mandrel based on the 3D coordinate flow; and modifying a numerical control (NC) program guiding the application of fiber reinforcement material at the laminating mandrel based on the difference between the alignment of the laminating mandrel and its nominal alignment.

Description

Technical Field

[0001] This disclosure relates to the field of manufacturing, and in particular to the manufacture of composite parts. Background Technology

[0002] To manufacture composite components, uncured fiber-reinforced composite tows are precisely laid onto a layup mandrel. The mandrel itself must be precisely positioned within the stationary work cell; otherwise, the tows will not be placed in the desired position on the mandrel. Therefore, indexing must be performed on the stationary mandrel within the cell to ensure that the tows do not exhibit out-of-tolerance conditions (including overlaps or gaps) when later placed onto the mandrel. If the mandrel is not in the desired position within the cell, it must be reoriented and re-indexed, resulting in increased time and labor.

[0003] The abstract of US 5117348 A discloses "a method and apparatus for aligning a real surface with the internal coordinate system of a machine on which it operates. A component program controls the movement of a tape-laying machine for depositing composite tape on a mandrel surface marked with multiple reference points. A probe assembly is attached to the tape-laying head of the machine and can be used to measure the coordinates of the reference points on the mandrel surface relative to the machine's internal coordinate system. These measurements and corresponding points on representative surfaces allow for the generation of a transformation function based on the rotation and translation of one surface relative to another. The geometric data of the component program's instructions are transformed from their orientation relative to the reference surfaces to a new orientation relative to the mandrel surface by this transformation function before being applied to the tape-laying machine."

[0004] Therefore, it is desirable to have a method and apparatus that takes into account at least some of the problems discussed above, as well as other possible problems. Summary of the Invention

[0005] The various examples described herein provide dynamic systems (e.g., periodic, continuous, etc.) for indexing laminating machines toward a laminating mandrel or other rigid tool that moves along the process direction during manufacturing. These dynamic systems enable indexing to be performed in an environment where the rigid tool moves regularly, unlike an environment where the rigid tool is expected to remain stationary within the cell. These dynamic systems can also provide inputs for modifying the numerical control (NC) program to accommodate deviations of the rigid tool from its intended position and / or orientation. This eliminates the need to reposition the rigid tool if it is not perfectly aligned.

[0006] One example is a method for progressing a lamination mandrel of a composite component. The method includes the following steps: identifying a first side surface of the lamination mandrel traveling along a process direction during the manufacture of the composite component; placing a laminating head in contact with said surface; traversing said surface using the laminating head; acquiring a 3D coordinate flow of the laminating head as it traverses said surface; characterizing the lamination mandrel based on the 3D coordinate flow; and modifying a numerical control (NC) program guiding the application of fiber reinforcement material at the lamination mandrel based on the difference between the alignment of the lamination mandrel and its nominal alignment.

[0007] Another example is a system for indexing a laminating mandrel of a composite component. The system includes a laminating head comprising: a roller, a suspension enabling the roller to deflect, a sensor measuring the deflection position of the roller, and a dispenser for distributing fiber reinforcement filaments. The system also includes a controller that: identifies a first side surface of the laminating mandrel traveling in a process direction during the manufacture of the composite component; guides the laminating head to position the roller of the laminating head in contact with said surface; guides the laminating head to traverse said surface using the roller; acquires a 3D coordinate flow of the roller as it traverses said surface; determines the alignment of the laminating mandrel based on the 3D coordinate flow; and modifies the numerical control (NC) program guiding the application of fiber reinforcement at the laminating mandrel based on the difference between the alignment of the laminating mandrel and the nominal alignment of the laminating mandrel.

[0008] Another example is a device for indexing the lamination mandrel of a composite component. The device includes a laminating head comprising: a roller, a suspension that enables the roller to deflect, a sensor that measures the deflection position of the roller, and a distributor for distributing fiber reinforcement filaments.

[0009] Other exemplary embodiments and examples (e.g., methods and computer-readable media related to the foregoing embodiments) may be described below. The features, functions, and advantages already discussed may be implemented independently in different embodiments or may be combined in other embodiments, and further details of these features, functions, and advantages may be understood with reference to the following description and drawings. Attached Figure Description

[0010] Now, some embodiments of this disclosure will be described by way of example only and with reference to the accompanying drawings. In all the drawings, the same reference numerals denote the same elements or elements of the same type.

[0011] Figure 1 This is a block diagram of a line assembly system for composite components in an exemplary embodiment.

[0012] Figure 2This is a flowchart illustrating a method for operating an indexing system based on the position of the laminating head rollers in an exemplary embodiment.

[0013] Figure 3 This is a perspective view of the laminating head across the surface of the laminating mandrel in an exemplary embodiment.

[0014] Figure 4 This is a top view of a rigid tool not in the nominal orientation in an exemplary embodiment.

[0015] Figure 5 This is a bottom view of a roller traversing a surface that changes relative to the intended nominal path in an exemplary embodiment.

[0016] Figure 6 This is a view of a roller traversing a curved surface in an exemplary embodiment.

[0017] Figure 7 This is a view across the roller that lays the laminate in an exemplary embodiment.

[0018] Figure 8 This is a view of a roller that traverses a closely spaced laying laminating element in an exemplary embodiment.

[0019] Figure 9 This is a flowchart illustrating a method for operating an indexing head that traverses a groove in a rigid tool, as exemplified in an exemplary embodiment.

[0020] Figure 10 This is a perspective view of a rotary head that follows a groove in a rigid tool in an exemplary embodiment to rotate the rigid tool.

[0021] Figure 11 This is a top view of the indexing head of the rigid tool in an exemplary embodiment, which follows the groove in the rigid tool to index the rigid tool.

[0022] Figures 12 to 14 This is a front view of the roller of the indexing head in the exemplary embodiment, which traverses a groove in a rigid tool.

[0023] Figure 15 This is a cut-through view of a roller-equipped rotary head supported by a suspension in an exemplary embodiment.

[0024] Figure 16 This is a flowchart illustrating a method for operating an indexing head that crosses a circumferential groove in a rigid tool, as exemplified in an exemplary embodiment.

[0025] Figure 17 This is a perspective view of an indexing head that crosses a circumferential groove in a rigid tool, as illustrated in an exemplary embodiment.

[0026] Figure 18 It is a report indicating the difference between the nominal position and the actual position of the indexing head in the exemplary embodiment.

[0027] Figure 19 This is a flowchart of an aircraft manufacturing and maintenance method in an exemplary embodiment.

[0028] Figure 20 This is a block diagram of an aircraft in an exemplary embodiment. Detailed Implementation

[0029] The accompanying drawings and the following description provide specific exemplary embodiments of this disclosure. Therefore, it should be appreciated that those skilled in the art will be able to design various arrangements that, while not expressly described or shown herein, embody the principles of this disclosure and are included within its scope. Furthermore, any examples described herein are intended to aid in understanding the principles of this disclosure and are to be construed as not being limited to such specific examples and conditions. Consequently, this disclosure is not limited to the specific embodiments or examples described below, but is limited by the claims.

[0030] Composite components (such as carbon fiber reinforced polymer (CFRP) components) are initially laid in multiple layers, collectively referred to as preforms, onto a rigid mandrel. Individual fibers within the individual layers of this preform are aligned parallel to each other, but different layers exhibit different fiber orientations to increase the strength of the resulting composite component along different dimensions. The preform includes a viscous resin that solidifies to harden the preform into a composite component (e.g., for use in aircraft). Carbon fibers already impregnated with uncured thermosetting or thermoplastic resins are called “prepregs.” Other types of carbon fibers include “dry fibers” that are not impregnated with thermosetting resins but may include tackifiers or adhesives. Dry fibers are foamed with resin prior to curing. For thermosetting resins, curing is a one-way process called curing, while for thermoplastic resins, the resin reaches a viscous form if it is reheated.

[0031] Figure 1This is a block diagram of a line assembly system 100 for composite components in an exemplary embodiment. The line assembly system 100 includes any system, device, or component operable to iteratively pulse a laminating mandrel 120 (e.g., for a half-barrel fuselage section approximately twenty to forty feet long) along track 110 or other paths in a process direction 127 (e.g., via an Autonomous Guided Vehicle). For example, the laminating mandrel 120 may be pulsed over its entire length, a portion of its length (e.g., a few inches), or may be moved continuously along the process direction 127. The line assembly system 100 is also capable of laying laminates, including layers of fiber-reinforced material, onto the laminating mandrel 120 (e.g., during pauses between pulses or during continuous movement of the laminating mandrel 120).

