Methods, systems, and header structures for calibrating fixing tools and post-curing fixing devices.

Abstract

To provide systems and methods for determining and correcting a tooling deviation by performing three-dimensional surface scans on a composite panel.SOLUTION: A system and a method allow for less accurate post-cure fixturing (e.g., holding a panel in a less constrained state, as compared to prior art techniques), while still maintaining a sufficient amount of precision for predictive shimming and shimless techniques. The method includes: performing a first three-dimensional surface scan; performing a second three-dimensional surface scan; and comparing the two three dimensional scans to determine a deformation function corresponding to a tooling deviation. In some of the systems, a header structure is used to hold the composite panel in a nominal configuration for the second three-dimensional surface scan. In some of the systems, a scanning device performs mirrored scanning on either of both sides of the composite panel, using a common reference frame.SELECTED DRAWING: Figure 13

Description

Technical Field

[0001] The present disclosure generally relates to methods for calibrating tooling fixtures and post-cure fixtures, and more specifically to methods for scanning surfaces to calibrate tooling fixtures and post-cure fixtures, and to systems and header structures for use with some of the disclosed methods.

Background Art

[0002] In FIG. 1, an example of an apparatus 10 that can be constructed from a composite structure such as a composite panel outer skin 12 is presented in the form of an aircraft 14. The aircraft 14 includes, for example, a fuselage 16 that generally corresponds to the body of the aircraft 14 for holding passengers, crew, cargo, and / or equipment depending on the particular configuration and / or function of the aircraft 14. The fuselage 16 is elongated, somewhat cylindrical or tubular, and is constructed from a plurality of fuselage sections 18 that are longitudinally spaced along the fuselage 16 and are functionally grouped together to define the fuselage 16. The aircraft 14 also includes wings 22, a horizontal stabilizer 24, and a vertical stabilizer 26, each of which can be constructed as a single structure or as subsections that are assembled continuously and grouped together. One or more of the fuselage 16, fuselage sections 18, wings 22, horizontal stabilizer 24, vertical stabilizer 26, and / or their structural subsections can be constructed using one or more composite panel outer skins 12.

[0003] Figure 2 shows an exemplary and non-limiting example of composite panel skins 12 used to form one of the fuselage sections 18 of the aircraft 14 in Figure 1. Some composite panel skins 12 are functionally coupled to and supported by a structural frame 28, as shown in Figure 2. The composite panel skins 12 can be described as defining the outer shape of the fuselage 16. Figures 3a and 3b show another non-limiting example of composite panel skins 12 used to form the wings of an aircraft, such as the wings 22 of the aircraft 14 in Figure 1. As shown in Figures 3a-3b, the wings 22 can be formed by fastening multiple composite panel skins 12 to an inner frame 30. The inner frame 30 is formed from multiple ribs 32 and spars 34 (Figure 3a), and one or more composite panel skins 12 are fastened to the inner frame 30 (Figure 3b) to form the wings 22. The wing 22 may also include flaps 36, ailerons 38, and wing caps 40.

[0004] When used herein in reference to the aircraft 14, fuselage 16, and / or the corresponding composite panel skin 12, the terms “inside” and “outside” refer to the radially inward and radially outward sides of the corresponding composite structure, respectively. Thus, the outside of a composite structure or its component parts generally faces away from the composite structure, and the inside generally faces the interior space defined by the composite structure. For example, the outside 42 of fuselage section 18 (Figure 2) is defined by the respective outer surfaces 43 of the composite panel skin 12, while the inside 44 of fuselage section 18 is defined by the respective inner surfaces 45 of the composite panel skin 12 and faces the interior space 46 of fuselage section 18. Similarly, the outside 48 of wing 22 (Figure 3b) is defined by the respective outer surfaces 43 of the composite panel skin 12, while the inside 50 of wing 22 is defined by the respective inner surfaces 45 of the composite panel skin 12 and is positioned to face the interior frame 30. Similar relative terms may be used with respect to composite panel skins 12 other than those used to form the fuselage 16 or wings 22, and / or with respect to devices 10 other than the aircraft 14. Such outer surfaces may also be referred to herein as outer mold line ("OML") surfaces, and inner surfaces may also be referred to herein as inner mold line ("IML") surfaces.

