Dynamic mapping for moving parts within a manufacturing environment

Abstract

To provide dynamic systems and methods for indexing a lamination machine to a layup mandrel or other rigid tool that proceeds in a process direction during fabrication.SOLUTION: One embodiment is a method for indexing a layup mandrel for a composite part. The method includes identifying a surface of a layup mandrel that travels in a process direction during fabrication of a composite part, placing a lamination head in contact with the surface, traversing the surface of the layup mandrel with the lamination head, acquiring a stream of 3D coordinates of the lamination head as the lamination head traverses the surface, characterizing the layup mandrel based on the stream of 3D coordinates, and altering a Numerical Control (NC) program that directs layup of fiber reinforced material at the layup mandrel, based on a difference between the alignment of the layup mandrel and a nominal alignment of the layup mandrel.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] FIELD OF THE DISCLOSURE The present disclosure relates to the field of manufacturing, and in particular to the manufacturing of composite parts. [Background technology]

[0002] To manufacture composite parts, tows of unconsolidated fiber-reinforced composite material are precisely laid up on a layup mandrel. The mandrel itself must be precisely positioned within a stationary work cell; otherwise, the tows will not be positioned in the desired location 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 laps and gaps, when they are subsequently placed on the mandrel. If the mandrel is not in the desired location within the cell, the mandrel must be reoriented and reindexed, which is time-consuming and labor-intensive.

[0003] The abstract of US 5,117,348 A states: "A method and apparatus are disclosed for aligning a real surface with the internal coordinate system of a machine operating thereon. A part program controls the motion of a tape laying machine to deposit a composite tape onto the surface of a mandrel marked with a plurality of 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 a representative surface allow a transformation function to be generated based on the rotation and translation of one surface relative to the other. The transformation function transforms the geometrical data of the part program instructions from their orientation relative to the reference surface to a new orientation relative to the mandrel surface before they are applied to the tape laying machine."

[0004] It would therefore be 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] Various embodiments described herein provide dynamic systems for mapping a layup machine to a layup mandrel or other rigid tool that advances (e.g., periodically, continuously, etc.) in a process direction during production. These dynamic systems allow the mapping to be performed in an environment where the rigid tool is periodically moved, as opposed to an environment where the rigid tool is expected to be held stationary within a cell. These dynamic systems can also provide input for a numerical control (NC) program to account for deviations from the expected position and / or orientation of the rigid tool. This eliminates the need to reposition the rigid tool if it is not perfectly aligned.

[0006] One example is a method for mapping a layup mandrel for a composite part, the method including identifying a surface of a layup mandrel that moves in a process direction during manufacturing of the composite part, positioning a layup head in contact with the surface, traversing the surface of the layup mandrel with the layup head, obtaining a stream of 3D coordinates of the layup head as the layup head traverses the surface, characterizing the layup mandrel based on the stream of 3D coordinates, and modifying a numerical control (NC) program that directs the layup of fiber reinforced material on the layup mandrel based on a difference between the position of the layup mandrel and a nominal position of the layup mandrel.

[0007] A further embodiment is a system for mapping a layup mandrel for a composite part. The system includes a layup head. The layup head includes a roller, a suspension that allows deflection of the roller, a position sensor that measures deflection of the roller, and a dispenser that dispenses tows of fiber reinforced material. The system further includes a controller. The controller is responsible for identifying a surface of a layup mandrel that moves in a process direction during manufacturing of the composite part, guiding the layup head to position a roller of the layup head in contact with the surface, guiding the layup head to traverse the surface with the roller, obtaining a stream of 3D coordinates of the roller as the roller traverses the surface, determining a position of the layup mandrel based on the stream of 3D coordinates, and modifying a numerical control (NC) program that guides the layup of the fiber reinforced material on the layup mandrel based on a difference between the position of the layup mandrel and a nominal position of the layup mandrel.

[0008] A further embodiment is an apparatus for associating lay-up mandrels for a composite part, the apparatus including a laying head having a roller, a suspension for permitting deflection of the roller, a position sensor for measuring deflection of the roller, and a dispenser for dispensing tows of fiber reinforcement material.

[0009] Other exemplary embodiments and examples (e.g., methods and computer-readable media related to the above-described embodiments) may also be described below. While the above-described features, functions, and advantages may be realized alone in various embodiments or combined in yet other embodiments, these embodiments may be more fully understood by reference to the following description and accompanying drawings.

[0010] Some embodiments of the present disclosure will now be described, by way of example only, with reference to the accompanying drawings, in which the same reference numerals represent the same elements or types of elements in all the drawings. [Brief explanation of the drawings]

[0011] [Figure 1] FIG. 1 is a block diagram of a line assembly system for composite components in an exemplary embodiment. [Figure 2] 10 is a flowchart illustrating a method for operating a registration system based on the position of a roller for a lamination head in an exemplary embodiment. [Figure 3] FIG. 1 is a perspective view of a laying head traversing the surface of a lay-up mandrel in an exemplary embodiment; [Figure 4] FIG. 10 is a top view of a rigid tool that is not within its nominal orientation in an exemplary embodiment. [Figure 5] FIG. 10 is a perspective view of a roller traversing a varying surface relative to its expected rated path in an exemplary embodiment. [Figure 6] FIG. 10 is an illustration of a roller traversing a curved surface in an exemplary embodiment. [Figure 7] FIG. 10 is an illustration of a roller moving across a laid-up laminate in an exemplary embodiment. [Figure 8] FIG. 10 is an illustration of a roller traversing a laid-up laminate laid up around a tight radius in an exemplary embodiment. [Figure 9] 10 is a flowchart illustrating a method for operating a registration head to traverse along a groove in a rigid tool in an exemplary embodiment. [Figure 10] FIG. 10 is a perspective view of an alignment head following a groove in a rigid tool to align the rigid tool in an exemplary embodiment; [Figure 11] FIG. 10 is a top view of an alignment head following a groove in a rigid tool to align the rigid tool in an exemplary embodiment; [Figure 12] 12-14 are front views of rollers for a registration head traversing along grooves in a rigid tool in an exemplary embodiment. [Figure 13]12-14 are front views of rollers for a registration head traversing along grooves in a rigid tool in an exemplary embodiment. [Figure 14] 12-14 are front views of rollers for a registration head traversing along grooves in a rigid tool in an exemplary embodiment. [Figure 15] FIG. 1 is a cut-through view of a mapping head having rollers supported by a suspension in an exemplary embodiment. [Figure 16] 10 is a flowchart illustrating a method for operating a mapping head traversing along a circumferential groove in a rigid tool in an exemplary embodiment. [Figure 17] FIG. 10 is a perspective view of an addressing head traversing along a circumferential groove in a rigid tool in an exemplary embodiment; [Figure 18] 10 is a report illustrating the difference between the nominal position and the actual position of the mapping head in an exemplary embodiment. [Figure 19] FIG. 1 is a flowchart of an aircraft manufacturing and service method in an illustrative embodiment. [Figure 20] FIG. 1 is a block diagram of an aircraft in an illustrative embodiment; DETAILED DESCRIPTION OF THE INVENTION

[0012] The figures and the following description provide specific and exemplary embodiments of the present disclosure. Thus, it will be recognized that those skilled in the art can devise various configurations (even if not explicitly described or shown herein) that embody the principles of the present disclosure and are within the scope of the present disclosure. Furthermore, any examples described herein are intended to aid in the understanding of the principles of the present disclosure and should not be construed as being limited to the specifically described examples and conditions. Consequently, it is the claims, rather than the specific embodiments or examples below, that limit the present disclosure.

[0013] Composite parts, such as carbon fiber reinforced polymer (CFRP) parts, are initially laid up on a rigid layup mandrel as multiple layers collectively referred to as a preform. Individual fibers within each layer of the preform are aligned parallel to one another but may exhibit various fiber orientations to enhance the strength of the resulting composite part along various dimensions. The preform contains a viscous resin that solidifies to solidify the preform into a composite part (e.g., for use in aircraft). Carbon fiber impregnated with an uncured thermosetting or thermoplastic resin is referred to as a "prepreg." Other types of carbon fiber include "dry fiber" that is not impregnated with a thermosetting resin but may contain a tackifier or binder. Dry fiber may be infused with resin prior to curing. For thermosetting resins, solidification is a unidirectional process referred to as curing, while for thermoplastic resins, the resin can become viscous upon reheating.