[0032] In this embodiment, the assembly line system 100 includes a track 110 that transports a laminating mandrel 120 (or other rigid tool 125) along a process direction 127. The laminating mandrel 120 includes a first side surface 122, a second side surface 124, and a laminating surface 129. A laminating machine 150 applies a laminator in the laminating region 130 of the laminating mandrel 120. Figure 1 (Not shown in the diagram). After the laminating mandrel 120 is further transported along the process direction 127, the laminate will be hardened into a composite component. The operation of the laminating machine 150 and / or other stations arranged in series along the process direction 127 is managed by the controller 112. In one embodiment, the controller 112 determines the progress of the laminating mandrel 120 along the track 110 (e.g., based on input from a technician, according to an automated process (such as input from a camera or physical sensors (such as linear or rotary actuators))) and uses that input to manage the operation of the laminating machine 150 according to instructions stored in a numerical control (NC) program. The controller 112 may be implemented, for example, as a custom circuit, a hardware processor that executes programmed instructions, or a combination thereof.

[0033] The laminating machine 150 moves along a frame 140 via an actuator 152 and includes a laminating head 160 that performs fiber reinforcement application. The laminating head 160 places the fiber reinforcement onto a pre-placed fiber reinforcement sheet or a lamination mandrel 120 to form a lamination. The laminating head 160 includes a roller 162 that travels along a lamination surface 129 of the lamination mandrel 120 and includes a suspension 164 that allows limited displacement of the roller 162 along all three axes. The suspension 164 supports the roller 162 while allowing limited deflection of the roller 162 across the lamination surface 129. For example, if the lamination surface 129 is higher or lower than a desired position, the suspension 164 can press the roller 162 into the lamination surface 129, resulting in a deflection from the default position. The laminator 160 also includes a position sensor 168 (e.g., a linear sensor, laser sensor, infrared sensor, etc.) that detects the displacement of the roller 162 along three-dimensional directions. The laminator 160 also includes a distributor 166 that applies unidirectional fiber-reinforced material tows (e.g., CFRP) according to instructions from an NC program 114 stored in a controller 112.

[0034] Because the laminating mandrel 120 can be tens of feet long, even small angular deviations from the intended orientation can lead to significant differences in the placement of the filament bundles by the laminating machine 150. For example, an angular deviation of less than one degree can result in a positional offset of several inches at one or more locations on the laminating mandrel 120. This presents a problem because the intended placement of the filament bundles on the laminating mandrel 120 is precisely in place and orientation (e.g., specified within a fraction of an inch). Moreover, gaps and / or overlaps between the filament bundles that exceed tolerances are not permitted. To address these issues and ensure that lamination is performed in the desired manner without requiring reorientation of the laminating mandrel 120, the assembly line system 100 includes one or more of the components discussed below to facilitate the transfer of the laminating mandrel 120 to the laminating machine 150. Furthermore, for example, if the components placed on the laminating mandrel 120 deviate from their intended positions, localized variations may occur at the laminating mandrel 120.

[0035] In one embodiment, the roller 162 of the laminating head 160 utilizes a position sensor 168 to determine the displacement over time as the roller 162 advances along the lamination surface 129 of the lamination mandrel 120. For example, the roller 162 may traverse either the first side surface 122 or the second side surface 124 according to a nominal (expected) path (i.e., a path comprising a series of 3D coordinates), and deviations from the nominal path 123 may be recorded by the position sensor 168 at various locations among multiple positions along the traversed surfaces. The controller 112 may then modify the NC program 114 to accommodate these discrepancies. It should be understood that the NC program 114 includes portions controlling the indexing operations described herein, and portions controlling the placement of composite materials (such as fiber bundles).

[0036] In another embodiment, the laminating machine 150 is positioned with a predetermined and precisely known offset O from the indexing head 170. In various embodiments, the laminating machine 150 includes the indexing head 170, or the laminating machine 150 swaps out its laminating head 160 for the indexing head 170. In such an embodiment, the indexing head 170 includes an indexing end 172 that traverses a groove, such as a first groove 126 and / or a second groove 128 (e.g., within tolerances), that has been precisely positioned on / machined into the laminating mandrel 120 (or other rigid tool 125), and a sensor 174 records positional deviations from the intended nominal path of the indexing end 172 as the indexing end 172 traverses the first groove 126 and / or the second groove 128. For example, the deviation can be recorded once every half inch of roller 162 travel, and the deviation can be recorded according to tolerance requirements. The controller 112 can use this information to update the NC program 114.

[0037] In one embodiment, indexing is performed at least according to the following description. The coating mandrel 120 (also referred to herein as a tool, rigid tool 125, and arcuate tool) is transported via a track 110 comprising a guide rail system (e.g., embedded in the ground, fixed to the ground, etc.). The guide rail is positioned at a location known to the controller 112. The coating mandrel 120 has been manufactured to precise dimensions, and this precise laying allows the coating mandrel 120 to be precisely positioned based on crossing its surface (e.g., first side 122 and / or second side 124) or grooves (e.g., first groove 126 and / or second groove 128). Thus, once the rigid tool 125 has been crossed by the roller 162 or the indexing head 170, the 3D position and orientation of the rigid tool 125 are known without requiring a complete scan at each station in the assembly line via probes or optical technology.

[0038] Therefore, the traversal operation of roller 162 or indexing head 170 is a shortcut for characterizing surface geometry and orientation without requiring a full scan via probes or optical techniques at each station in the assembly line (such as lamination station 150). This technique benefits from the rigidity of the lamination mandrel 120 (or its lack of deflection, particularly outside tolerances), as the lamination mandrel 120 traverses the lamination machine 150 from one micropulse to the next. A micropulse is a distance that advances the lamination mandrel 120 by a distance less than its length. A pulsation is a distance that advances the lamination mandrel 120 by a distance equal to or greater than its length. From one micropulse to the next, the rigidity of the system, the precision of tooling, the lamination being tooled, and the lack of change in tooling and lamination allow for characterization of the structure being micropulsed without rescanning after each pulsation. The pulsation is insufficient to disrupt the structure of the coating mandrel 120, nor to damage the preform thereon. Therefore, the characterization technique can be successfully repeated after each micropulsation.

[0039] Because precise indexing is performed, the laminating machine 150 (or another tool) at a station in the assembly line precisely knows its position relative to the rigid tool 125 (such as the laminating mandrel 120) before performing work at the laminating mandrel 120. The 3D position and orientation of the rigid tool 125 are then established or indexed into any NC programming or automation system used at the station. After this information is initially established, downstream stations or tools can assume that the laminating mandrel 120 does not change its orientation and / or shape as it moves or pulsates along the assembly line. Therefore, no setup time or scan is required after each micropulse of the rigid tool 125 along the process direction 127 (e.g., one foot, several inches, the full length of the pulsating rigid tool 125, etc.). That is, since the precise shape of the rigid tool 125 is known (i.e., within tolerances), the transverse sides 122, 124, transverse grooves 126, 128, and / or the laminating surface 129 are precisely manufactured into the laminating mandrel 120, enabling the controller 112 to determine the precise orientation and / or position of the rigid tool 125 relative to the laminating machine 150 (e.g., within tolerances). When these two are in a known relationship, the laminating operation at the laminating machine 150 can be modified to accommodate the rigid tool 125.

[0040] In one embodiment, the laminating machine 150 includes one of a plurality of stations arranged along track 110 and spaced apart in the process direction 127 by a length less than that of the rigid tool 125. Operations performed by the other stations may include: performing additional laying, inspecting green (uncured) laminates, and / or performing other tasks.

[0041] Reference Figure 2 The following are illustrative details of the operation of the assembly line system 100. For this embodiment, it is assumed that the laminating mandrel 120 has advanced along track 110 to the laminating machine 150, but the precise position and orientation of the laminating mandrel 120 (e.g., fractions of an inch and a hundredth of a degree) are unknown. Therefore, if the laminating machine 150 advances according to the “default” NC program, and the laminating mandrel 120 deviates even slightly from its nominal value, overlaps or gaps outside the expected tolerances may occur, and the resulting laminate may have to be reworked.

[0042] Figure 2 This is a flowchart illustrating a method 200 for operating a rotation system based on the position of the roller 162 of the laminating head 160 in an exemplary embodiment. (Refer to...) Figure 1 The steps of method 200 are described using a production line assembly system 100 as an example; however, those skilled in the art will recognize that method 200 can be performed in other systems. The steps in the flowcharts described herein are not exhaustive and may include other steps not shown. The steps described herein may also be performed in an alternative order.

[0043] Initially, the coating surface 129 of the coating mandrel 120 is identified by the controller 112. The coating mandrel 120 travels along the process direction 127 during the manufacture of the composite component. For example, the coating mandrel 120 may periodically “micro-pulse” a predetermined distance over time in the process direction 127 (e.g., pulsating the entire length of the coating mandrel 120 every fifteen minutes, and / or every two hours, etc.), or it may move continuously in the process direction 127 at a predetermined rate (e.g., one inch per minute). The controller 112 may identify the coating surface 129 of the coating mandrel 120 based on pre-programmed information indicating the expected starting position of the first side surface 122 or the second side surface 124 of the coating mandrel 120, or it may visually inspect the coating mandrel 120 to identify the first side surface 122 and / or the second side surface 124.