[0005] Composite structures, such as composite panel outer panels 12, are generally formed by laminating multiple layers of composite material onto a mold tool or a fixed tool such as a layup mandrel. The composite material is placed under vacuum, cured, and then removed from the fixed tool for post-curing processing. Composite parts are often formed with one side ("tool side") positioned relative to the fixed tool and the other side facing away from the fixed tool ("bag side"). Depending on the specific part and its application, composite parts may also be formed with either the inner (IML) surface or the outer (OML) surface facing the mold. Figure 4 shows an example of an IML-controlled mold tool 52, in which a composite part (such as one of the composite panel outer panels 12 in fuselage section 18 in Figure 2) may be formed with the inner surface 45 of the composite panel outer panel 12 positioned relative to a convex mold surface 54. Figure 5 shows an example of an OML-controlled molding tool 56, which can be used to produce the same composite part as the IML-controlled molding tool 52 in Figure 4, except that the outer surface 43 of the composite panel skin 12 is positioned relative to a concave molding surface 58. Composite panel skins of aircraft are generally processed with OML tools (e.g., generally formed on OML-controlled molding tools), and the surface that will ultimately become the outer surface of the panel is positioned to contact the molding tool. This helps to increase the smoothness of the surface exposed to the airflow, on the other hand, the bag-side surface of the composite part is often subject to more variation than the tool side due to, for example, the bagging process, the flow of resin through the part, the arrangement of subassemblies (e.g., the arrangement of stringers in the case of an aircraft wing assembly), the stacking order of plies, and / or variations in the thickness of individual plies used to form the part.

[0006] Throughout conventional panel manufacturing processes, deviations often cause parts to deviate from their engineering reference design state. For example, joint assembly, tool deviation, bagging, curing, unbagging, inspection, trimming, drilling, and / or painting can all contribute to deviations in the manufactured part compared to its reference configuration. Often, due to residual stress in the panel, the composite panel sheath will "spring off" from the fixing tool when the fixing tool is removed after curing. The panel sheath will then take on a slightly different shape when held by separate post-curing fixtures that hold the panel sheath during post-curing processes such as trimming and drilling (due to the individual loads applied to the part by the post-curing fixtures, which are generally large and semi-adaptive).

[0007] During assembly, substructures do not load the part in the same way as the cured fixture, so the part typically does not deform again to the configuration it was in when held by the cured fixture. Therefore, deviations in the cured fixture (e.g., a discrepancy between the exact shape of the part when held by the cured fixture and the part's reference configuration) can lead to deviations in the final part. In certain cases, any deviation present in the cured fixture can affect the placement of holes drilled in the part, edge trimming accuracy, and / or the final shape of the part. Such deviations are difficult to isolate and can impair the integrity of surface scans performed on the part, introducing an unknown into manufacturing. However, maintaining the precision of cured fixtures in a manufacturing environment can be very costly and / or difficult.

[0008] Compensating for deviations in how a hardened fastener holds a panel sheath is generally time-consuming and costly, and may require sacrificial machining of the component or substructure to which the panel sheath is assembled (e.g., sacrificial machining of ribs in an aircraft wing assembly) and / or the placement of shims. Other conventional techniques for compensating for hardened fastener deviations include specialized hard tools that precisely hold one side of the component. However, such specialized hard tools are limited in their manufacture because they require multiple tool settings and more trim / drill gantry, each of which increases manufacturing time and capital tool costs. [Overview of the Initiative]

[0009] The systems and methods of this disclosure provide for determining and correcting tool deviations by comparing two different three-dimensional surface scans of a composite panel (e.g., a large semi-compliant structure) after curing. Such methods and systems allow for less precise post-curing fixation (e.g., less constrained panel holding compared to prior art techniques) while still maintaining a sufficient degree of precision for predictive shimming and shimless techniques. Simplified tool constraints on post-curing fixation may also provide further cost avoidance. The disclosed methods and systems generally involve establishing an outer mold line (OML) surface of a panel relative to an inner mold line (IML) surface of the panel.

[0010] One exemplary method for post-curing fixture calibration to determine deviations introduced to a panel during manufacturing includes performing a first scan to generate a first three-dimensional surface scan of the inner surface of the panel while the panel is fixed to a fixing tool or post-curing tool, and performing a second scan to generate a second three-dimensional surface scan of the inner surface of the panel while the panel is held in a reference configuration by a header structure. The fixing tool is configured to support the panel during the formation of the panel with the outer surface of the panel facing the fixing tool. The method also includes removing the panel from the fixing tool (or post-curing fixture) and fixing the panel to the header structure after the first scan has been performed. The header structure is specifically configured to hold the panel in a reference design state, and the difference between its two scans reflects the deviation present in the fixing tool or post-curing fixture. The method also includes determining a deformation function corresponding to the deviation between the first three-dimensional surface scan and the second three-dimensional surface scan.