[0014] 1 is a block diagram of a line assembly system 100 for composite parts in one exemplary embodiment. The line assembly system 100 comprises any system, device, or component operable to repeatedly pulse a layup mandrel 120 (e.g., for a semi-cylindrical fuselage section approximately 20 to 40 feet long) along a track 110 or other path in a process direction 127 (e.g., via an automated guided vehicle (AGV)). For example, the layup mandrel 120 may be pulsed in the process direction 127 its entire length, a fraction of its length (e.g., a few inches), or moved continuously. The line assembly system 100 may further lay up a laminate including layers of fiber reinforced material onto the layup mandrel 120 (e.g., at a standstill between pulses or during the continuous movement of the layup mandrel 120).

[0015] In this embodiment, line assembly system 100 includes a track 110. Track 110 transports a layup mandrel 120 (or other rigid tool 125) in a process direction 127. Layup mandrel 120 includes a first side 122, a second side 124, and a layup surface 129. A layup machine 150 adds a layup (not shown in FIG. 1 ) within a layup region 130 of layup mandrel 120. The layup will be consolidated into a composite part after layup mandrel 120 is further transported in process direction 127. Operation of layup machine 150 and / or other stations arranged in series along process direction 127 is governed by a controller 112. In one embodiment, the controller 112 determines the progression of the layup mandrel 120 along the trajectory 110 (e.g., based on input from a technician, according to an automated process such as input from a camera, or according to physical sensors such as linear or rotary actuators) and uses this input to manage the operation of the layup machine 150 according to instructions stored in a numerical control (NC) program. The controller 112 may be implemented, for example, as custom circuitry, as a hardware processor that executes programmed instructions, or some combination thereof.

[0016] The layup machine 150 moves along the frame 140 via actuators 152. The layup machine 150 includes a layup head 160 that performs the layup of fiber-reinforced material. The layup head 160 places the fiber-reinforced material on the layup mandrel 120 or on previously placed plies of fiber-reinforced material to create a layup. The layup head 160 includes a roller 162 that moves along the layup surface 129 of the layup mandrel 120 and further 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 with the layup surface 129. For example, the suspension 164 may press the roller 162 against the layup surface 129, resulting in deflection from a default position if the layup surface 129 is above or below an expected position. The laying head 160 further includes a position sensor 168 (e.g., a linear sensor, a laser sensor, an infrared sensor, etc.) that detects the displacement of the roller 162 along three dimensions. The laying head 160 further includes a dispenser 166 that applies tows of unidirectional fiber reinforced material (e.g., CFRP) according to instructions from the NC program 114 stored in the controller 112.

[0017] Because the layup mandrel 120 can be tens of feet long, even small angular deviations from the expected orientation of the layup mandrel 120 can result in substantial differences in the locations at which tows are placed by the layup machine 150. For example, angular deviations of less than one degree can result in a positional offset of several inches at one or more locations on the layup mandrel 120. This presents a problem because the tows are expected to be placed at precise locations and orientations on the layup mandrel 120 (e.g., locations defined within fractions of an inch). Furthermore, gaps and / or overlaps between multiple tows that exceed acceptable tolerances are unacceptable. To address these concerns and ensure that the layup is performed in the desired manner without having to reorient the layup mandrel 120, the line assembly system 100 includes one or more of the following components, described below, to facilitate mapping of the layup mandrel 120 to the layup machine 150. Additionally, local variations may exist in the layup mandrel 120, for example, if components placed on the layup mandrel 120 deviate from their expected positions.

[0018] In one embodiment, as the rollers 162 of the laying head 160 advance along the layup surface 129 of the layup mandrel 120, the rollers 162 utilize position sensors 168 to determine their displacement over time. For example, the rollers 162 may traverse the first side 122 or the second side 124 by following a nominal (expected) path (i.e., a path having a series of 3D coordinates), and deviations from the nominal path 123 may be recorded by the position sensors 168 at each of multiple positions along the traversed surface(s). The controller 112 may then modify the NC program 114 to take these differences into account. It should be understood that the NC program 114 includes a portion that controls the mapping operations described herein as well as a portion that controls the placement of composite material, such as fiber tows.

[0019] In a further embodiment, the layup machine 150 is positioned at a predetermined and precisely known offset O from the registration head 170. In various embodiments, the layup machine 150 includes the registration head 170, or the layup machine 150 replaces its layup head 160 with the registration head 170. In one such embodiment, the registration head 170 includes a registration end 172 that traverses along grooves, e.g., first groove 126 and / or second groove 128, that are precisely positioned on / machined (e.g., within tolerances) the layup mandrel 120 (or other rigid tool 125), and a sensor 174 records the positional deviation of the registration end 172 from an expected rated path as the registration end 172 traverses along the first groove 126 and / or second groove 128. For example, the deviation may be recorded once for every half-inch of movement of the roller 162 and may be recorded against the tolerance requirements. This information may be used by the controller 112 to update the NC program 114 .

[0020] In one embodiment, the registration is performed according to at least the following description: A layup mandrel 120 (also referred to as a tool, a rigid tool 125, and an arcuate tool) is supported on a track 110 (e.g., embedded in the floor, attached to the floor, etc.) comprising a rail system. The track is positioned at a location known to the controller 112. The layup mandrel 120 is manufactured to precise dimensions. This precise layup allows the layup mandrel 120 to be precisely located based on a traverse along its surface(s) (e.g., first side 122 and / or second side 124) or groove(s) (e.g., first groove 126 and / or second groove 128). Thus, as the rigid tool 125 is traversed by rollers 162 or registration head 170, the 3D position and orientation of the rigid tool 125 is known without the need for a full scan via probes or optical techniques at each station in the assembly line.

[0021] Thus, traversal by roller 162 or mapping head 170 acts as a shortcut for characterizing the geometry and orientation of a surface without the need for a full scan via probe or optical techniques at each station, such as lamination station 150, in an assembly line. This technique benefits from the stiffness (or lack thereof, particularly outside of tolerance limits) of the layup mandrel 120 as it passes through the lamination machine 150 from one micropulse move to the next. A micropulse move is the advancement of the layup mandrel 120 a distance less than the length of the layup mandrel 120. A pulse move is the advancement of the layup mandrel 120 a distance equal to or greater than the length of the layup mandrel 120. The precision of the tool placement, the precision of the layup on the tool, and the lack of change to the tool placement and layup due to the stiffness of the system from one micropulse move to the next allows for characterization of the structure being micropulsed without rescanning after each pulse move. The pulse movements do not significantly disturb the configuration of the layup mandrel 120 and do not disturb the preforms on the layup mandrel 120. Therefore, the characterization technique can be successfully repeated after each micropulse movement.

[0022] Because accurate mapping is performed, the layup machine 150 (or other tool) at a station in the assembly line knows exactly its position relative to the rigid tool 125, such as the layup mandrel 120, before any work is performed on the layup mandrel 120. The 3D position and orientation of the rigid tool 125 is then defined or mapped into any NC programming system or other automated system used at the station. After initially defining this information, downstream stations or tools may assume that the layup mandrel 120 is not changing its orientation and / or geometry as it advances or pulses along the assembly line. Therefore, no settling time or scanning is required after each micropulse movement of the rigid tool 125 a distance in the process direction 127 (e.g., a micropulse movement of one foot, a pulse movement the entire length of the rigid tool 125, etc.). That is, because the exact shape of rigid tool 125 is already known (i.e., to within tolerances), traversing sides 122, 124, traversing grooves 126, 128 and / or traversing along layup surface 129 is precisely machined into layup mandrel 120, allowing controller 112 to determine the exact orientation and / or position (to within tolerances) of rigid tool 125 relative to layup machine 150. When the two are in a known relationship, the layup operation on layup machine 150 can be modified to accommodate rigid tool 125.

[0023] In one embodiment, the layup machine 150 comprises one of a plurality of stations arranged along the track 110 and separated in the process direction 127 by less than the length of the rigid tool 125. Operations performed by the other stations may include performing further layups, inspecting the green (uncured) layup, and / or performing other operations.

[0024] Exemplary details of the operation of assembly system 100 will be described in relation to FIG. 2. In this embodiment, it is assumed that layup mandrel 120 is advanced along track 110 to layup machine 150, but the exact position and orientation of layup mandrel 120 (e.g., to fractions of an inch and to hundredths of a degree) is not known. Thus, if layup machine 150 advances according to a "default" NC program and layup mandrel 120 has a slight deviation from nominal, overlaps or gaps beyond the desired tolerances may occur. The resulting layup may need to be reworked.

[0025] 2 is a flowchart illustrating a method 200 for operating an indexing system based on the position of rollers 162 for a layup head 160 in one exemplary embodiment. The steps of method 200 are described with reference to line assembly system 100 of FIG. 1, but one skilled in the art will understand that method 200 may be performed in other systems. The flowchart steps described herein are not exhaustive and may include other steps not shown. The steps described herein may be performed in an alternative order.