[0044] The controller 112 guides the laminating machine 150 to position itself (i.e., via roller 162) in contact with either the first side surface 122 or the second side surface 124. The laminating head 160 traverses either the first side surface 122 or the second side surface 124 using roller 162. During this process, the laminating mandrel 120 remains in place. Roller 162 advances along a nominal path that indicates the intended position of the laminating mandrel 120 along its length. As used herein, a “path” is a series of positions that can be measured and compared with a 3D coordinate flow. If the laminating mandrel 120 is not in the intended position and / or orientation, roller 162 encounters physical resistance from the surface being traversed, and this physical resistance causes roller 162 to deflect from the nominal path. These deflections indicate the surface geometry (such as shape) of the laminating surface 129, the first side surface 122, and the second side surface 124, and are recorded by position sensor 168.

[0045] In the next step, as the laminator 160 traverses the coating surface 129, the controller 112 acquires a three-dimensional (3D) coordinate flow of the laminator 160 (i.e., roller 162). This may include periodically acquiring coordinates from the position sensor 168 over time or space (e.g., every tenth of an inch, every tenth of a second, etc.) and storing the coordinate flow in memory.

[0046] Continuing, controller 112 determines, based on 3D coordinate flow characterization 210, that the alignment and / or shape of the covering mandrel 120 is within tolerance. This can be performed by loading the known shape of the covering mandrel 120 into memory and applying a mathematical transformation to the nominal alignment of that shape (which makes the shape match the 3D coordinate flow). In other embodiments, the alignment of the covering mandrel 120 is more generally determined to be aligned or misaligned based on whether the 3D coordinate flow is within tolerance of the nominal path (e.g., a fraction of an inch of the nominal path).

[0047] Ultimately, based on the difference between the alignment of the lamination mandrel 120 and its nominal alignment, the controller 112 modifies the NC program 114 guiding the application of fiber reinforcement material at the lamination mandrel 120. In one embodiment, this includes applying a mathematical transformation to the coordinates found in the instructions within the NC program 114, based on a previously determined mathematical transformation. In another embodiment, this includes identifying the position in the NC program 114 corresponding to the position in the nominal path, and modifying the position in the NC program 114 by an amount equal to the difference detected from the nominal path in the 3D coordinate stream. In yet another embodiment, the NC program 114 is modified in real-time as needed to accommodate the layup thickness of the material already placed on the lamination mandrel 120 at specific points during the lamination process.

[0048] Method 200 offers technical benefits over existing systems and techniques because it enables the rigid tool 125 to be precisely indexed into the laminating machine 150 without any additional indexing equipment. Specifically, no probes or other devices are required to perform the indexing, and the laminating machine 150 can accommodate changes in nominal orientation without needing to reorient the laminating mandrel 120. In embodiments, the laminating mandrel 120 can weigh hundreds or even thousands of pounds and would be difficult to reorient as needed.

[0049] Figure 3 This is a perspective view of a laminating head 160 traversing the first side surface 122 of the laminating mandrel 120 in an exemplary embodiment. According to... Figure 3 The laminating mandrel 120 advances along the process direction 127 and includes a first side surface 122 and a second side surface 124. The laminating head 160 performs fiber-reinforced material application along a region 130 between the first side surface 122 and the second side surface 124 and is mounted to an extendable arm 342 (e.g., a robotic arm, telescopic arm, etc., formed by a kinematic chain of a rigid body and actuators), which moves laterally relative to the frame 140 as the frame 140 moves along the track 110. The frame 140 moves rearward 372 and forward 374 relative to the process direction 127 along the track 110 and / or a support (not shown). Figure 3 The laminating head 160 is shown performing an initial indexing operation by traversing the first side surface 122 and the second side surface 124 before laying begins at the laminating mandrel 120. These operations can be performed during continuous movement of the laminating mandrel 120 (e.g., at a low speed) or during pauses between pulsations of the laminating mandrel 120 in the process direction 127. Moreover, these operations can also occur during each micro-pulse, and the pulsation and / or laying operation can occur during micro-pulses or pauses between pulsations.

[0050] Figure 4 This is a top view of the rigid tool 125 (e.g., the lamination mandrel 120) not in the nominal orientation in the exemplary embodiment, and is consistent with... Figure 3 The view arrow 4 corresponds to this. For example... Figure 4 As shown, the plating mandrel 120 exhibits an angular offset θ of less than 1 degree relative to the nominal alignment 400 (in Figure 4 (The offset of less than 1 degree is exaggerated). However, the lamination mandrel 120 has a length L (e.g., 25 feet, 40 feet, etc.). This means that positional differences (Δ) cause region 130 to deviate from the nominal lamination region 410, and these positional differences may exceed the expected tolerances. Therefore, if the fiber reinforcement is laid using the default NC procedure, the fiber reinforcement filaments may be misplaced, resulting in conditions exceeding tolerances, thus requiring rework of the laminate before or after curing.

[0051] Figure 5 This is a bottom view of a roller 162 traversing a surface 500 that changes relative to the intended nominal path in an exemplary embodiment. Figure 5 and Figure 3 The view corresponds to arrow 5. In this embodiment, surface 500 includes variations relative to the nominal path 510. As the laminating head 160 attempts to follow this nominal path using roller 162, the variations in surface 500 amplify the positional variations (Δx, Δy, and Δz) on roller 162. Sensors (e.g., sensors that measure positional offsets of components of the suspension that allow roller 162 to deflect) measure these positional offsets for later comparison with the nominal path. In embodiments where the sensor is a rotational sensor that measures the degree of travel / rotation of roller 162, a larger radius R of roller 162 can result in reduced measurement accuracy. The radius R of roller 162 can vary from less than an inch to several inches. The sensor can measure these offsets as fractions of an inch along the respective axes and can measure these offsets at any suitable rate (e.g., kilohertz, megahertz, etc.). In one embodiment, an example of surface 500 is a first side surface 122 of the laminating mandrel 120, and the laminating head 160 is also operated to traverse a second side surface 124 of the laminating mandrel 120. In such a case, the controller 112 of the laminating head 160 acquires a second 3D coordinate flow of the roller 162 as the roller 162 traverses the second side surface.

[0052] Figure 6 This is a view of the roller 162 traversing the curved surface in an exemplary embodiment. According to... Figure 6 The laminating head 160 traverses surfaces 602 and 604 of the laminating mandrel 120. By traversing the two surfaces on different sides of the laminating mandrel 120, the orientation of the laminating mandrel 120 along the X, Y, and Z axes can be determined quickly and accurately.

[0053] Figure 7 This is a view of the roller 162 that crosses the laminating layer 700 in an exemplary embodiment. According to... Figure 7 During the laying process, the active tracking roller 162 acquires a second 3D coordinate stream as it follows the surface 702 defined by the laminate 700. This information enables the determination of the thickness of the resulting laminate 700 and transmits this information (e.g., the second 3D coordinate stream, along with any previously determined offset information) to a downstream laminating machine 1070 having a downstream laminating head 1072 spaced apart from the laminating head 160 by a distance D in the process direction 127 (e.g., as follows). Figure 11(As shown). The downstream laminator 1070 updates its own NC program using measurement results from the laminator 160 and / or the downstream laminator 1072.

[0054] Figure 8 This is a view of a roller 162 that traverses a laying laminate 830 laid with a closely spaced radius in an exemplary embodiment. According to... Figure 8 The roller 162 of the laminator head 160 traverses the surfaces of the laminating mandrel 120 and / or the laminating piece 830 within desired tolerances, such as surfaces corresponding to the outer radius of the corner 833 of the laminating piece 830. This can be performed by the roller 162 passing through multiple arched portions of curve 832 and by integrating the resulting sensor data to characterize curve 832 along the length of the laminating piece 830, which wraps around the edges 810 and 820 of the laminating mandrel 120. This operation can be performed during lamination after receiving the laminating piece 830 from an upstream station (such as laminating station 150) or after lamination before the laminating mandrel 120 advances to the downstream laminating machine 1070. This information can then be used to modify the existing NC program 114. For example, if the information indicates that the concave radius (not shown) is too small, an additional layer can be applied to fill the outer radius, or the laminator 160 and NC program 114 can be adjusted to resolve the geometric difference. Similarly, if the information indicates that the convex radius R1 is too large, an additional layer can be applied to fill the outer radius to the desired R1, or the laminator 160 and NC program 114 can be adjusted to resolve the geometric difference.

[0055] Figure 9 This is a flowchart illustrating a method 900 for operating an indexing head 170 across grooves 126, 128 in a rigid tool 125, as exemplified in an exemplary embodiment. According to... Figure 9 Method 900 includes: marking 902 a recess 126 within a rigid tool 125 (e.g., a coating mandrel 120 or other component). The recess 126 extends along a process direction 127 of the rigid tool 125 during the manufacture of the composite part and may exhibit a depth of one-eighth to one-quarter inch or more.

[0056] The indexing head 170 is placed 904 into the groove 126. For example, the indexing head 170 can be pressed into the groove 126 at a desired pressure level (e.g., 25 pounds per square inch). This physically engages the indexing end 172 of the indexing head 170 with the groove 126, meaning that if the groove 126 advances from the nominal path in an unexpected direction, it also causes the indexing head 170 to deviate. The position of the indexing head 170 is measured over time by the sensor 174. Therefore, the deviation can be determined by analyzing the 3D coordinate flow from the sensor 174.