[0011] Other methods of the present disclosure include mirror scanning for determining deviations introduced into a panel during manufacturing. Such methods include fixing a panel by holding it at at least two locations via a fixture. While the panel is held by the fixture, a first measurement scan is performed on the outer surface of the panel and a second measurement scan is performed on the inner surface of the panel. Each measurement scan is performed with respect to the same reference frame, resulting in a first three-dimensional surface scan of the outer surface of the panel and a second three-dimensional surface scan of the inner surface of the panel, respectively. The method also includes using the first and second three-dimensional surface scans to determine the IML surface of the panel relative to the OML surface and to characterize tool deviations of the fixing tool used to form the panel or the post-cured fixing tool. [Brief explanation of the drawing]

[0012] [Figure 1] This is a perspective view of the prior art of an aircraft that may be formed from one or more composite panel outer panels. [Figure 2]This is a composite panel outer casing, an example of prior art. [Figure 3a] An example of prior art is the inner frame of an aircraft wing assembly. [Figure 3b] Figure 3a shows a wing assembly of an aircraft from prior art, including the inner frame. [Figure 4] Prior art is an IML-controlled molding tool. [Figure 5] Prior art is the OML-controlled molding tool. [Figure 6] This is a schematic black-box diagram of a non-limiting example of a tool calibration system as disclosed herein. [Figure 7] This disclosure provides an example of a header structure used for tool calibration. [Figure 8] This disclosure provides an example of a composite panel that undergoes surface scanning while being constrained by a header structure. [Figure 9] Figure 7 is a close-up view of a part of the header structure. [Figure 10] This is an example of a composite panel, illustrating an example of mounting points for fixing the composite panel to a header structure, as disclosed herein. [Figure 11] This is a schematic flowchart illustrating the method for calibrating a fixing tool (and / or a cured fixing device) according to this disclosure. [Figure 12] This diagram shows a non-limiting example of a mirror-type scanning system for tool calibration as disclosed herein. [Figure 13] This is a schematic flowchart of the mirror-type scanning method described herein. [Modes for carrying out the invention]

[0013] The disclosed methods, systems, and apparatus are intended to identify and / or compensate for deviations occurring in fixing tools designed to hold parts, such as composite panel outer shells, during manufacturing (e.g., layup and curing) and / or deviations occurring in post-cured fixings designed to hold parts during post-curing manufacturing processes. Such disclosed methods, systems, and apparatus may be useful, for example, in shimless or predictive shimming applications and / or in the assembly of large-scale semi-adaptive structures, such as aircraft wing and fuselage manufacturing.

[0014] Generally, in the drawings, elements that are likely to be included in a given (i.e., a particular) embodiment are shown with solid lines, while elements that are optional to a given embodiment are shown with dashed lines. However, elements shown with solid lines are not essential to all embodiments, and they may be omitted from a given embodiment without departing from the scope of this disclosure. Similar or at least substantially similar elements are given similar numbers in the drawings, and these elements may not be described in detail when referring to each drawing herein. Similarly, not all elements are shown in every drawing, but the reference numbers associated with them may be used consistently herein. Elements, components and / or characteristics described herein with reference to one or more drawings may be included in and / or utilized in any other drawings without departing from the scope of this disclosure. Similarly, in diagrams showing flowcharts of methods, some steps are shown in dashed boxes, indicating that such steps may be optional or may correspond to an optional version of the method according to this disclosure. However, not all methods according to this disclosure must include steps enclosed in solid lines. As can be understood from the description herein, the methods and steps shown in the drawings are not limiting, and other methods and steps are within the scope of this disclosure and include methods having more or fewer steps than those exemplified.

[0015] Figure 6 schematically illustrates an example of a fixture calibration system 60 for determining deviations introduced to the panel during manufacturing. The system 60 generally includes a fixture tool 62, a header structure 64, a scanning device 66, and a processing unit 68. The fixture tool 62 supports the composite panel 70 during its formation. For example, the fixture tool 62 may be a layup mandrel into which multiple layers of composite material are laid and cured, and the layers of composite material form the composite panel 70 taking the shape of the fixture tool 62. In some examples, the fixture tool 62 may be OML-controlled so that the outer surface of the composite panel 70 faces the fixture tool 62 while the composite panel 70 is being formed. In these examples, the inner surface 72 faces away from the fixture tool 62 during formation. In other examples, the fixture tool 62 may be IML-controlled so that the inner surface 72 of the composite panel 70 faces the fixture tool 62 while the panel is being formed. In some examples of the system 60, the fixing tool 62 may be a post-curing fixture 63 designed to hold the composite panel 70 for post-curing processes such as trimming and drilling.