[0026] Initially, the layup surface 129 of the layup mandrel 120 is identified (202) by the controller 112. The layup mandrel 120 moves in a process direction 127 during the production of the composite part. For example, the layup mandrel 120 may be periodically "micropulsed" a predetermined distance in the process direction 127 over time (e.g., pulsed one foot every 15 minutes and / or the entire length of the layup mandrel 120 every two hours), or may be continuously moved in the process direction 127 at a predetermined rate (e.g., one inch per minute). The controller 112 may identify the layup surface 129 of the layup mandrel 120 based on pre-programmed information indicating the expected starting position of the first side 122 or the second side 124 of the layup mandrel 120, or may visually inspect the layup mandrel 120 to identify the first side 122 and / or the second side 124.

[0027] The controller 112 guides the layup machine 150 to position itself (204) (i.e., via rollers 162) into contact with the first side 122 or the second side 124. The layup head 160 traverses (206) the first side 122 or the second side 124 using rollers 162. During this process, the layup mandrel 120 remains in the same position. The rollers 162 advance along a rated path, which indicates the expected position of the layup mandrel 120 along its length. As used herein, a "path" is a series of multiple positions that may be measured and compared to a stream of 3D coordinates. If the layup mandrel 120 is not in the expected position and / or orientation, the rollers 162 encounter physical resistance from the surface being traversed, and this physical resistance causes the rollers 162 to deflect from the rated path. These deflections, which are indicative of surface geometries such as the undulations of the layup surface 129 , the first side 122 , and the second side 124 , are recorded by the position sensor 168 .

[0028] In the next step, the controller 112 acquires (208) a stream of three-dimensional (3D) coordinates of the lay head 160 (i.e., the rollers 162) as the lay head 160 traverses the layup surface 129. This may involve acquiring coordinates from the position sensor 168 periodically through space and time (e.g., every tenth of an inch, every tenth of a second, etc.) and storing the stream of coordinates in memory.

[0029] Continuing, the controller 112 characterizes (210) (e.g., determines the position and / or shape of the layup mandrel 120 to within a tolerance) based on the stream of 3D coordinates. This may be performed by loading the known shape of the layup mandrel 120 into memory and applying a mathematical transformation to the nominal position of that shape that causes the shape to fit the stream of 3D coordinates. In further embodiments, the position of the layup mandrel 120 is determined more generally based on whether the stream of 3D coordinates is within a tolerance of the nominal path (e.g., a fraction of an inch of the nominal path), whether aligned or not.

[0030] Finally, the controller 112 modifies (212) the NC program 114 that directs the layup of fiber-reinforced material on the layup mandrel 120 based on the difference between the position of the layup mandrel 120 and the nominal position of the layup mandrel 120. In one embodiment, this involves applying a mathematical transformation to coordinates found in the instructions in the NC program 114 based on an earlier determined mathematical transformation. In a further embodiment, this involves identifying a location in the NC program 114 that corresponds to a location in the nominal path and modifying the location in the NC program 114 by an amount equal to the detected difference from the nominal path in the stream of 3D coordinates. In yet another embodiment, the NC program 114 is modified in real time as needed to accommodate the laid thickness of laid material already placed on the layup mandrel 120 at a particular point during the layup process.

[0031] Method 200 provides technical advantages over prior systems and techniques because method 200 allows rigid tool 125 to be accurately registered to layup machine 150 without the need for any kind of additional registration equipment. In particular, probes and other devices are not required to perform the registration, and layup machine 150 can be configured to vary from a nominal orientation without the need to reorient layup mandrel 120. In one embodiment, layup mandrel 120 can weigh hundreds or even thousands of pounds and can be difficult to reorient if necessary.

[0032] 3 is a perspective view of a laying head 160 traversing a first side 122 of a layup mandrel 120 in an exemplary embodiment. According to FIG. 3 , the layup mandrel 120 advances in a process direction 127 and includes a first side 122 and a second side 124. The laying head 160 may perform a layup of fiber-reinforced material along a region 130 between the first side 122 and the second side 124 and is attached to an extendable arm 342 (e.g., a robotic arm, a telescoping arm, etc.) that 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). 3 is shown performing an initial alignment operation by traversing the first side 122 and the second side 124 before initiating layup on the layup mandrel 120. These operations may be performed during continuous movement (e.g., at a slow speed) of the layup mandrel 120, or may be performed during pauses between pulse movements of the layup mandrel 120 in the process direction 127. Furthermore, these operations may also be performed during each micropulse movement, pulse movement, and / or the layup operation may be performed during pauses between micropulse movements or pulse movements.

[0033] FIG. 4 is a top view of a rigid tool 125 (e.g., layup mandrel 120) that is not within its nominal orientation in an exemplary embodiment, corresponding to visual arrow 4 in FIG. 3 . As shown in FIG. 4 , the layup mandrel 120 exhibits an angular offset θ from its nominal position 400 of less than 1 degree (offsets of less than 1 degree are exaggerated in FIG. 4 ). However, the layup mandrel 120 has a length L (e.g., 25 feet, 40 feet, etc.). This means that position differences (Δ) will occur that result in deviations of area 130 from the nominal layup area 410, and these differences in position may exceed the desired tolerance. Therefore, when a default NC program is utilized to lay up the fiber-reinforced material, the tows of the fiber-reinforced material will not be positioned as desired, resulting in an out-of-tolerance condition and requiring rework of the layup before or after curing.

[0034] FIG. 5 is a perspective view of roller 162 traversing a surface 500 that varies relative to the expected rated path in one exemplary embodiment. FIG. 5 corresponds to visual arrow 5 in FIG. 3 . In this embodiment, surface 500 includes variations from rated path 510. As lamination head 160 attempts to follow the rated path with roller 162, variations in surface 500 impose positional variations (Δx, Δy, and Δz) on roller 162. A sensor (e.g., a sensor measuring the positional offset of a suspension component that allows roller 162 to flex) measures these positional offsets for later comparison to the rated path. In embodiments where the sensor is a rotational sensor that measures the degree of movement / rotation of roller 162, a larger radius R of roller 162 may result in reduced accuracy of the measurements. The radius R of roller 162 may range from less than 1 inch to several inches. The sensors may measure these offsets to fractions of an inch along each axis and may do so at any suitable speed (e.g., kilohertz, megahertz, etc.). In one embodiment, an example of surface 500 is first side 122 of layup mandrel 120, and laying head 160 is further operated to traverse second side 124 of layup mandrel 120. In such a case, roller 162 moves to the second Side 124 , the controller 112 of the laying head 160 acquires a second stream of 3D coordinates of the roller 162.

[0035] 6 is a diagram of roller 162 traversing a curved surface in an example embodiment. According to FIG. 6, laying head 160 traverses surface 602 and surface 604 of layup mandrel 120. By traversing two surfaces on different sides of layup mandrel 120, the orientation of layup mandrel 120 along the X, Y, and Z axes may be quickly and accurately determined.

[0036] FIG. 7 is a diagram of roller 162 traversing a laid-up stack 700 in one example embodiment. According to FIG. 7 , the position of roller 162 is actively tracked during layup to obtain a second stream of 3D coordinates as roller 162 follows a surface 702 defined by stack 700. This information allows the thickness of the resulting stack 700 to be determined, and this information (e.g., the second stream of 3D coordinates along with any previously determined offset information) is passed to a downstream layup machine 1070 having a downstream layup head 1072 (e.g., as shown in FIG. 11 below) separated from stack head 160 by a distance D in the process direction 127. The downstream layup machine 1070 uses measurements from stack head 160 and / or the downstream layup head 1072 to update its own NC program.

[0037] FIG. 8 is a diagram of rollers 162 traversing a laid-up laminate 830 laid up around a tight radius in one example embodiment. According to FIG. 8 , rollers 162 of laying head 160 traverse a surface of layup mandrel 120 and / or laid-up laminate 830, such as a surface corresponding to the outer radius of a corner 833 of laminate 830, within a desired tolerance. This may be performed through multiple passes of rollers 162 at different arcuate portions of curvature 832 and integrating the resulting sensor data to characterize curvature 832 along the length of laminate 830. Laminate 830 is positioned around edges 810 and 820 of layup mandrel 120. This operation may be performed during layup after receiving laminate 830 from an upstream station, such as lamination station 150, or after layup before layup mandrel 120 advances to downstream lamination machine 1070. That 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, more layers can be added to pan out the outer radius, or the lay head 160 and NC program 114 can be adjusted to account for the difference in geometry. Similarly, if the information indicates that the convex radius R1 is too large, more layers can be added to pan out the outer radius to the desired R1, or the lay head 160 and NC program 114 can be adjusted to account for the difference in geometry.