[0057] The indexing head 170 traverses the groove 906. That is, the controller 112 operates the indexing head 170 to move along the nominal path. If the groove 126 deviates from the nominal path, the indexing head 170 is deflected from its intended position.

[0058] As the indexing head 170 traverses the recess 126, a 3D coordinate flow of the indexing head 170 is acquired. Alternatively, in addition to or instead of 3D coordinates, in 908, as the indexing head 170 traverses the recess 126, the arcuate motion of the indexing head 170 and the orientation of that arcuate motion are acquired. This may include: the controller 112 sampling the input from the sensor 174 at a desired rate (e.g., multiple times per second, multiple times per inch, etc.).

[0059] In step 910, the alignment of the layer mandrel 125 is determined based on the 3D coordinate flow obtained in step 908. Step 910 can be performed in a manner similar to method 200 provided above.

[0060] In step 912, based on the difference between the alignment of rigid tool 125 and its nominal alignment, the numerical control (NC) program 114 that guides the operation at rigid tool 125 is modified. Modification step 912 can be performed in a similar manner to modification step 212 described above.

[0061] Figure 10 This is a perspective view of an indexing head 170 following one or more grooves 126 and 128 of a rigid tool 125 in an exemplary embodiment to index the rigid tool 125 having a lamination region 130. The grooves 126 follow a series of non-repeating curves 1026. In this embodiment, the indexing head 170 moves along a frame 140 perpendicular to the process direction 127, and the frame 140 moves along a track 110 parallel to the process direction 127. The rigid tool 125 advances downstream along the process direction 127 to a downstream laminator 1070 having a lamination head 1072 (i.e., a second or downstream lamination head). In this embodiment, the downstream laminator 1070 is spaced from the upstream laminator 150 along the process direction 127 by a distance D ( Figure 11 ).

[0062] like Figure 10As shown, each groove in grooves 126 and 128 can exhibit a unique series of non-repeating curves. Therefore, each position along grooves 126 and 128 is uniquely identifiable based on curvature information. By analyzing the positional changes in the 3D coordinate flow, the precise position along the rigid tool 125 (e.g., to inches, to fractions of an inch, etc.) can be determined. In the embodiment where grooves 126 and 128 are unique, the exact grooves 126 and 128 being traversed can also be determined based on the curvature of grooves 126 and 128. In other embodiments, features of grooves 126 and 128 are used to convey information. This information may include the width, depth, angle, or slope of the groove walls, or the cross-sectional shape such as a triangle, square, rectangle, or semicircle, or an ellipse. This information may also include: changing the cross-sectional shape along grooves 126 and 128; placing notches or splines along the walls of grooves 126 and 128; or applying a magnetic field of varying intensity downwards along grooves 126 and 128, etc. This information can be used to indicate specific areas along the lengths of the individual grooves 126, 128.

[0063] Figure 11 This is a top view of the indexing head 170 of the rigid tool 125 in an exemplary embodiment, following the grooves 126, 128 in the rigid tool 125 to index the rigid tool 125, and is related to... Figure 10 The view arrow 11 corresponds to this. Figure 11 Each groove in grooves 126 and 128 exhibits a unique, non-repeating series of curves. The roller 162 discussed herein can be made of a rigid material that will not scratch or damage the underlying rigid tool 125. Since the rigid tool 125 can be made of steel or other metals, the roller 162 can, for example, be made of high-density polyurethane.

[0064] Figures 12 to 14 This is a front view of the different rollers of the indexing head 170 in the exemplary embodiment, used to traverse the grooves in the rigid tool, and is related to... Figure 11 The view arrow 12 corresponds to this. Specifically, Figure 12 An example is shown of a roller 1210 having a triangular notch 1212 for rolling within a triangular groove 1200. Figure 13 An example is shown of a roller 1310 having a rectangular notch 1312 for rolling within a rectangular groove 1300, and Figure 14 An example is shown of a roller 1410 with balls 1420 for traversing a semi-circular groove 1400, the roller 1410 having a semi-circular notch 1412.

[0065] Figure 15This is a cross-sectional view of the indexing head 1500 with rollers 1510 carried by the suspension 1502 in an exemplary embodiment, and is related to... Figure 11 The view arrow 15 corresponds to this. Roller 1510 includes a notch 1512 with a triangular cross-section (corresponding to roller 1210) that continues along the curvature of roller 1510 for rolling along the triangular groove. Rollers 1310 and 1410 can replace roller 1510 if it is necessary to match groove 1300 or groove 1400 respectively. Roller 1510 rotates about rod 1520, and the linear travel of roller 1510 is measured by rotation sensor 1530. Suspension cylinders 1540 and 1550 (and additional suspension cylinders along the additional axis entering the page) absorb positional deviations caused by the groove when the groove does not follow the nominal path, and these deviations can then be measured by position sensors. In some other embodiments, profiles 126-1 and 128-1 ( Figure 11 Additional information is added to the grooves or groove surfaces to deliver additional information to different workstations. In other embodiments, multiple grooves 126 and / or 128 are added to the rigid tool 125 to deliver additional information to different workstations, such as lamination workstation 150 and downstream lamination workstation 1070. For example, the individual grooves may be used by different workstations for different indexing purposes to conform to different sets of constraints. The information being delivered by the grooves 126 and 128 includes, but is not limited to, layup pattern, ramp rate, ply orientation, and other ply or laminate details. In additional embodiments, portions of the grooves 126 and 128 are designed to deliver information only to lamination workstation 150, while other portions are designed to deliver information only to downstream lamination workstation 1070.

[0066] Figure 16 This is a flowchart illustrating a method 1600 for operating the indexing head 1710 across the circumferential groove 1704 in an exemplary embodiment. The operation of method 1600 is related to... Figure 17 The system described herein includes the following steps: identifying an arched tool 1700 1602, which travels along the process direction 127 during the manufacture of the composite part. Method 1600 is similar to that described above, except that the grooves 1702, 1704 advance circumferentially relative to the arched tool 1700. Figure 9 Method 900.

[0067] A groove 1704 is marked within the arched tool 1700, extending along a portion of the arched tool 1700. In this embodiment, a groove 1704 is marked within the arched tool 1700, extending along a portion of the arched tool 1700. This may include: using a camera to detect the position of the groove 1704 at the arched tool 1700; placing the indexing end 1712 of the indexing head 1710 above the groove 1704; or placing the indexing head 1710 at a position where the groove 1704 will mate with the indexing end 1712 as the arched tool 1700 travels along the process direction 127.

[0068] As mentioned, the indexing end 1712 is placed 1606 into the groove 1704. This may further include placing the indexing end 1722 of the second indexing head 1720 into the second groove 1702. In such an embodiment, the indexing head 1710 is downstream of the second indexing head 1720, and the laminating machine 1730 is disposed between the indexing heads 1710 and 1720.

[0069] The arched tool 1700 is rotated 1608 relative to the indexing head 1710, such that the indexing head 1710 traverses the groove 1704. In one embodiment, this includes rotating the arched tool 1700 about its central axis or via a swivel support 1750 (held by a frame 1752), the swivel support 1750 being configured to hold the arched tool 1700 and to rotate the arched tool 1700 relative to the indexing head 1710 such that the indexing end 1712 traverses the groove 1704. In another embodiment, this includes moving the indexing heads 1710 and 1720 circumferentially about the arched tool 1700. In embodiments where the arched tool 1700 moves continuously along the process direction 127, the indexing heads 1710 and 1720 are matched to the speed of the arched tool 1700 to maintain their position relative to the arched tool 1700 as the arched tool 1700 moves.

[0070] As the indexing heads 1710 and 1720 traverse the corresponding grooves 1704 and 1702, the 3D coordinate flow of the indexing heads 1710 and 1720 is acquired. This input is from the position sensors at the indexing heads 1710 and 1720. Figure 17 Not shown, but similar to Figure 1 The sensor 168 shown is used to acquire the data. In one embodiment, a single indexing head traverses multiple grooves of the arched tool 1700 (i.e., by traversing the first groove 1704 in a first time period and by traversing the second groove 1702 in a second time period). This results in multiple 3D coordinate flows for analysis.

[0071] The alignment of the arch tool 1700 is determined based on the 3D coordinate flow. This can be performed in a manner similar to the characterizing step 210 of method 200 discussed above. Based on the difference between the alignment of the arch tool 1700 and its nominal alignment (as represented by the 3D coordinates associated with the nominal path), the NC program 114 guiding the operation at the arch tool 1700 is modified 1614. This can be performed in a manner similar to the modification step 212 of method 200 discussed above.

[0072] With the NC program 114 adjusted, the laminating machine 1730 continues to operate its laminating head 1732 to lay one or more bundles 1740 of the laminate. The laminate is then hardened into a composite component, such as a half-barrel segment of an aircraft fuselage.