[0016] The scanning device 66 is configured to perform a first three-dimensional surface scan of the surface of the composite panel 70 facing away from the fixing tool 62 (or the cured fixing device 63). For example, the scanning device 66 may be configured to perform a first three-dimensional surface scan of the inner surface 72 of the composite panel 70 while the composite panel 70 is supported by the fixing tool 62 (for example, before the panel is removed from the layup mandrel or other fixing tool 62). After the first three-dimensional surface scan is performed, the composite panel 70 is removed from the fixing tool 62 (or the cured fixing device 63) and fixed to a header structure 64 configured to hold the composite panel 70 in a reference configuration. The reference configuration corresponds to the size and shape of the composite panel 70 as designed, and the header structure 64 is configured to hold and support the composite panel 70 in the correct reference configuration even if the composite panel 70 "springs off" the fixing tool 62 due to residual stress in the composite panel 70, thus deviating from its intended or designed reference configuration. In some examples, the header structure 64 may be formed from a material that is easy to manufacture or mold, and thus the header structure 64 may serve as a relatively inexpensive way to hold a composite panel 70 with as little deviation from a reference as possible. In one example, the header structure 64 may be formed from a foam header, but other materials are also within the scope of this disclosure. The header structure 64 also allows the composite panel 70 to be constrained at more joint surfaces than when the composite panel 70 is held by the fixing tool 62. Once the composite panel is fixed by the header structure 64, while the composite panel 70 is held in its reference configuration by the header structure 64, the scanning device 66 may then perform a second three-dimensional surface scan, which is also surface scanned during a first three-dimensional surface scan (e.g., the inner surface 72).

[0017] By comparing the first and second three-dimensional surface scans, the difference between the configuration of the composite panel 70 held by the fixing tool 62 (or the fixture 63 after curing) and the reference configuration of the composite panel 70 (held by the header structure 64) can be identified. Thus, the difference between the first three-dimensional surface scan and the second three-dimensional surface scan reflects the tool deviation present in the fixing tool 62 (or the fixture 63 after curing). The processing unit 68 is configured to analyze and process the first and second three-dimensional surface scans to determine a deformation function corresponding to the deviation between them.

[0018] The scanning device 66 may be a non-contact scanning device spaced apart from the composite panel 70 (or may include such a non-contact scanning device). For example, the scanning device 66 may take the form of a time-of-flight 3D laser scanner, a triangulation-based 3D laser scanner, a hand-held laser scanner, a structured light 3D scanner, a modulated light 3D scanner, a stereo video camera system, a photometric camera system, a laser pulse-based 3D scanner, a laser phase shift 3D scanner, and / or a lidar system. Additionally or alternatively, the scanning device 66 may be a contact scanning device configured to physically contact the composite panel 70 during scanning (or may include such a contact scanning device). For example, the scanning device 66 may take the form of a coordinate measuring machine (CMM), an articulated arm suspended from a gantry, and / or a touch probe.

[0019] Some systems 60 may include a vacuum system 74 configured to press the composite panel 70 against the header structure 64 until the composite panel 70 reaches its reference configuration.

[0020] Figure 7 shows an example of a header structure 64 in the form of a header structure 76, while Figure 8 shows an example of a composite panel 70 fixed to and supported by the header structure 76 while being scanned by an example of a scanning device 66. The examples in Figures 7-8 are not exclusive and do not limit the header structure 64, composite panel 70, or scanning device 66 to the embodiments shown in Figures 7-8. That is, the header structure 64, composite panel 70, and scanning device 66 are not limited to specific embodiments of those shown in Figures 7-8, and any number of configurations, configurations, features, properties, etc., can be incorporated without needing to include the various aspects, configurations, configurations, features, properties, etc., that are considered with reference to the schematic diagrams of Figure 6 and / or the embodiments in Figures 7-8, and their variations. For the sake of brevity, none of the aforementioned components, parts, sections, aspects, regions, etc., or their variations may be described, illustrated, and / or classified again in Figure 7-8; however, the use of the aforementioned features and variations, etc., in the examples shown in Figure 7-8 is within the scope of this disclosure.