[0038] 9 is a flowchart illustrating a method 900 for operating the registration head 170 to traverse along grooves 126, 128 in a rigid tool 125 in one example embodiment. According to FIG. 9, the method 900 includes identifying 902 a groove 126 in the rigid tool 125 (e.g., a layup mandrel 120 or other component). The groove 126 extends in a process direction 127 in which the rigid tool 125 moves during fabrication of the composite part and may measure from one-eighth of an inch to one-quarter of an inch or more in depth.

[0039] The registration head 170 is placed in the groove 126 (904). For example, the registration head 170 may be pressed into the groove 126 with a desired level of pressure (e.g., 25 pounds per square inch). This physically engages the registration end 172 of the registration head 170 with the groove 126. This means that if the groove 126 moves in an unexpected direction from its nominal path, the registration head 170 will deviate as well. The position of the registration head 170 is measured by a sensor 174 over time. Therefore, deviations can be determined by analyzing the stream of 3D coordinates from the sensor 174.

[0040] The groove is traversed by the registration head 170 (906). That is, the controller 112 operates the registration head 170 to move along the nominal path. If the groove 126 deviates from the nominal path, it will cause the registration head 170 to deflect from its expected position.

[0041] A stream of 3D coordinates of the correspondence head 170 are acquired (908) as the correspondence head 170 traverses along the groove 126. Alternatively, in addition to or instead of the 3D coordinates, the arc and arc orientation of the correspondence head 170 are acquired at 908 as the correspondence head 170 traverses along the groove 126. This involves the controller 112 sampling the input from the sensor 174 at a desired rate (e.g., several times per second, several times per inch, etc.).

[0042] The position of the rigid tool 125 is determined at 910 based on the stream of 3D coordinates obtained at 908. The determining (910) step may be performed in a manner similar to that of the method 200 described above.

[0043] The numerical control (NC) program 114 that directs the operation on the rigid tool 125 is modified at 912 based on the difference between the position of the rigid tool 125 and the nominal position of the rigid tool 125. The modifying (912) step may be performed in a manner similar to the modifying (212) step described above.

[0044] FIG. 10 is a perspective view of an aligning head 170 following one or more grooves 126 and 128 in a rigid tool 125 to align the rigid tool 125 with a layup area 130, in one exemplary embodiment. The grooves 126 follow a series of non-repeating curves 1026. In this embodiment, the aligning head 170 moves perpendicular to the process direction 127 along a frame 140, which moves parallel to the process direction 127 along a track 110. The rigid tool 125 advances downstream in the process direction 127 to a downstream layup machine 1070 having a layup head 1072 (i.e., a second or downstream layup head). In this embodiment, the downstream layup machine 1070 is separated in the process direction 127 from the upstream layup machine 150 by a distance D ( FIG. 11 ).

[0045] As shown in FIG. 10 , each of the grooves 126, 128 may exhibit a unique series of non-repeating curvatures. Therefore, each location along the grooves 126, 128 is uniquely identifiable based on the curvature information. Thus, by analyzing the change in position of the stream of 3D coordinates, a precise location along the rigid tool 125 may be determined (e.g., to the nearest inch, fractions of an inch, etc.). In embodiments in which the grooves 126, 128 are each unique, the exact groove 126, 128 being traversed may also be determined based on the curvature of the grooves 126, 128. In further embodiments, the characteristics of the grooves 126, 128 are used to communicate information. This information may include the width, depth, angle, or slope of the groove walls, or cross-sectional shape, such as triangular, square, rectangular, or semicircular, or elliptical. This information may further include varying the cross-sectional shape along the grooves 126, 128, placing notches or splines along the walls of the grooves 126, 128, applying a magnetic field having a strength that places the grooves 126, 128, etc. This information can be used to indicate specific regions along the length of each groove 126, 128.

[0046] 11 is a top view of the registration head 170 following the grooves 126, 128 in the rigid tool 125 to register the rigid tool 125 in one exemplary embodiment, corresponding to the visual arrow 11 in FIG. 10. According to FIG. 11, each of the grooves 126, 128 exhibits a unique, non-repeating series of curvatures. The rollers 162 described herein may be made from a rigid material that will not scratch or damage the underlying rigid tool 125. While the rigid tool 125 may be made from steel or other materials, the rollers 162 may be made from, for example, high-density polyurethane.

[0047] 12-14 are front views of different rollers for the mapping head 170 that traverse along grooves in a rigid tool in an exemplary embodiment, corresponding to the visual arrow 12 in FIG. 11. Specifically, FIG. 12 shows a roller 1210 with a triangular notch 1212 for rolling within a triangular groove 1200, FIG. 13 shows a roller 1310 with a rectangular notch 1312 for rolling within a rectangular groove 1300, and FIG. 14 shows a roller 1410 with a roller ball 1420 with a semicircular notch 1412 for traversing along a semicircular groove 1400.

[0048] FIG. 15 is a cut-through view of a registration head 1500 having a roller 1510 supported by a suspension 1502 in one exemplary embodiment, corresponding to visual arrow 15 in FIG. 11 . Roller 1510 includes notches 1512 that are triangular in cross section (corresponding to roller 1210) and continuous along the curvature of roller 1510 to roll along the triangular groove. Rollers 1310 and 1410 can be replaced with roller 1510 as needed to fit groove 1300 or groove 1400, respectively. Roller 1510 rotates around bar 1520, and the linear movement of roller 1510 is measured by rotation sensor 1530. Suspension cylinders 1540 and 1550 (as well as additional suspension cylinders along additional axes that run into the page) absorb positional deviations caused by the groove when it does not follow its nominal path; these deviations can then be measured by the position sensor. In further embodiments, contours 126-1 and 128-1 ( FIG. 11 ) are added to the grooves or groove surfaces to convey additional information to different stations. In further embodiments, multiple grooves 126 and / or 128 are added to rigid tool 125 to convey additional information to different stations, such as lamination station 150 and downstream lamination station 1070. For example, each groove may be utilized by different stations for different mapping purposes to meet different sets of constraints. Information conveyed by grooves 126 and 128 includes, but is not limited to, layup patterns, slope rates, ply orientations, and other ply or laminate specifications. Further embodiments have portions of grooves 126 and 128 intended to convey information only to lamination station 150 and other portions intended to convey information only to downstream lamination station 1070.

[0049] Figure 16 is a flowchart illustrating a method 1600 for operating a mapping head 1710 to traverse along a circumferential groove 1704 in an arcuate tool 1700, according to one embodiment. The operation of method 1600 is described with respect to the system depicted in Figure 17 and includes identifying 1602 an arcuate tool 1700 to move in a process direction 127 during the manufacture of a composite part. Method 1600 is similar to method 900 of Figure 9 described above, except that the grooves 1702, 1704 continue circumferentially about the arcuate tool 1700.

[0050] A groove 1704 extending along a portion of the arcuate tool 1700 is identified 1604 in the arcuate tool 1700. In one embodiment, a groove 1704 extending along an arcuate portion of the arcuate tool 1700 is identified 1604 in the arcuate tool 1700. This may include utilizing a camera to detect the location of the groove 1704 in the arcuate tool 1700, positioning 1606 a mating end 1712 of a mating head 1710 over the groove 1704, or positioning 1606 the mating head 1710 in a position where the groove 1704 can engage the mating end 1712 as the arcuate tool 1700 moves in the process direction 127.

[0051] As described above, the mating end 1712 is positioned 1606 in the groove 1704. This further includes positioning 1606 the mating end 1722 of the second mating head 1720 in the second groove 1702. In one such embodiment, the mating head 1710 is downstream from the second mating head 1720, and the lamination machine 1730 is positioned between the mating heads 1710, 1720.

[0052] The arcuate tool 1700 is rotated 1608 relative to the registration head 1710 so that the mating end 1712 traverses along the groove 1704. In one embodiment, this includes rotating the arcuate tool 1700 about its axis of rotation, or via a rotatable support 1750 (held by a frame 1752) configured to hold the arcuate tool 1700 and rotate the arcuate tool 1700 relative to the registration head 1710 so that the mating end 1712 traverses along the groove 1704. In a further embodiment, this includes moving the registration heads 1710 and 1720 circumferentially around the arcuate tool 1700. In embodiments in which the arcuate tool 1700 is moved continuously in the process direction 127, the mapping heads 1710 and 1720 adapt to the velocity of the arcuate tool 1700 so as to remain in the same position relative to the arcuate tool 1700 as the arcuate tool 1700 moves.