[0073] Method 1600 may be particularly valuable in environments where a heavy-duty arch tool 1700 (e.g., weighing several tons) is held at one end by a support 1750. In such cases, the weight of the arch tool 1700 results in a smaller deflection / angular deviation along the length of the arch tool 1700.

[0074] In other embodiments, grooves 126, 128, 1702, and 1704 comprise continuous protrusions from rigid tool 125 and arched tool 1700, which are paired with indexing heads 170, 1710, and 1720 having paired rollers (e.g., one roller on either side of the protrusion). In yet another embodiment, grooves 126, 128, 1702, and 1704 are not physical grooves, but rather drawn or colored lines tracked by sensors in the form of high-precision cameras. The sensors may also include distance sensors (such as laser or ultrasonic sensors) that track across rigid tool 125 and arched tool 1700 while measuring distances. Thus, indexing can be performed based on imaging from sensors that follow visually different patterns at the rigid tools without actually contacting those tools and, in particular, without passing through indexing head 1500.

[0075] Figure 18 This is an example report 1800 indicating the difference between the nominal and actual positions of one of the indexing heads described herein in an exemplary embodiment. The report includes a stream of 3D coordinates acquired over time. For each measured 3D coordinate, the controller compares that coordinate with the expected 3D coordinate and calculates the difference between the measured and expected 3D coordinates. The controller then modifies the instructions in the NC program to perform a task (e.g., laying) at the rigid tool being indexed by identifying the position indicated in the instructions and applying the corresponding difference in position to the instructions.

[0076] Example

[0077] Referring more specifically to the accompanying drawings, embodiments of this disclosure can be implemented as follows: Figure 19 The aircraft manufacturing and maintenance methods shown in 1900 and as follows Figure 20 The description is presented within the context of the aircraft 1902. During pre-production, method 1900 may include the specification and design 1904 of aircraft 1902 and the procurement of materials 1906. During production, the manufacturing of components and sub-assemblies of aircraft 1902 1908 and system integration 1910 may be carried out. Subsequently, aircraft 1902 may undergo certification and delivery 1912 for use 1914. When in use by the customer, routine maintenance and upkeep 1916 are performed on aircraft 1902 (this may also include modifications, reconfigurations, refurbishments, etc.). The equipment and methods specifically implemented herein may be employed during any one or more suitable stages of production and use as described in Method 1900 (e.g., Specification and Design 1904, Material Procurement 1906, Component and Sub-component Manufacturing 1908, System Integration 1910, Certification and Delivery 1912, In Use 1914, Maintenance and Care 1919) and / or any suitable component of Aircraft 1902 (e.g., Frame 1918, System 1920, Interior 1922, Propulsion System 1924, Electrical System 1926, Hydraulic System 1928, Environment 1930).

[0078] The various processes in the process described in Method 1900 may be performed or implemented 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 main system subcontractors; a third party may include, but is not limited to, any number of vendors, subcontractors, and suppliers; and an operator may be an airline, leasing company, military entity, service organization, etc.

[0079] like Figure 20 As shown, an aircraft 1902 produced according to method 1900 may include a frame 1918 having multiple systems 1920 and an interior 1922. Examples of systems 1920 include one or more of the following:

[0080] The propulsion system 1924, electrical system 1926, hydraulic system 1928, and environmental system 1930 are included. Any number of other systems may be included. Although an aerospace example is shown, the principles outlined in this disclosure can be applied to other industries such as the automotive industry.

[0081] As mentioned above, the equipment and methods specifically implemented herein can be used during any or more suitable stages of the production and maintenance phases described in method 1900. For example, components or sub-components corresponding to component and sub-component manufacturing 1908 can be made or manufactured in a manner similar to that of components or sub-components produced when aircraft 1902 is in use. Moreover, during sub-component manufacturing 1908 and system integration 1910, one or more equipment implementations, method implementations, or combinations thereof can be utilized, for example, by significantly accelerating the assembly of aircraft 1902 or reducing the cost of the aircraft. Similarly, when aircraft 1902 is in use (e.g., and without limitation, during maintenance and servicing 1916), one or more equipment implementations, method implementations, or combinations thereof can be utilized. Therefore, the elements described can be used at any stage or in any combination thereof discussed herein, such as specifications and design 1904, material procurement 1906, component and sub-component manufacturing 1908, system integration 1910, certification and delivery 1912, in use 1914, maintenance and servicing 1916, and / or any suitable component of the aircraft 1902 (e.g., frame 1918, systems 1920, interior 1922, propulsion system 1924, electrical system 1926, hydraulic system 1928 and / or environment 1930).

[0082] In one embodiment, the component comprises a portion of a frame 1918 and is manufactured during component and subassembly manufacturing 1908. The component can then be assembled into the aircraft during systems integration 1910 and utilized during use 1914 until wear renders it unusable. Then, during maintenance and upkeep 1916, the component can be discarded and replaced with a newly manufactured component. The inventive components and methods can be readily utilized throughout component and subassembly manufacturing 1908 to produce new components.

[0083] Any of the various control elements (e.g., electrical or electronic components) shown in the figures or described herein can be implemented as hardware, a processor executing software, a processor executing firmware, or a combination thereof. For example, an element can be implemented as dedicated hardware. The dedicated hardware element can be referred to as a “processor,” a “controller,” or a similar term. When provided by a processor, the functionality can be provided by a single dedicated processor, a single shared processor, or multiple individual processors, some of which may share the functionality. Furthermore, the terms “processor” or “controller” as explicitly used should not be construed as referring specifically to hardware capable of executing software, but may implicitly include, but are not limited to, digital signal processor (DSP) hardware, network processors, application-specific integrated circuits (ASICs) or other circuitry, field-programmable gate arrays (FPGAs), read-only memory (ROM) storing software, random access memory (RAM), non-volatile memory, logic, or some other physical hardware component or module.

[0084] Furthermore, control elements can be implemented as instructions executable by a processor or computer to perform the function of that element. Some examples of instructions are software, program code, and firmware. The instructions are operable when executed by a processor to instruct the processor to perform the function of the element. The instructions can be stored on a storage device that can be read by a processor. Some examples of storage devices are digital or solid-state memories, magnetic storage media such as disks and tapes, hard disk drives, or optically readable digital data storage media.

[0085] Although specific embodiments have been described herein, the scope of this disclosure is not limited to those specific embodiments. The scope of this disclosure is defined by the following:

[0086] The following terms are presented as illustrative examples to aid in understanding this application.

[0087] Terms:

[0088] 1. A method (200) for indexing a coating mandrel (120) of a composite component, the method (200) comprising the following steps:

[0089] The first side surface (122) of the coating mandrel (120) that is marked (202) during the manufacturing of the composite component and travels along the process direction (127);

[0090] The laminating head (160) is positioned (204) in contact with the first side surface (122);

[0091] The laminating head (160) is used to cross (206) the first side surface (122) of the lamination mandrel (120);

[0092] As the laminator (160) traverses the first side surface (122), a 3D coordinate flow of the laminator (160) is obtained (208);

[0093] The layering mandrel (120) is based on the 3D coordinate flow characterization (210); and

[0094] Based on the difference between the alignment of the cladding mandrel (120) and the nominal alignment of the cladding mandrel (120), the numerical control (NC) program (114) guiding the application of fiber reinforcement material at the cladding mandrel (120) is modified (212).

[0095] 2. The method (200) according to Clause 1, wherein:

[0096] The step of traversing (206) the first side surface (122) includes: maintaining the roller (162) of the laminating head (160) in contact with the first side surface (122), the roller (162) traversing (206) the first side surface (122) according to the indexing NC program (114), the indexing NC program guiding the roller (162) to follow the nominal path (123) along the lamination mandrel (120), the roller (162) deflecting when the first side surface (122) deviates from the nominal path (123);

[0097] The acquired 3D coordinate flow is compared with the nominal path (123) to determine the positional difference with the nominal path (123), and wherein,

[0098] The modification step (212) includes: integrating the differences into the NC program (114) that guides the laying.

[0099] 3. The method (200) according to clause 1 or 2, wherein the step of obtaining (208) the 3D coordinate flow of the laminator (160) includes: measuring the positional offset of the components of the suspension (164) that enable the roller (162) of the laminator (160) to deflect for later comparison with the nominal path.

[0100] 4. The method described according to any of the foregoing clauses, further comprising the following steps:

[0101] The laminate is laid onto the lamination mandrel (120) according to the NC program;

[0102] A second 3D coordinate flow of the roller (162) of the laminating head (160) is acquired during the laying process;

[0103] The lamination mandrel (120) is transported to the downstream lamination head (1072) along the process direction (127);

[0104] The controller (112) transmits the second 3D coordinate stream to the downstream laminating head (1072); and

[0105] The alignment of the lamination mandrel (120) at the downstream lamination head (1072) is determined based on the second 3D coordinate flow.