[0021] As is most commonly seen in Figure 7, the header structure 76 includes multiple foam headers 78, but in other examples, headers formed from other materials may be used instead of the foam headers 78. The foam headers 78 are sized, shaped, and positioned relative to each other to hold the composite panel in its basic configuration. As shown in Figure 7, the foam headers 78 may be spaced apart from each other, with the foam headers 78 fixed to one or more elongated supports 80. In the example shown in Figure 7, the header structure 76 includes three elongated supports 80, with two outer supports 82 being longer than the intermediate support 84 and positioned on either side thereof. In other examples, other configurations of the elongated supports 80 may be used. For example, the header structure 64 may include more or fewer elongated supports 80, with more or fewer intermediate supports 84 and / or more or fewer outer supports 82. Each foam header 78 is generally fixed to at least two elongated supports 80, while one or more individual foam headers 78 may be fixed to different elongated supports 80 (and / or more or fewer elongated supports 80) than one or more other individual foam headers 78. For example, foam header 78a is fixed to both the outer support 82 and the intermediate support 84, while foam header 78b is fixed to the outer support 82 but not to the intermediate support 84. In some examples, the foam headers 78 are fixed to the elongated supports 80 and then machined in place to ensure that the header structure 76 is appropriately configured to constrain the composite panel as close as possible to its base configuration. Of course, other examples of the header structure 76 may include more or fewer foam headers 78, and the number and relative positioning of the foam headers 78 are determined by the specific needs of the header structure 76, as well as the shape, size, and / or complexity of the base configuration of the composite panel.

[0022] Each foam header 78 may include its own top surface 86 and its own bottom surface 88. Figure 9 shows a close-up view of a portion of the header structure 76 of Figure 7. As is best seen in Figure 9, the top surface 86 of one or more foam headers 78 includes a vacuum port grid 90, which may help position the composite panel onto the header structure 76. For example, the vacuum port grid 90 may include a plurality of grooves or channels, each of which allows the movement of air through a vacuum system (e.g., vacuum system 74) functionally coupled to the header structure 76. In some examples, the header structure 76 includes seals (e.g., rubber seals or gaskets) positioned within the grooves of the vacuum port grid 90, which help apply vacuum to the composite panel constrained by the header structure 76. When vacuum is drawn through the vacuum port grid 90, the composite panel is pulled and comes into contact with the top surface 86 of the foam header 78, thereby constraining the composite panel to its base configuration. Such a header structure 64, including a vacuum port grid 90 or other vacuum systems for securing composite panels to the header structure, is sometimes referred to as a vacuum fixture. In some examples, the location of the vacuum port grid 90 and / or the location of the holes that functionally connect the vacuum systems are selected to avoid interference from other manufacturing processes, such as drilling, which may occur while the composite panels are constrained and / or supported by the header structure 64.

[0023] The foam header 78 is generally positioned relative to an elongated support 80, with each lower surface 88 of the foam header 78 facing and / or engaging with (e.g., in contact with) the elongated support 80, while the upper surface 86 of the foam header 78 faces and engages with a composite panel supported and constrained by the header structure 76. As is most commonly seen in Figure 8, the composite panel 70 is fixed to the header structure 76, with the tool-side surface of the composite panel 70 facing the foam header 78. For example, for an OML-tooled composite panel (e.g., a composite panel formed by an outer surface or OML surface relative to a molding tool), the outer surface 73 is positioned against the upper surface 86 of the foam header 78, and while the composite panel 70 is held by the header structure 76, the inner surface 72 faces and is scanned by the scanning device 66.

[0024] The composite panel 70 is generally secured to the header structure 76 at multiple mounting points, but via at least two mounting points. For example, the composite panel 70 may be secured at at least one mounting point for each foam header 78. In some examples, the composite panel 70 may be secured at at least two mounting points for each foam header 78. In some examples, the composite panel 70 may be secured to a subset of the foam headers 78 of the header structure 76, while in other examples, the composite panel 70 may be secured to each foam header 78 of the header structure 76. In some examples, the mounting points are configured to be selectively controlled relative to each other in order to hold the composite panel 70 in its basic configuration. For example, the position and / or orientation of one or more of the foam headers 78 may be selectively adjustable to adjust how the composite panel 70 is held in the header structure 76. In some examples, the angle of each foam header 78 may be selectively adjusted with respect to one or more elongated supports 80, and / or each foam header 78 may be selectively translated along the length of one or more elongated supports 80. Additionally or alternatively, each of the one or more foam headers 78 may be machined or have additional material to selectively control one or more mounting points for holding the composite panel in its basic configuration.