[0053] A stream of 3D coordinates of the registration heads 1710, 1720 is acquired 1610 as they traverse along their respective grooves 1704, 1702. This input is obtained from position sensors (not shown in FIG. 17 but similar to sensor 168 shown in FIG. 1) on the registration heads 1710, 1720. In one embodiment, a single registration head traverses along multiple grooves of the arcuate tool 1700 (i.e., by traversing along the first groove 1704 for a first time period and by traversing along the second groove 1702 for a second time period). This results in multiple streams of 3D coordinates for analysis.

[0054] The position of the arcuate tool 1700 is determined (1612) based on the stream of 3D coordinates. This may be performed in a manner similar to the characterizing (210) step of method 200 described above. The numerical control (NC) program 114 directing the operation on the arcuate tool 1700 is modified (1614) based on the difference between the position of the arcuate tool 1700 and the nominal position of the arcuate tool 1700 represented by the 3D coordinates associated with the nominal path. This may be performed in a manner similar to the modifying (212) step of method 200 described above.

[0055] Once the NC program 114 is adjusted, the layup machine 1730 proceeds to operate its layup head 1732 to lay up one or more tows 1740 for a layup. The layup is then consolidated into a composite part, such as a semi-cylindrical section of an aircraft fuselage.

[0056] Method 1600 may be particularly valuable in embodiments in which a heavy arcuate tool 1700 (e.g., weighing several tons) is held at one end by a support 1750. In such situations, the weight of the arcuate tool 1700 will result in slight deflection / angular deviation along the length of the arcuate tool 1700.

[0057] In yet further embodiments, the grooves 126, 128, 1702, 1704 are protrusions that comprise continuous protrusions from the rigid tool 125, arcuate tool 1700 (e.g., one roller on either side of the protrusion) that engage with the registration heads 170, 1710, 1720 having pairs of rollers. In still further embodiments, the grooves 126, 128, 1702, 1704 are not physical grooves, but rather painted or colored lines that are tracked by a sensor in the form of a high-precision camera. The sensor may further comprise a distance sensor, such as a laser or ultrasonic sensor, that tracks across the rigid tool 125, arcuate tool 1700, measuring distance. Thus, registration can be performed based on imaging from a sensor that follows visual distance patterns on the rigid tools, particularly without the registration head 1500 actually contacting those rigid tools.

[0058] 18 is an example report 1800 showing the difference between the nominal position and the actual position of one of the registration heads described herein in one example embodiment. The report includes a stream of 3D coordinates acquired over time. For each measured 3D coordinate, the controller compares that coordinate with an expected 3D coordinate and calculates the difference between the measured 3D coordinate and the expected 3D coordinate. The controller then locates the position indicated in the instruction. and modifying commands in an NC program to perform an operation (e.g., layup) on the associated rigid tool by applying the corresponding position difference to the commands.

[0059] Example Referring more particularly to the drawings, embodiments of the present disclosure may be described in terms of aircraft manufacturing and service in a method 1900 shown in FIG. 19 and in terms of an aircraft 1902 shown in FIG. 20. During pre-production, the method 1900 may include specification and design 1904 of the aircraft 1902 and material procurement 1906. During production, component and subassembly manufacturing 1908 and system integration 1910 of the aircraft 1902 occurs. The aircraft 1902 may then undergo certification and delivery 1912 and be placed into service 1914. While in operation by a customer, the aircraft 1902 is scheduled for periodic maintenance and service 1916, which may include modification, reconfiguration, refurbishment, etc. Apparatus and methods embodied herein may be used in one or more of any suitable stages of manufacturing and service described in method 1900 (e.g., specification and design 1904, materials procurement 1906, component and subassembly manufacturing 1908, system integration 1910, certification and delivery 1912, operation 1914, maintenance and service 1919) and / or any suitable component of aircraft 1902 (e.g., airframe 1918, systems 1920, interior 1922, propulsion system 1924, electrical system 1926, hydraulic system 1928, environmental system 1930).

[0060] Each step of method 1900 may be performed or carried out by a system integrator, a third party, and / or an operator (e.g., a customer). For purposes of this specification, 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 vendors, subcontractors, and suppliers, and an operator may be an airline, leasing company, military organization, service organization, etc.

[0061] 20 , an aircraft 1902 produced by method 1900 may include an airframe 1918 having a plurality of systems 1920 and an interior 1922. Examples of the plurality of systems 1920 include one or more of a propulsion system 1924, an electrical system 1926, a hydraulic system 1928, and an environmental system 1930. Any number of other systems may also be included. While an aerospace example is provided, the principles described herein may be applied to other industries, such as the automotive industry.

[0062] As already described above, apparatus and methods embodied herein may be used in any one or more stages of manufacturing and service described in method 1900. For example, components or subassemblies corresponding to component and subassembly manufacturing 1908 may be fabricated or manufactured in a manner similar to components or subassemblies produced during the service life of aircraft 1902. Also, one or more apparatus embodiments, method embodiments, or a combination thereof may be utilized in subassembly manufacturing 1908 and system integration 1910, for example, by significantly streamlining the assembly of aircraft 1902 or significantly reducing the cost of aircraft 1902. Similarly, one or more apparatus embodiments, method embodiments, or a combination thereof may be utilized during the service life of aircraft 1902, for example, but not limited to, during maintenance and service 1916. Thus, the present invention may be utilized in any stage, or combination thereof, described herein. For example, specification and design 1904, material procurement 1906, component and subassembly manufacturing 1908, system integration 1910, certification and delivery 1912, operation 1914, maintenance and maintenance 1916, and / or may be used in any suitable component of the aircraft 1902 (e.g., airframe 1918, systems 1920, interior 1922, propulsion system 1924, electrical system 1926, hydraulic system 1928, and / or environmental system 1930).

[0063] In one embodiment, a part, including a portion of the airframe 1918, is manufactured during component and subassembly manufacturing 1908. The part may then be assembled to the aircraft in system integration 1910 and then utilized in service 1914 until wear renders the part unusable. The part may then be discarded and replaced with a newly manufactured part in maintenance and service 1916. Components and methods of the present invention may be utilized throughout component and subassembly manufacturing 1908 to manufacture new parts.

[0064] Any of the various control elements (e.g., electrical components or electronic components) shown in the figures or described herein may be implemented as hardware, processor-implemented software, processor-implemented firmware, or some combination thereof. For example, an element may be implemented as dedicated hardware. A dedicated hardware element may be referred to as a “processor,” “controller,” or some similar terminology. When provided by a processor, functions may be provided by a single dedicated processor, by a single shared processor, or by multiple individual processors, some of which may be shared. Furthermore, explicit use of the terms “processor” or “controller” should not be construed as referring only to hardware capable of executing software, but may implicitly include, without limitation, digital signal processor (DSP) hardware, network processors, application-specific integrated circuits (ASICs) or other circuitry, field-programmable gate arrays (FPGAs), read-only memory (ROM) for storing software, random access memory (RAM), non-volatile storage, logic, or any other physical hardware component or module.

[0065] Also, a control element can be implemented as instructions executable by a processor or computer to perform the function of the element. Some examples of instructions are software, program code, and firmware. When executed by a processor, the instructions are operable to instruct the processor to perform the function of the element. The instructions can be stored in a storage device readable by the processor. Some examples of storage devices are digital or solid-state memory, magnetic storage media such as magnetic disks and magnetic tapes, hard drives, or optically readable digital data storage media.