[0106] 5. The method according to Clause 4, further comprising the following steps:

[0107] The roller (162) is positioned to contact the second side surface (124) of the coating mandrel (120);

[0108] The roller (162) of the laminating head (160) traverses the second side surface (124);

[0109] As the roller (162) traverses the second side surface (124), a second 3D coordinate flow of the roller (162) is obtained.

[0110] 6. The method according to Clause 5, further comprising the following steps:

[0111] The laminating head (160) is operated according to the NC program (114) to lay fiber-reinforced material in the lamination region (130) between the first side surface (122) and the second side surface (124).

[0112] 7. The method according to any of the preceding clauses, the method further comprising the step of: modifying the NC program (114) in real time to accommodate the thickness of the fiber reinforcement material already placed on the cladding mandrel (120).

[0113] 8. A system (100) for indexing a coating mandrel (120) of a composite component, the system (100) comprising:

[0114] Laminating head (160), the laminating head comprising:

[0115] Roller (162);

[0116] A suspension (164) that allows the roller (162) to deflect;

[0117] Position sensor (168), which measures the deflection of the roller (162); and

[0118] Distributor (166), the distributor distributing fiber-reinforced material bundles; and

[0119] A controller (112) identifies a first side surface (122) of a laminating mandrel (120) traveling along a process direction (127) during the manufacture of the composite component; guides the laminating head (160) to position the roller (162) in contact with the first side surface (122); guides the laminating head (160) to traverse the first side surface (122) using the roller (162); acquires a 3D coordinate flow of the roller (162) as the roller (162) traverses the first side surface (122); determines the alignment of the laminating mandrel (120) based on the 3D coordinate flow; and modifies a numerical control (NC) program (114) guiding the application of fiber reinforcement material at the laminating mandrel (120) based on the difference between the alignment of the laminating mandrel (120) and the nominal alignment of the laminating mandrel (120).

[0120] 9. The system (100) according to Clause 8, further comprising:

[0121] Downstream laminator (1072), wherein:

[0122] The controller (112) operates the laminating head (160) to:

[0123] The laminate is laid onto the lamination mandrel (120) according to the NC program (114);

[0124] Acquire a second 3D coordinate flow of the roller (162) during laying; and

[0125] The second 3D coordinate stream is transmitted to the controller (112) to control the operation of the downstream laminating head (1072).

[0126] 10. The system (100) according to Clause 9, wherein the laminating head (160) and the downstream laminating head (1072) are spaced apart by a distance along the process direction (127).

[0127] 11. The system (100) according to any one of the clauses 8 to 10, the system further comprising a track (110) that transports the coating mandrel (120) along the process direction (127).

[0128] 12. The system (100) according to any one of the clauses 8 to 11, the system further comprising a frame (140) that positions the laminating head (160) relative to the lamination mandrel (160).

[0129] 13. The system (100) according to any one of the clauses 8 to 12, wherein the controller (112) is programmed to modify the NC program (114) in real time to accommodate the thickness of the fiber reinforcement material that has been placed on the cladding mandrel (120).

[0130] 14. A laminating machine (150) for composite components, said laminating machine preferably comprising a system according to any one of clauses 8 to 13, said laminating machine (150) comprising:

[0131] Laminating head (160), the laminating head comprising:

[0132] Roller (162);

[0133] A suspension (164) that allows the roller (162) to deflect;

[0134] Position sensor (168), which measures the deflection of the roller (162); and

[0135] Distributor (166), the distributor distributing fiber-reinforced material bundles; and

[0136] A controller (112) operable to use measured deflection to rotate the laminating head (160) relative to the lamination mandrel (120).

[0137] 15. The laminating machine (150) according to Clause 14, the laminating machine further comprising: a frame (140) that positions the laminating head (160) relative to the laminating mandrel (160).

[0138] 16. The laminating machine (150) according to Clause 14 or 15, wherein the controller (112) is configured to acquire a 3D coordinate flow of the laminating head (160) from the position sensor (168), the 3D coordinate flow representing a measurement of the position offset of the suspension (164) that enables the roller (162) to deflect, and the controller is further configured to compare the position offset with a nominal path.

[0139] 17. A laminating machine (150) according to any one of clauses 14 to 16, wherein the controller (112) is configured such that the roller (162) of the laminating head (160) crosses two surfaces (602, 604) on different sides of the laminating mandrel (120, 600), such that the controller (112) can determine the orientation of the laminating mandrel (120, 600) using the measured deflection of the laminating head (160).

[0140] 18. The laminating machine (150) according to any one of clauses 14 to 17, wherein the controller (112) is configured to cause the roller (162) of the laminating head (160) to:

[0141] During installation, the surface (702) defined by the laminate (700) is actively tracked to obtain a second 3D coordinate flow;

[0142] The thickness of the resulting laminate (700) is determined by tracking the active surface (702); and

[0143] The determined thickness, the second 3D coordinate flow, and the indexing of the laminating head (160) relative to the lamination mandrel (120) are transmitted to a downstream laminating machine (1070) having a downstream laminating head (1072).

[0144] 19. The laminating machine (150) according to any one of clauses 14 to 18, wherein the controller (112) is configured to cause the laminating head (160):

[0145] At different arched portions of the curve (832) of the outer radius at the corner of the laminate (830), traversing the surface of the laminate (830), the surface corresponding to the outer radius; and

[0146] Data from the position sensor (168) is integrated to characterize a curve (832) along the length of the laminate (830), the curve wrapping around one or both of the edges (810) and (820) of the cladding mandrel (800).

[0147] 20. To manufacture a part of the aircraft (1902) using the laminating machine (150) described in any of the clauses 14 to 19.

[0148] 21. A method (900) for indexing a rigid tool (125) of a composite component, the method (900) comprising the following steps:

[0149] A groove (126) is marked (902) on the rigid tool (125), and the groove extends along the process direction (127) of the rigid tool (125) during the manufacture of the composite part;

[0150] The indexing head (170) is placed (904) relative to the groove (126);

[0151] The indexing head (170) is traversed (906) along the groove (126);

[0152] As the indexing head (170) traverses the groove (126), the 3D coordinate flow of the indexing head (170) is obtained (908);

[0153] The alignment of the rigid tool (125) is determined (910) based on the 3D coordinate flow; and

[0154] Based on the difference between the alignment of the rigid tool (125) and the nominal alignment of the rigid tool (125), the numerical control (NC) program guiding the operation at the rigid tool (125) is modified (192).

[0155] 22. The method (900) according to Clause 21, wherein the step of placing the indexing head (170) comprises: pressing the indexing end (172) of the indexing head (170) into the groove (126).

[0156] 23. The method (900) according to Clause 22, wherein the step of traversing (906) the indexing head (170) comprises: moving the indexing head (170) along a nominal path, while the indexing end (172) remains in the groove (126).

[0157] 24. The method (900) according to Clause 23, wherein the step of obtaining (908) the 3D coordinate flow of the indexing head (170) includes: determining the deflection of the indexing head (170) from the nominal path as the indexing end (172) travels along the groove (126).

[0158] 25. The method (900) according to any one of clauses 21 to 24, wherein the step of traversing (906) the indexing head (170) comprises: traversing the groove (126) according to an indexing NC program (114) that guides the indexing head (170) to follow a nominal path along the rigid tool (125), wherein the indexing end (172) of the indexing head (170) is pressed into the groove (126) during the traversal (906).

[0159] 26. The method (900) according to Clause 25, wherein the step of determining (910) the alignment of the rigid tool (125) comprises: comparing a 3D coordinate flow from the indexing head (170) with a 3D coordinate flow of the nominal path to determine the deviation of the groove (126) from the nominal path.

[0160] 27. The method according to Clause 26, wherein the step of modifying (192) the numerical control (NC) program (114) includes: integrating the deviation into the NC program (114), the NC program applying composite material on the rigid tool (125).

[0161] 28. The method (900) according to any one of clauses 21 to 27, wherein the groove (126) comprises a unique series of non-repeating curves, the method further comprising the step of: identifying the position of the indexing head (170) at the rigid tool (125) based on the 3D coordinates of a curve in the flow that indicates one of the unique curves of the non-repeating series.

[0162] 29. The method (900) pursuant to any of clauses 21 to 28, wherein:

[0163] The step of marking (902) the groove (126) on the rigid tool (125) includes one or more of the following:

[0164] The continuous protrusions on the rigid tool (125) indicated by (902); and

[0165] Identify (902) one or more lines on the rigid tool (125); and

[0166] The step of placing (904) the indexing head (170) relative to the groove (126) includes one or more of the following:

[0167] The rollers of the indexing head (170) are paired with the continuous protrusions; and

[0168] Use one or more cameras to track the one or more lines.

[0169] 30. The method (900) pursuant to any one of clauses 21 to 29, further comprising the following steps:

[0170] The indexing head (170) is replaced with a laminating head (160); and

[0171] Laying is performed by dispensing fiber-reinforced material from the laminating head (160).