[0025] In some examples, a header structure 64 (e.g., a header structure 76) may be configured to hold a composite panel at multiple joint surface locations, ensuring that the joint surface locations are precisely in place according to the basic configuration of the composite panel. For example, a header structure 64 may be designed and configured to hold a composite panel in its OML basic configuration at the locations of ribs and spars, so that the composite panel will connect (or mesh) with the ribs and spars of the wing assembly to which the composite panel will ultimately be attached. For example, Figure 10 shows an example of a composite panel 70 in the form of a composite panel 92. The composite panel 92 is designed to be attached to a rib-spar assembly (e.g., an inner frame 30 in Figure 3a), so that the composite panel 92 engages with the rib-spar assembly at a certain joint surface. For example, the composite panel 92 includes a spar flange joint surface 94 that extends substantially longitudinally along the composite panel 92, designed to engage with the spar flange of the rib-spar assembly when the panel is assembled. Similarly, the composite panel 92 includes a rib / shutter joint surface 96 designed to engage with the ribs and / or shutters of the rib-spar assembly when the composite panel is assembled. Some header structures 64 according to this disclosure are configured, in particular, to ensure that such spar flange joint surfaces 94 and rib / shutter joint surfaces 96 are held in a precise reference configuration when the composite panel 92 is held by the header structure 64. In some examples, the disclosed header structure 64 may be configured to restrict the composite panel at more joint surfaces than is permitted while the composite panel is secured to a fixing tool.

[0026] When in use, the system 60 and header structure 64 of Figure 6-9 may be used to calibrate a fixing tool (e.g., fixing tool 62) and / or a cured fixing device (e.g., cured fixing device 63) and to determine the deviations introduced into a panel (e.g., composite panel 70) during manufacturing. In certain examples, the system 60 and / or header structure 64 may be used in the manufacture of aircraft wing and / or fuselage panels. Additionally or alternatively, the system 60 and / or header structure 64 may be used in shimless or predictive shimming applications. Figure 11 schematically presents a flowchart representing an exemplary and non-limiting example of such a method 100 according to the present disclosure.

[0027] Method 100 generally includes, in 102, performing a first scan of the panel; in 104, removing the panel from the fixing tool or post-curing fixture; in 106, fixing the panel to a header structure (e.g., header structure 64); in 108, performing a second scan of the panel; and in 110, determining a deformation function, thereby determining the deviations introduced by the fixing tool or post-curing fixture while the panel was being formed. Performing the first scan of the panel in 102 is performed while the panel is fixed to the fixing tool (e.g., layup mandrel or other molding tool) or while the panel is fixed to a post-curing fixture. In the case of an OML-controlled fixing tool, while the panel is still on the fixing tool after curing, the outer surface of the panel faces the fixing tool, and therefore, performing the first scan in 102 would be performed by scanning the inner surface of the panel. Performing the first scan in 102 involves generating a first three-dimensional surface scan of the surface to be scanned (e.g., the inner surface of the panel). Of course, in the example where the fixing tool is an IML-controlled fixing tool, the first scan would be performed on the outer surface of the panel while the inner surface of the panel faces the fixing tool.

[0028] After the first scan is performed at 102, the panel is removed from the fixing tool or cured fixing device at 104 and then fixed to the header structure at 106, which is configured to hold the panel in a reference configuration corresponding to the size and shape of the panel as designed. At 106, once the panel is fixed in this manner and constrained by the header structure, a second scan is performed at 108 while the panel is being fixed to the header structure. Again, in the case of a panel formed on an OML-controlled fixing tool, at 106 the panel is fixed to the header structure, the outer surface of the panel faces the header structure, and therefore the second scan at 108 will be performed by scanning the inner surface of the panel. Performing the second scan at 108 involves generating a second three-dimensional surface scan of the surface being scanned (e.g., the inner surface of the panel). Of course, in the example where the fixing tool is an IML-controlled fixing tool, the second scan will be performed on the outer surface of the panel while the inner surface of the panel faces the header structure. During the second scan, the header structure holds the panel in its reference configuration, so the second three-dimensional surface scan represents the three-dimensional surface of the panel in its reference configuration. Therefore, any difference between the first three-dimensional surface scan and the second three-dimensional surface scan represents the difference or deviation between the configuration in which the panel was held while fixed to the fixing tool and the reference configuration of the panel. Determining the deformation function in 110 is used to determine the difference (deviation) between the first three-dimensional surface scan and the second three-dimensional surface scan, to map this deformation, and to determine the deviation present in the fixing tool or cured fixture, and thus to calibrate the fixing tool or cured fixture, and / or to use the fixing tool or cured fixture to explain such deviation from a given fixing tool or cured fixture during future panel manufacturing.