[0066] Although specific embodiments are described herein, the scope of the disclosure is not limited to such specific embodiments. The scope of the disclosure is defined by the following:

[0067] The following clauses are presented as illustrative examples that may be helpful in understanding the present application. Article 1. A method (200) for associating a lay-up mandrel (120) for a composite part, comprising: identifying (202) a first side (122) of a lay-up mandrel (120) that moves in a process direction (127) during fabrication of a composite part; placing (204) a laying head (160) in contact with the first side (122); traversing (206) the first side (122) of the lay-up mandrel (120) with the laying head (160); acquiring (208) a stream of 3D coordinates of the laying head (160) as the laying head (160) traverses the first side (122); characterizing (210) the layup mandrel (120) based on the stream of 3D coordinates; and The method (200) includes modifying (212) a numerically controlled (NC) program (114) that guides the layup of fiber reinforced material on the layup mandrel (120) based on a difference between the position of the layup mandrel (120) and a nominal position of the layup mandrel (120). Article 2. traversing (206) the first side (122) includes holding a roller (162) of the laying head (160) in contact with the first side (122), the roller (162) traversing (206) the first side (122) in accordance with an associated NC program (114) that directs the roller (162) to follow a rated path (123) along the lay-up mandrel (120), and the roller (162) deflects when the first side (122) deviates from the rated path (123); The method further includes comparing the acquired stream of 3D coordinates with the nominal path (123) to determine a positional difference from the nominal path (123); 2. The method (200) of claim 1, wherein modifying (212) includes integrating the difference into the NC program (114) that guides the layup. Article 3. The method (200) according to clause 1 or 2, wherein acquiring (208) a stream of 3D coordinates of the laying head (160) includes measuring positional offsets of components of a suspension (164) that allow deflection of rollers (162) of the laying head (160) for later comparison with a nominal path. Article 4. laying up a laminate on the layup mandrel (120) according to the NC program; obtaining a second stream of 3D coordinates of rollers (162) of said laying head (160) during said layup; transferring the lay-up mandrel (120) downstream in the process direction (127) to a lay-up head (1072); passing the second stream of 3D coordinates to a controller (112) of the downstream lamination head (1072); and 4. The method of any one of clauses 1 to 3, further comprising determining a position of the lay-up mandrel (120) at the downstream laying head (1072) based on the second stream of 3D coordinates. Article 5. positioning the roller (162) in contact with a second side (124) of the lay-up mandrel (120); traversing the second side (124) with a roller (162) of the laying head (160); and 5. The method of clause 4, further comprising obtaining a second stream of 3D coordinates of the roller (162) as the roller (162) traverses the second side (124). Article 6. 6. The method of claim 5, further comprising operating the laying head (160) according to the NC program (114) to lay up fiber reinforced material in a layup region (130) between the first side (122) and the second side (124). Article 7. 7. The method of any one of clauses 1 to 6, further comprising modifying the NC program (114) in real time to accommodate a thickness of fiber reinforced material already placed on the lay-up mandrel (120). Article 8. 1. A system (100) for associating a lay-up mandrel (120) for a composite part, comprising: A lamination head (160), Roller (162), a suspension (164) that allows the roller (162) to flex; a position sensor (168) for measuring the deflection of the roller (162); and a laying head (160) including a dispenser (166) for dispensing tows of fiber reinforcement material; The method includes a controller (112) configured to identify a first side (122) of a lay-up mandrel (120) moving in a process direction (127) during the manufacture of a composite part, to guide the laying head (160) to position the roller (162) in contact with the first side (122), to guide the laying head (160) to traverse the first side (122) with the roller (162), and to cause the roller (162) to traverse the first side (122). acquiring a stream of 3D coordinates of the roller (162) as it traverses a lathe; determining a position of the layup mandrel (120) based on the stream of 3D coordinates; and modifying a numerical control (NC) program (114) that guides the layup of fiber reinforced material on the layup mandrel (120) based on a difference between the position of the layup mandrel (120) and a nominal position of the layup mandrel (120). Article 9. Further comprising a downstream lamination head (1072), The controller (112) controls the stacking head (160) to: laying up a laminate on the layup mandrel (120) according to the NC program (114); obtaining a second stream of 3D coordinates of the roller (162) during the layup; and The system (100) described in clause 8, wherein the stacking head (160) is operated to pass the second stream of 3D coordinates to a controller (112) for controlling the operation of the downstream stacking head (1072). Article 10. 10. The system (100) of clause 9, wherein the lay-up head (160) is separated from the downstream lay-up head (1072) by a distance in the process direction (127). Article 11. 11. The system (100) of any one of clauses 8 to 10, further comprising a track (110) for transporting the lay-up mandrel (120) in the process direction (127). Article 12. 12. The system (100) of any one of clauses 8 to 11, further comprising a frame (140) that positions the laying head (160) relative to the lay-up mandrel (120). Article 13. 13. The system (100) of any one of clauses 8 to 12, wherein the controller (112) is programmed to modify the NC program (114) in real time to accommodate a thickness of fiber reinforced material already placed on the lay-up mandrel (120). Article 14. A lamination machine (150) for composite parts, preferably comprising a system according to any one of clauses 8 to 13, A lamination head (160), Roller (162), a suspension (164) that allows the roller (162) to flex; a position sensor (168) for measuring the deflection of the roller (162); and a laying head (160) including a dispenser (166) for dispensing tows of fiber reinforcement material; A layup machine (150) comprising a controller (112) operable to use the measured deflection to correspond the layup head (160) to the layup mandrel (120). Article 15. Clause 15. The layup machine (150) of clause 14, further comprising a frame (140) for positioning the layup head (160) relative to the layup mandrel (120). Article 16. 16. The lamination machine (150) of clause 14 or 15, wherein the controller (112) is configured to acquire (208) a stream of 3D coordinates of the lamination head (160) from the position sensor (168), the stream representing a measurement of a positional offset of the suspension (164) that allows the roller (162) to flex, and the controller is further configured to compare the position offset with a nominal path. Article 17. 17. The layup machine (150) according to any one of clauses 14 to 16, wherein the controller (112) is configured to cause the roller (162) of the layup head (160) to traverse two surfaces (602, 604) on different sides of the layup mandrel (120, 600), such that the controller (112) can use the measured deflection of the layup head (160) to determine an orientation of the layup mandrel (120, 600). Article 18. The controller (112) controls the roller (162) of the laying head (160) to: actively tracking a surface (702) defined by the laminate (700) during layup to obtain a second stream of 3D coordinates; determining the thickness of the resulting stack (700) from the active tracking of the surface (702); and 18. The layup machine (150) of any one of clauses 14 to 17, configured to pass the determined thickness, the second stream of 3D coordinates, and the association of the layup head (160) with the layup mandrel (120) to a downstream layup machine (1070) having a downstream layup head (1072). Article 19. The controller (112) controls the layup head (160) to: traversing a surface of the laminate (830), the surface being traversed at a plurality of arcuate portions of different outer radii of curvature (832) of the corners of the laminate (830) corresponding to the outer radii; and 19. The lamination machine (150) of any one of clauses 14 to 18, configured to integrate data from the position sensors (168) to characterize the curvature (832) along the length of the laminate (830), wherein the curvature wraps around one or both of an edge (810) and an edge (820) of a lay-up mandrel (800). Article 20. Manufacture a portion of an aircraft (1902) using a laminating machine (150) according to any one of clauses 14 to 19. Article 21. A method (900) for associating a rigid tool (125) for a composite part, comprising: identifying (902) a groove (126) on a rigid tool (125) and extending in a process direction (127) along which the rigid tool moves during manufacturing of the composite part; Positioning (904) a mating head (170) relative to the groove (126); traversing (906) the alignment head (170) along the groove (126); acquiring (908) a stream of 3D coordinates of the registration head (170) as the registration head (170) traverses along the groove (126); determining (910) a position of the rigid tool (125) based on the stream of 3D coordinates; and A method (900) comprising modifying (192) a numerical control (NC) program that directs operations on the rigid tool (125) based on a difference between the position of the rigid tool (125) and a nominal position of the rigid tool (125). Article 22. 22. The method (900) of claim 21, wherein positioning the mating head (170) includes pressing a mating end (172) of the mating head (170) into the groove (126). Article 23. Clause 23. The method (900) of clause 22, wherein traversing (906) the mapping head (170) includes moving the mapping head (170) along a rated path while the mapping end (172) remains within the groove (126). Article 24. The method (900) of clause 23, wherein obtaining (908) a stream of 3D coordinates of the mapping head (170) includes determining a deflection of the mapping head (170) from the nominal path as the mapping end (172) moves along the groove (126). Article 25. 25. The method (900) of any one of clauses 21 to 24, wherein traversing (906) the mapping head (170) includes traversing along the groove (126) according to a mapping NC program (114) that guides the mapping head (170) to follow a nominal path along the rigid tool (125), and wherein a mapping end (172) of the mapping head (170) is pressed into the groove (126) during traversing (906). Article 26. The method (900) of clause 25, wherein determining (910) the position of the rigid tool (125) includes comparing the stream of 3D coordinates from the alignment head (170) with 3D coordinates of the nominal path to determine a deviation of the groove (126) from the nominal path. Article 27. 27. The method of claim 26, wherein modifying (192) a numerically controlled (NC) program (114) includes integrating the deviation into the NC program (114) that lays up the composite material on the rigid tool (125). Article 28. The method (900) of any one of clauses 21 to 27, wherein the groove (126) comprises a non-repeating series of characteristic curvatures, and the method further comprises determining a position of the mapping head (170) on the rigid tool (125) based on 3D coordinates in the stream that indicate one of a plurality of the characteristic curvatures in the non-repeating series of characteristic curvatures. Article 29. Identifying (902) a groove (126) on a rigid tool (125) includes: Identifying (902) a continuous protrusion on the rigid tool (125); and identifying one or more lines on the rigid tool (125); Positioning (904) the mating head (170) relative to the groove (126) includes: engaging a roller of said mapping head (170) with said successive protrusions; and 29. The method (900) of any one of clauses 21 to 28, comprising one or more of: tracking said one or more lines using one or more cameras. Article 30. replacing the mating head (170) with the laying head (160); and 30. The method (900) of any one of clauses 21 to 29, further comprising performing a layup by dispensing a fiber reinforcement material from the laying head (160). Article 31. The rigid tool (125) includes a first groove (126) and a second groove (128), both extending in a process direction (127); traversing (906) the mating head (170) includes traversing (906) along both the first groove (126) and the second groove (128) using at least one mating head (170); Obtaining (908) a stream of 3D coordinates includes obtaining (908) a stream of 3D coordinates for each of the first groove (126) and the second groove (128); 31. The method (900) of any one of clauses 21 to 30, wherein determining (910) the position of the rigid tool (125) comprises determining (910) the position of the rigid tool (125) based on both streams of 3D coordinates. Article 32. Clause 32. The method (900) of any one of clauses 21 to 31, wherein traversing (906) the mating head (170) includes rolling the mating end (172) of the mating head (170) along the groove (126). Article 33. 