[0172] 31. The method (900) according to any one of clauses 21 to 30, wherein the rigid tool (125) includes a first groove (126) and a second groove (128), both extending along the process direction (127), and wherein:

[0173] The step of traversing (906) the indexing head (170) includes: using at least one indexing head (170) to traverse (906) both the first groove (126) and the second groove (128);

[0174] The steps of obtaining the 3D coordinate flow (908) include: obtaining the 3D coordinate flow of each groove in the first groove (126) and the second groove (128); and

[0175] The step of determining the alignment of the rigid tool (125) (910) includes: determining the alignment of the rigid tool (125) (910) based on two 3D coordinate flows.

[0176] 32. The method (900) according to any one of clauses 21 to 31, wherein the step of traversing (906) the indexing head (170) comprises: rolling the indexing end (172) of the indexing head (170) along the groove (126).

[0177] 33. The method (900) according to any one of clauses 21 to 32, wherein the step of obtaining (908) the 3D coordinate flow of the indexing head (170) comprises: determining the arcuate motion of the indexing head (170) and the orientation of the arcuate motion as the indexing head (170) traverses the groove (126).

[0178] 34. A system (100) for indexing a rigid tool (125) relative to a laminating machine (150), the system (100) comprising:

[0179] A sorting head (170), the sorting head including a sorting end (172);

[0180] A position sensor (174) measures the 3D coordinates of the indexing end (172) of the indexing head (170); and

[0181] Controller (112), the controller:

[0182] The indexing end (172) is guided to be displaced into a groove (126) formed in a rigid tool (125), the groove (126) extending along the process direction (127) of the rigid tool (125) during the manufacture of the composite part;

[0183] Guide the indexing head (170) across the groove (126);

[0184] As the indexing head (170) traverses the groove (126) using the indexing end (172) therein, the 3D coordinate flow of the indexing head (170) is acquired via the position sensor (174);

[0185] The alignment of the rigid tool (125) is determined based on the acquired 3D coordinate flow; and

[0186] Based on the difference between the determined alignment of the rigid tool (125) and the nominal alignment of the rigid tool (125), the numerical control (NC) program (114) guiding the operation at the rigid tool (125) is modified.

[0187] 35. The system (100) according to clause 34, wherein the indexing end (172) is configured to roll within the groove (126).

[0188] 36. The system (100) described in clause 34 or 35, wherein:

[0189] The indexing head (170) is configured to apply pressure to the indexing end (172) within the groove (126) as the indexing end (172) traverses the groove (126), such that the indexing head (170) deflects from the nominal path when the groove (126) deviates from the nominal path.

[0190] 37. The system (100) according to clause 36, wherein the controller (112) is configured to:

[0191] The indexing head (170) is guided to traverse the groove (126) according to the indexing NC program (114), which guides the indexing head (170) to follow the nominal path of the rigid tool (125);

[0192] Compare the acquired 3D coordinate flow from the indexing head (170) with the nominal path to determine the positional difference from the nominal path; and

[0193] The positional differences are integrated into the NC program (114), which guides the placement of the composite material at the rigid tool (125).

[0194] 38. To manufacture a part of an aircraft (1902) using the system (100) described in any of the clauses 34 to 37.

[0195] 39. An apparatus for indexing a rigid tool (125) of a composite component, the apparatus comprising:

[0196] A sorting head (170), the sorting head including a sorting end (172); and

[0197] A position sensor (174) measures the 3D coordinates of the rotating head (170).

[0198] 40. The device according to Clause 39, wherein the indexing end (172) is configured to roll within a groove (126) formed in a rigid tool (125).

[0199] 41. The device as described in clause 39 or 40, wherein:

[0200] The indexing head (170) is configured such that when the indexing head (172) traverses the groove (126), the indexing end (172) is pressed into the groove (126), such that the indexing head (170) deflects according to the deviation of the groove (126) from the nominal path.

[0201] 42. The device according to Clause 41, wherein the controller (112) identifies the position of the indexing head (170) relative to the rigid tool (125) based on the 3D coordinates of the groove (126) of the flow, which includes at least one non-repeating series of unique curves.

[0202] 43. A method (1600) for indexing an arched tool (1700) of a composite component, the method (1600) comprising the following steps:

[0203] The identifier (1604) is associated with a groove (1704) of the arched tool (1700), the groove extending along a portion of the arched tool (1700);

[0204] The indexing head (1710) is placed (1606) relative to the groove (1704);

[0205] The arched tool (1700) is rotated (1608) relative to the indexing head (1710) so that the indexing head (1710) traverses the groove (1704);

[0206] As the indexing head (1710) traverses the groove (1704), the 3D coordinate flow of the indexing head (1710) is obtained (1610);

[0207] The alignment of the arched tool (1700) is determined (1612) based on the acquired 3D coordinate flow; and

[0208] Based on the difference between the alignment of the arch tool (1700) and the nominal alignment of the arch tool (1700), the numerical control (NC) program (114) guiding the operation at the arch tool (1700) is modified (1614).

[0209] 44. The method (1600) according to clause 43, wherein the step of placing (1606) the indexing head (1712) relative to the groove (1704) comprises: pressing the indexing end (1712) of the indexing head (1710) into the groove (1704).

[0210] 45. The method (1600) according to clause 43 or 44, wherein the step of rotating (1608) the arch tool (1700) relative to the indexing head (1710) includes: deflecting the indexing head (1710) from the nominal path when the groove (1704) deviates from the nominal path.

[0211] 46. ​​The method (1600) pursuant to any of clauses 43 to 45, wherein:

[0212] The step of determining (1612) the alignment of the arched tool (1700) based on the acquired 3D coordinate flow includes: comparing the acquired 3D coordinate flow with the 3D coordinates associated with the nominal path to determine the positional difference between the arched tool (1700) and the nominal path; and

[0213] The steps of modifying (1614) the numerical control (NC) program (114) include: integrating the positional differences into the NC program, which guides the operation at the arched tool (1700).

[0214] 47. The method (1600) according to any one of the clauses 43 to 46, wherein the step of determining (1612) the alignment of the arch tool (1700) comprises: identifying the position of the indexing head (1710) relative to the arch tool (1700) based on the 3D coordinates of a curve in a unique series of non-repeating curves in the acquired flow of the indicator groove (1704).

[0215] 48. The method (1600) according to any one of clauses 43 to 47, wherein the step of placing the indexing head (1606) comprises:

[0216] The first indexing end (1712) of the first indexing head (1710) is placed relative to the first groove (1704) of the arched tool (1700), the first groove being upstream of the laminating machine (1730); and

[0217] The second indexing end (1722) of the second indexing head (1720) is placed into the second groove (1702) downstream of the laminating machine (1730).

[0218] 49. The method according to Clause 48, the method further comprising the step of: operating the laminating machine (1730) to lay the composite material according to the modified NC program (114).

[0219] 50. The method (1600) according to any one of the clauses 43 to 49, wherein the step of rotating (1608) the arched tool (1700) relative to the indexing head (1710) comprises: rolling the indexing end (1712) of the indexing head (1710) relative to the groove (1704).

[0220] 51. A part of an aircraft (1902) assembled by the method (1600) according to any one of the provisions 43 to 50.

[0221] 52. A system for indexing an arched tool (1700) used in the manufacture of composite parts, the system comprising:

[0222] A sorting head (1710) includes a sorting end (1712) and a position sensor, the position sensor measuring the 3D coordinates of the sorting head (1710) relative to the sorting end (1712);

[0223] An arched tool (1700) comprising at least one groove (1704) around an arched portion of the arched tool (1700);

[0224] A rotating support (1750) configured to hold the arched tool (1700), and further configured to rotate the arched tool (1700) relative to the indexing head (1710) such that the indexing end (1712) traverses the groove (1704); and

[0225] A controller (112) guides the indexing head (1710) to be positioned (1606) relative to the arch tool (1700), guides the rotating support (1750) to rotate (1608) the arch tool (1700), and as the indexing end (1712) traverses the groove (1704), acquires (1610) a 3D coordinate flow indicating the position of the indexing head (1710), determines (1612) the alignment of the arch tool (1700) relative to the nominal tool alignment based on the acquired 3D coordinate flow, and modifies (1614) the numerical control (NC) program (114) guiding the composite material laying operation at the arch tool (1700) based on the difference between the determined (1612) alignment of the arch tool (1700) and the nominal alignment of the arch tool (1700).

[0226] 53. The system according to Clause 52, wherein the indexing end (1712) is configured to roll within the groove (1704).

[0227] 54. The system according to clause 52 or 53, wherein the indexing head (1710) is configured to press the indexing end (1712) into the groove (1704) when the indexing end (1712) traverses the groove (1704), such that when the groove (1704) deviates from the nominal path, the indexing head (1710) deflects from the nominal path.

[0228] 55. The system according to Clause 54, wherein the controller (112) is configured to:

[0229] The indexing head (1710) is guided across the groove (1704) according to the indexing portion of the NC program (114), the indexing portion guiding the indexing head (1710) to follow the nominal path of the arched tool (1700);

[0230] The acquired 3D coordinate stream is compared with the 3D coordinates representing the nominal path to determine the positional difference between the rotation head (1710) and the nominal path; and

[0231] The location difference is integrated into the NC program (114), which guides the laying operation at the arch tool (1700).