[0029] In some methods 100, determining the deformation function in 110 is performed by one or more processing units (e.g., processing unit 68). Once the deformation function for a particular panel is determined, this information may be used in 114 to assemble the panel with other components (e.g., to assemble a composite panel 70 into a rib-spar assembly of an aircraft wing), or in 112 to plastically deform or bend the panel (actually and / or physically). For example, the deformation function can indicate how to bend the panel during assembly with the rib-spar assembly so that the OML of the panel during assembly is as close as possible to a reference value. Additionally or alternatively, the deformation function may be used in 112 to bend the panel and minimize the gap between the panel and the assembly to which the panel is attached. Bending the panel in 112 may include deforming the inner and / or outer surfaces of the panel. Determining the deformation function in 110 may include identifying specific areas of the panel that deviate from the reference value, and / or the extent to which those areas deviate from the reference value. Determining the deformation function at 110 may also involve actually mapping such deviations and determining where the gaps will be located when attempting to assemble the panels with the rest of the structure.

[0030] Some methods 100 include drawing a vacuum at 116 to hold the panel against the header structure in a basic configuration. Additionally or alternatively, some methods 100 include forming a header structure from a plurality of foam headers (e.g., foam headers 78) at 118 and / or confirming at 120 that the header structure is configured to hold the panel in a basic configuration. Forming the foam header at 118 may include positioning the foam header so as to support all important joint surfaces of the panel. For example, the foam header may be positioned to support the surface of the panel that will join or engage with the rest of the assembly. In a particular example, forming the header structure at 118 may include positioning the foam header so as to support the spar flange joint surface and / or the rib / shutter joint surface of the panel.

[0031] Performing a first scan at 102 and a second scan at 108 may be performed using the same scanning device (e.g., scanning device 66) or different scanning devices. In some examples, performing a first scan at 102 and / or a second scan at 108 may include scanning the panel using a non-contact scanning device such as a time-of-flight 3D laser scanner, a triangulation-based 3D laser scanner, a handheld laser scanner, a stereoscopic illumination 3D scanner, a modulated light 3D scanner, a stereoscopic video camera system, a photometric camera system, a laser pulse-based 3D scanner, a laser phase-shift 3D scanner, and / or a LiDAR system. Additionally or alternatively, performing a first scan at 102 and / or a second scan at 108 may include scanning the panel using a contact scanning device configured to physically contact the panel during scanning, such as a coordinate measuring machine (CMM), an articulated arm suspended from a traveling carriage, and / or a touch probe. Performing a first scan in 102 and / or a second scan in 108 may include laser scanning (e.g., 3D laser scanning), optical scanning, computed tomography scanning, stereoillumination scanning, conoscopy holography, photogrammetry, contact-based 3D scanning, and / or laser pulse scanning.

[0032] In some methods 100, determining the deformation function in 110 may involve establishing the IML plane of the panel relative to the OML plane of the panel using a first three-dimensional surface scan and a second three-dimensional surface scan. One or more processing units may be used to determine the IML plane relative to the OML plane.

[0033] Method 100 may be performed multiple times to characterize a set of panels (e.g., a set of panel skins for one or more aircraft wings). A set of first and second 3D surface scans provided may be used to characterize a set of panels and form a dataset of offset distances between the IML and OML surfaces of each panel. Information from such features, first and second 3D surface scans, and / or deformation functions may also be used for predictive shimming, along with known data analysis.

[0034] Additionally or alternatively, some methods 100 include compensating for deviations in 122. For example, compensating for deviations in 122 may include using a deformation function to compensate for deviations of the outer surface of the panel compared to a reference configuration of the panel. Similarly, compensating for deviations in 122 may include using a deformation function to compensate for deviations of the inner surface of the panel compared to a reference configuration of the panel. In some examples, compensating for deviations in 122 includes applying a deformation function to correct tool deviations of the fixed tool during the subsequent manufacturing of panels on the fixed tool. Additionally or alternatively, compensating for deviations in 122 may include using an established deformation function to compensate for machining of holes in the panel.