33. The method (900) of any one of clauses 21 to 32, wherein obtaining (908) a stream of 3D coordinates of the alignment head (170) includes determining an arc of the alignment head (170) and an orientation of the arc as the alignment head (170) traverses along the groove (126). Article 34. A system (100) for associating a rigid tool (125) with a layup machine (150), comprising: a mating head (170) having a mating end (172); a position sensor (174) for measuring the 3D coordinates of the registration end (172) of the registration head (170); and a controller (112), the controller (112) placing the mating end (172) in a groove (126) formed in a rigid tool (125), the groove (126) extending in a process direction (127) along which the rigid tool (125) moves during manufacturing of the composite part; guiding said alignment head (170) to traverse along said groove (126); acquiring a stream of 3D coordinates of the registration head (170) via the position sensor (174) as the registration head (170) traverses along the groove (126) with the registration end (172) in the groove (126); determining a position of the rigid tool (125) based on the acquired stream of 3D coordinates; and A system (100) that executes modifying a numerical control (NC) program (114) that guides operations on the rigid tool (125) based on a difference between the determined position of the rigid tool (125) and a nominal position of the rigid tool (125). Article 35. 35. The system (100) of claim 34, wherein the mating end (172) is configured to roll within the groove (126). Article 36. 36. The system (100) of clause 34 or 35, wherein the mating head (170) is configured to apply pressure to the mating end (172) within the groove (126) while the mating end (172) traverses along the groove, such that when the groove (126) deviates from the rated path, the mating head (170) deflects from the rated path. Article 37. The controller (112) guiding the mapping head (170) to traverse along the groove (126) in accordance with a mapping NC program (114) that guides the mapping head (170) to follow a nominal path along the rigid tool (125); comparing the stream of 3D coordinates obtained from the registration head (170) with the nominal path to determine a positional difference from the nominal path; and integrating the positional differences into the NC program (114) that guides placement of the composite material on the rigid tool (125). Article 38. Manufacture a portion of an aircraft (1902) using the system (100) described in any one of clauses 34 to 37. Article 39. 1. An apparatus for associating a rigid tool (125) for a composite part, comprising: a mating head (170) having a mating end (172); and The apparatus comprises a position sensor (174) for measuring the 3D coordinates of the registration head (170). Article 40. 40. The apparatus of clause 39, wherein the mating end (172) is configured to roll within a groove (126) formed in the rigid tool (125). Article 41. 41. The apparatus of clause 39 or 40, wherein the mapping head (170) is configured to press the mapping end (172) into the groove (126) while the mapping head (170) traverses along the groove (126) so that the mapping head (170) deflects according to deviations of the groove (126) from a rated path. Article 42. The apparatus described in clause 41, wherein the controller (112) determines the position of the mapping head (170) relative to the rigid tool (125) based on 3D coordinates in the stream that indicate the groove (126) having at least one non-repetitive series of unique curvatures. Article 43. 1. A method (1600) for associating an arcuate tool (1700) for a composite part, comprising: Identifying (1604) a groove (1704) associated with the arcuate tool (1700) extending along a portion of the arcuate tool (1700); Positioning (1606) a mating head (1710) relative to the groove (1704); rotating (1608) the arcuate tool (1700) relative to the registration head (1710) so that the registration head (1710) traverses along the groove (1704); acquiring (1610) a stream of 3D coordinates of the registration head (1710) as the registration head (1710) traverses along the groove (1704); determining (1612) a position of the arcuate tool (1700) based on the acquired stream of 3D coordinates; and A method (1600) including modifying (1614) a numerical control (NC) program (114) that directs operations on the arcuate tool (1700) based on a difference between the position of the arcuate tool (1700) and a nominal position of the arcuate tool. Article 44. The method (1600) of clause 43, wherein positioning (1606) a mating head (1712) relative to the groove (1704) includes pressing a mating end (1712) of the mating head (1710) into the groove (1704). Article 45. The method (1600) described in clause 43 or 44, wherein rotating (1608) the arcuate tool (1700) relative to the mating head (1710) includes deflecting the mating head (1710) from the rated path when the groove (1704) deviates from the rated path. Article 46. Determining (1612) the position of the arcuate tool (1700) based on the acquired stream of 3D coordinates comprises comparing the acquired stream of 3D coordinates with 3D coordinates associated with the nominal path to determine a difference in the position of the arcuate tool (1700) from the nominal path; and The method (1600) of any one of clauses 43 to 45, wherein modifying (1614) the numerical control (NC) program (114) includes integrating the position difference into the NC program that guides operation on the arcuate tool (1700). Article 47. A method (1600) according to any one of clauses 43 to 46, wherein determining (1612) the position of the arcuate tool (1700) includes identifying the position of the mapping head (1710) relative to the arcuate tool (1700) based on 3D coordinates in the acquired stream that indicate one of a series of unique, non-repetitive curvatures in the groove (1704). Article 48. The step of placing the matching head (1606) includes: positioning (1606) a first mating end (1712) of a first mating head (1710) relative to a first groove (1704) of the arcuate tool (1700) upstream of a layup machine (1730); and A method (1600) according to any one of clauses 43 to 47, comprising positioning (1606) a second mating end (1722) of a second mating head (1720) in a second groove (1702) downstream of the laminating machine (1730). Article 49. 49. The method of claim 48, further comprising operating the layup machine (1730) to lay up composite material according to the modified NC program (114). Article 50. A method (1600) according to any one of clauses 43 to 49, wherein rotating (1608) the arcuate tool (1700) relative to the mating head (1710) includes rolling a mating end (1712) of the mating head (1710) relative to the groove (1704). Article 51. A part of an aircraft (1902) assembled in accordance with the method (1600) set forth in any one of clauses 43 to 50. Article 52. 1. A system for associating an arcuate tool (1700) for manufacturing a composite part, comprising: a matching head (1710) having a matching end (1712) and a position sensor that measures the 3D coordinates of the matching head (1710) relative to the matching end (1712); an arcuate tool (1700) comprising at least one groove (1704) around the arcuate portion of said arcuate tool (1700); a rotatable support (1750) configured to hold the arcuate tool (1700) and further configured to rotate the arcuate tool (1700) relative to the registration head (1710) so that the registration end (1712) traverses along the groove (1704); and The method includes a controller (112) configured to position (1606) the registration head (1710) relative to the arcuate tool (1700), guide the rotatable support (1750) to rotate (1608) the arcuate tool (1700), and obtain (1609) a stream of 3D coordinates indicating the position of the registration head (1710) as the registration end (1712) traverses along the groove (1704). 610), determining (1612) a position of the arcuate tool (1700) relative to a nominal tool position based on the acquired stream of 3D coordinates, and modifying (1614) a numerical control (NC) program (114) that guides composite layup operations at the arcuate tool (1700) based on the difference between the determined (1612) position of the arcuate tool (1700) and the nominal position of the arcuate tool (1700). Article 53. 53. The system of claim 52, wherein the mating end (1712) is configured to roll within the groove (1704). Article 54. The system described in clause 52 or 53, wherein the mating head (1710) is configured to press the mating end (1712) into the groove (1704) while the mating end (1712) traverses along the groove (1704) so ​​that the mating head (1710) deflects from the rated path when the groove (1704) deviates from the rated path. Article 55. The controller (112) guiding the mapping head (1710) to traverse along the groove (1704) in accordance with an NC program (114) that guides the mapping head (1710) to follow a nominal path along the arcuate tool (1700); comparing the acquired stream of 3D coordinates with 3D coordinates representing the nominal path to determine a difference in position of the registration head (1710) from the nominal path; and 55. The system of claim 54, configured to: integrate the positional differences into the NC program (114) that guides layup operations on the arcuate tool (1700). Article 56. The system described in any one of clauses 52 to 55, wherein, to determine the position of the mapping head (1710) relative to the arcuate tool (1700), the controller (112) is configured to utilize the 3D coordinates in the acquired stream to recognize a non-repetitive series of unique curvatures in the groove (1704), thereby determining the position of the mapping head (1710) relative to the arcuate tool (1700). Article 57. a second mating head (1720) having a second mating end (1722); the mating end (1712) of the mating head (1710) is positioned relative to a groove (1704) of the arcuate tool (1700), the groove (1704) being upstream of a layup machine (1730); The system described in any one of clauses 52 to 56, wherein the second mating end (1722) of the second mating head (1720) is positioned relative to a second groove (1702) of the arcuate tool (1700) downstream of the lamination machine (1730). Article 58. The system described in clause 57, wherein the grooves (1702, 1704) are operable to communicate information, including at least one of layup pattern, gradient rate, and ply orientation, to the controller (112) via the corresponding ends (1712, 1722). Article 59. 1. An apparatus for associating a laying head (1730) with a composite part arc tool (1700), comprising: a registration head (1710) comprising a registration end (1712) and a position sensor providing 3D coordinates of the registration end (1712); and a rotatable support (1750) for said arcuate tool (1700); and An apparatus comprising: a controller having an NC program (114), the controller being configured to position the mating head (1710) relative to a groove (1704) in the arcuate tool (1700), and further configured to rotate the arcuate tool (1700) relative to the mating head (1710) so that the mating end (1712) traverses along the groove. Article 60. The apparatus described in clause 59, wherein the mating end (1712) is configured to roll within the groove (1704) so ​​that when the groove (1704) deviates from the rated path for the arcuate tool (1700), the mating head (1710) deflects from the rated path. Article 61. The apparatus described in clause 60 further comprises a second alignment head (1720) having a second alignment end (1722) and a position sensor that provides 3D coordinates of the alignment end (1722), wherein the alignment head (1710) is upstream of a stacking machine (1730) and the second alignment head (1720) is downstream of the stacking machine (1730). Article 62. Manufacture of a part of an aircraft (1902) using the apparatus described in any one of clauses 59 to 61.