[0232] Clause 56. The system according to any of Clauses 52 to 55, wherein, in order to identify the position of the indexing head (1710) relative to the arch tool (1700), the controller (112) is configured to identify the position of the indexing head (1710) relative to the arch tool (1700) by using 3D coordinates in the acquired flow to identify a unique series of non-repeating curves in the groove (1704).

[0233] 57. The system according to any one of clauses 52 to 56, the system further comprising a second indexing head (1720), the second indexing head including a second indexing end (1722), wherein:

[0234] The indexing end (1712) of the indexing head (1710) is positioned relative to the groove (1704) of the arched tool (1700), which is upstream of the laminating machine (1730); and

[0235] The second indexing end (1722) of the second indexing head (1720) is positioned relative to the second groove (1702) of the arched tool (1700), which is downstream of the laminating machine (1730).

[0236] 58. The system according to Clause 57, wherein the grooves (1702, 1704) are operable to transmit information to the controller (122) via the indexing ends (1712, 1722), the information including at least one of the following: a coating pattern, a slope, and a layer orientation.

[0237] 59. An apparatus for indexing a laminator head (1730) relative to an arched tool (1700) for composite components, said apparatus comprising:

[0238] A rotation head (1710), the rotation head including a rotation end (1712) and a position sensor, the position sensor providing the 3D coordinates of the rotation head (1710); and

[0239] A rotating support (1750) for the arched tool (1700); and

[0240] A controller having an NC program (114) is configured to position the indexing head (1710) relative to a groove (1704) in the arched tool (1700), and the controller is also configured to rotate the arched tool (1700) relative to the indexing head (1710) such that the indexing end (1712) crosses the groove.

[0241] 60. The device according to Clause 59, wherein the indexing end (1712) is configured to roll within the groove (1704) such that when the groove (1709) deviates from the nominal path, the indexing head (1710) deflects from the nominal path of the arch tool (1700).

[0242] 61. The apparatus according to Clause 60, further comprising: a second indexing head (1720) including a second indexing end (1722) and a position sensor, the position sensor providing 3D coordinates of the second indexing head (1722), the indexing head (1710) being located upstream of the laminating machine (1730), and the second indexing head (1720) being located downstream of the laminating machine (1730).

[0243] 62. To manufacture a part of the aircraft (1902) using the equipment described in any of the provisions of 59 to 61.

Claims

1. A method for indexing a coating mandrel (120) of a composite component, the method comprising the following steps: The first side surface (122) and the coating surface (129) of the coating mandrel (120) are identified, wherein the coating mandrel (120) travels along the process direction (127) between stations arranged in series during the manufacture of the composite component; Position the laminating head (160) to contact the first side surface (122); The laminating head (160) is used to cross the first side surface (122) of the lamination mandrel (120). As the laminator (160) traverses the first side surface (122), a 3D coordinate flow of the laminator (160) is obtained; Based on the 3D coordinate flow, the layering mandrel (120) is characterized; and Based on the difference between the alignment of the cladding mandrel (120) and the nominal alignment of the cladding mandrel (120), the numerical control program (NC program, 114) for guiding the application of fiber reinforcement material on the cladding surface (129) at the cladding mandrel (120) is modified.

2. The method according to claim 1, wherein: The step of crossing the first side surface (122) includes: keeping the roller (162) of the laminating head (160) in contact with the first side surface (122), the roller (162) crossing the first side surface (122) according to the indexing NC program, the indexing NC program guiding the roller (162) to follow the nominal path (123) along the lamination mandrel (120), and the roller (162) deflecting when the first side surface (122) deviates from the nominal path (123); The acquired 3D coordinate flow is compared with the nominal path (123) to determine the positional difference with the nominal path (123), and wherein, The modification steps include: integrating the differences into the NC program (114) that guides the laying.

3. The method according to claim 1 or 2, wherein, The step of obtaining the 3D coordinate flow of the laminator (160) includes measuring the positional offset of the components of the suspension (164) that enable the rollers (162) of the laminator (160) to deflect, for later comparison with the nominal path.

4. The method according to claim 1 or 2, further comprising the following step: According to the NC program, the laminate is laid onto the lamination mandrel (120); A second 3D coordinate flow of the roller (162) of the laminating head (160) is acquired during the laying process; The lamination mandrel (120) is transported to the downstream lamination head (1072) along the process direction (127). The controller (112) transmits the second 3D coordinate stream to the downstream laminator (1072); and Based on the second 3D coordinate flow, the alignment of the lamination mandrel (120) at the downstream lamination head (1072) is determined.

5. The method according to claim 4, further comprising the following step: The roller (162) is positioned to contact the second side surface (124) of the coating mandrel (120); The roller (162) of the laminating head (160) traverses the second side surface (124); and As the roller (162) traverses the second side surface (124), a second 3D coordinate flow of the roller (162) is obtained.

6. The method according to claim 5, further comprising the following step: The laminating head (160) is operated according to the NC program (114) to lay fiber-reinforced material in the lamination region (130) between the first side surface (122) and the second side surface (124).

7. The method according to claim 1 or 2, further comprising the following step: The NC program (114) is modified in real time to adapt to the thickness of the fiber reinforcement material that has been placed on the cladding mandrel (120).

8. A system (100) for indexing a coating mandrel (120) of a composite component, the system (100) comprising: Laminating head (160), the laminating head comprising: Roller (162); A suspension (164) that allows the roller (162) to deflect; Position sensor (168), which measures the deflection of the roller (162); and Distributor (166), the distributor (166) distributing fiber-reinforced material tows; and The controller (112) performs the following operations: identifies a first side surface (122) and a laminating surface (129) of a laminating mandrel (120), wherein the laminating mandrel (120) travels along a process direction (127) between tandemly arranged stations during the manufacture of the composite component; guides the laminating head (160) to position the roller (162) in contact with the first side surface (122); and guides the laminating head (160) to traverse the laminating surface using the roller (162). The first side surface (122) is described; as the roller (162) traverses the first side surface (122), a 3D coordinate flow of the roller (162) is obtained; the alignment of the coating mandrel (120) is determined based on the 3D coordinate flow; and the numerical control program (NC program) (114) for guiding the application of fiber reinforcement material on the coating surface (129) at the coating mandrel (120) is modified based on the difference between the alignment of the coating mandrel (120) and the nominal alignment of the coating mandrel (120).

9. The system (100) according to claim 8, wherein the system (100) further comprises: Downstream laminator (1072), wherein: The controller (112) operates the laminating head (160) to: The laminate is laid onto the lamination mandrel (120) according to the NC program (114); Acquire a second 3D coordinate flow of the roller (162) during laying; and The second 3D coordinate stream is transmitted to the controller (112) to control the operation of the downstream laminating head (1072).

10. The system (100) according to claim 9, wherein, The laminating head (160) and the downstream laminating head (1072) are separated by a distance along the process direction (127).

11. The system (100) according to claim 8 or 9, the system (100) further includes a track (110) that transports the coating mandrel (120) along the process direction (127).

12. The system (100) according to claim 8 or 9, the system (100) further includes a frame (140) that positions the laminating head (160) relative to the lamination mandrel (120).

13. The system (100) according to claim 8 or 9, wherein, The controller (112) is programmed to modify the NC program (114) in real time to accommodate the thickness of the fiber reinforcement material that has been placed on the cladding mandrel (120).

14. A laminating machine (150) for composite components, said laminating machine (150) comprising the system according to any one of claims 8 to 13, wherein, The controller (112) is configured to allow the roller (162) of the laminating head (160) to traverse two surfaces on different sides of the laminating mandrel (120), such that the controller (112) can use the measured deflection of the laminating head (160) to determine the orientation of the laminating mandrel (120).

15. A laminating machine (150) for composite components, said laminating machine (150) comprising the system according to any one of claims 8 to 13, wherein, The controller (112) is configured to cause the roller (162) of the laminating head (160) to perform the following operations: During installation, the surface (702) defined by the laminate (700) is actively tracked to obtain a second 3D coordinate flow; The thickness of the resulting laminate (700) is determined from the actively tracked surface (702); as well as The determined thickness, the second 3D coordinate flow, and the rotation of the laminating head (160) relative to the lamination mandrel (120) are transmitted to a downstream laminating machine (1070) having a downstream laminating head (1072).

16. A laminating machine (150) for composite components, said laminating machine (150) comprising the system according to any one of claims 8 to 13, wherein, The controller (112) is configured to cause the laminating head (160) to perform the following operations: At different arched portions of the curve (832) of the outer radius at the corner of the laminate, the surface of the laminate is traversed, the surface corresponding to the outer radius; as well as Data from the position sensor (168) is integrated to characterize a curve (832) along the length of the laminate, the curve wrapping around one or both of the first edge (810) and the second edge (820) of the cladding mandrel (120).

17. To manufacture a part of an aircraft (1902) using a laminating machine (150) according to any one of claims 14 to 16.

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