Claims

1. A method (200) for associating a lay-up mandrel (120) for a composite part, comprising: Identifying (202) a first side (122) of a lay-up mandrel (120) that moves in a process direction (127) during manufacturing of a composite part; placing a laying head (160) in contact with the first side (122); traversing (206) the first side (122) of the lay-up mandrel (120) with the laying head (160); acquiring (208) a stream of 3D coordinates of the laying head (160) as the laying head (160) traverses the first side (122); characterizing (210) the lay-up mandrel (120) based on the stream of 3D coordinates; and The method (200) includes modifying (212) a numerically controlled (NC) program (114) that directs the layup of fiber reinforced material on the layup mandrel (120) based on a difference between the position of the layup mandrel (120) and a nominal position of the layup mandrel (120).

2. Traversing (206) the first side (122) includes holding a roller (162) of the laying head (160) in contact with the first side (122), the roller (162) traversing (206) the first side (122) according to an associated NC program (114) that directs the roller (162) to follow a nominal path (123) along the lay-up mandrel (120), the roller (162) deflecting as the first side (122) deviates from the nominal path (123), The method further includes comparing the acquired stream of 3D coordinates with the nominal path (123) to determine a positional difference from the nominal path (123); The method (200) of claim 1, wherein modifying (212) includes integrating the difference into the NC program (114) that guides the layup.

3. 3. The method of claim 1, wherein acquiring a stream of 3D coordinates of the laying head includes measuring positional offsets of components of a suspension that allows deflection of rollers of the laying head for later comparison to a nominal path.

4. laying up a laminate on the lay-up mandrel (120) according to the NC program; acquiring a second stream of 3D coordinates of the rollers (162) of the laying head (160) as the rollers (162) of the laying head (160) traverse a second side (124) of the lay-up mandrel (120); transferring said lay-up mandrel (120) in said process direction (127) downstream to a lay-up head (1072); passing the second stream of 3D coordinates to a controller (112) of the downstream lamination head (1072); and 4. The method of claim 1, further comprising determining a position of the lay-up mandrel (120) at the downstream laying head (1072) based on the second stream of 3D coordinates.

5. positioning the roller (162) in contact with a second side (124) of the lay-up mandrel (120); and 5. The method of claim 4, further comprising operating the laying head (160) according to the NC program (114) to lay up fiber reinforced material in a layup region (130) between the first side (122) and the second side (124).

6. 6. The method of claim 1, further comprising modifying the NC program (114) in real time to accommodate a thickness of fiber reinforced material already placed on the lay-up mandrel (120).

7. 1. A system (100) for associating a lay-up mandrel (120) for a composite part, comprising: A laying head (160), roller (162), a suspension (164) that allows the roller (162) to flex; a position sensor (168) for measuring the deflection of said roller (162); and a laying head (160) including a dispenser (166) for dispensing tows of fiber reinforcement material; The method includes a controller (112) configured to identify a first side (122) of a lay-up mandrel (120) moving in a process direction (127) during manufacturing of a composite part, to guide the laying head (160) to position the roller (162) in contact with the first side (122), to guide the laying head (160) to traverse the first side (122) with the roller (162), and to guide the roller (162) to traverse the first side (122). acquiring a stream of 3D coordinates of the roller (162) as it traverses a lathe; determining a position of the lay-up mandrel (120) based on the stream of 3D coordinates; and modifying a numerical control (NC) program (114) that directs the lay-up of fiber reinforced material on the lay-up mandrel (120) based on a difference between the position of the lay-up mandrel (120) and a nominal position of the lay-up mandrel (120).

8. Further comprising a downstream lamination head (1072), The controller (112) controls the stacking head (160) to: laying up a laminate on the lay-up mandrel (120) according to the NC program (114); obtaining a second stream of 3D coordinates of the rollers (162) by actively tracking a surface (702) defined by the laminate (700) during the layup; and 8. The system (100) of claim 7, wherein the layering head (160) is operated to pass the second stream of 3D coordinates to a controller (112) to control operation of the downstream layering head (1072), the layering head (160) being separated from the downstream layering head (1072) by a distance in the process direction (127).

9. The system (100) of claim 7 or 8, further comprising a track (110) that transports the lay-up mandrel (120) in the process direction (127).

10. The system (100) of any one of claims 7 to 9, further comprising a frame (140) that positions the laying head (160) relative to the lay-up mandrel (120).

11. 11. The system (100) of claim 7, wherein the controller (112) is programmed to modify the NC program (114) in real time to correspond to a thickness of fiber reinforced material already placed on the lay-up mandrel (120).

12. 12. A layup machine (150) for a composite part, comprising the system of any one of claims 7 to 11, wherein the controller (112) is configured to cause the rollers (162) of the layup head (160) to traverse two surfaces (602, 604) on different sides of a layup mandrel (120, 600), such that the controller (112) can use the measured deflection of the layup head (160) to determine an orientation of the layup mandrel (120, 600).

13. 12. A layup machine (150) for composite parts comprising the system of any one of claims 7 to 11, wherein the controller (112) controls the rollers (162) of the layup head (160) to: actively tracking a surface (702) defined by the laminate (700) during layup to obtain a second stream of 3D coordinates; determining the thickness of the resulting laminate (700) from the active tracking of the surface (702); and and passing the determined thickness, the second stream of 3D coordinates, and the association of the lay-up head (160) with the lay-up mandrel (120) to a downstream lay-up machine (1070) having a downstream lay-up head (1072).

14. 12. A layup machine (150) for composite parts comprising the system of any one of claims 7 to 11, wherein the controller (112) controls the layup head (160) to: traversing a surface of the laminate (830), the surface being traversed at a plurality of arcuate portions of different outer radii of curvature (832) of the corners of the laminate (830) corresponding to the outer radii; and a layup machine (150) configured to integrate data from the position sensors (168) to characterize the curvature (832) along the length of the layup (830), the curvature wrapping around one or both of an edge (810) and an edge (820) of a layup mandrel (800).

15. 15. A method of manufacturing a portion of an aircraft (1902) using the layering machine (150) of any one of claims 12 to 14.

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