[0035] Figures 12 and 13 schematically illustrate a system 200 (Figure 12) that may be used to perform a mirror-type scanning method 300 (Figure 13) for determining deviations introduced into a panel during manufacturing. Similar to the methods and systems described with respect to Figure 6-11, the systems and methods of Figure 12-13 may be used to determine a deformation function of deviations present in a fixed tool, to compensate for such deviations, and / or, for a given panel, to determine the OML surface relative to the IML surface (or vice versa). While the systems and methods of Figure 6-11 generally involve scanning one surface of the panel at two different times, the systems and methods of Figure 12-13 generally involve scanning two different surfaces of the panel using a shared reference frame.

[0036] The system 200 generally includes a fixture 202 configured to hold a panel 204 (an example of a composite panel 70) at at least two locations, mounting points, or fixing points 206, 206'. The fixture 202 is configured to hold the panel 204, with both the inner surface 208 and the outer surface 210 (opposite the inner surface 208) positioned so that a three-dimensional surface scan is performed on both sides thereof. Figure 12 shows the panel 204 held substantially vertically, but in other examples, the panel 204 may be held substantially horizontally or in other configurations.

[0037] System 200 also includes a first scanning device 212 and a second scanning device 214. The first scanning device 212 is configured to perform and generate a first three-dimensional surface scan of the inner surface 208 with respect to a reference frame 216. The second scanning device 214 is configured to perform and generate a second three-dimensional surface scan of the outer surface 210 with respect to the same reference frame 216. As shown in Figure 12, the first scanning device 212 may be positioned on one side of the panel 204 (e.g., facing the inner surface 208), while the second scanning device 214 may be positioned on the opposite side of the panel 204 (e.g., facing the outer surface 210). In other examples, the first and second scanning devices 212, 214 may be positioned such that one is perpendicular to the bottom of the panel 204, while the other is perpendicular to the top of the panel 204, for example, when the panel 204 is held substantially horizontally by a fixture 202. Of course, any configuration is also within the scope of this disclosure, and such mirror-type scanning may be performed by arranging the first and second scanning devices 212, 214 to scan the opposite side of the panel 204.

[0038] In some examples, the first scanning device 212 may scan the inner surface 208 substantially simultaneously with the second scanning device 214 scanning the outer surface 210. In other examples, such first and second scans may be performed at different times. In some examples, a single scanning device may be used to perform the first and second surface scans. For example, a single scanning device (e.g., scanning device 212 or 214) may be used to scan the inner surface 208, and then the scanning device may be moved to position it to scan the outer surface 210. Alternatively, the panel 204 may move between the first and second scans, with the scanning devices relatively stationary, while the panel 204 is oriented to a first orientation during the first three-dimensional surface scan and to a second orientation during the second three-dimensional surface scan. For example, the panel 204 may be positioned such that its inner surface 208 faces the scanning device during the first scan, and its outer surface 210 faces the scanning device during the second scan.

[0039] A fixture 202 is shown that includes a first mounting point 206 and a second mounting point 206' configured to hold the panel 204, but in other examples, the fixture 202 may include more or fewer mounting points 206. In some examples, each mounting point 206 may be selectively controlled (e.g., positioned) relative to one another and configured to position and / or hold the panel 204 as desired.

[0040] The system 200 may include a processing unit 218 configured to determine the inner surface 208 relative to the outer surface 210 (or vice versa) using a first three-dimensional surface scan and a second three-dimensional surface scan. In this way, the processing unit 218 is further configured to characterize the tool deviation of the fixing tool used to form the panel 204. The fixing tool 202 is generally not a fixing tool used to form the panel 204 (typically such as a fixing tool that does not allow access to both sides of the panel), but in some cases the fixing tool 202 may be a fixing tool used to form the panel (or composite structure).

[0041] The first scanning device 212 and / or the second scanning device 214 may be, or include, non-contact scanning devices that are spaced away from the panel, such as time-of-flight 3D laser scanners, triangulation-based 3D laser scanners, handheld laser scanners, stereoscopic illumination 3D scanners, modulated light 3D scanners, stereoscopic video camera systems, photometric camera systems, laser pulse-based 3D scanners, laser phase-shift 3D scanners, and / or LiDAR systems. Additionally or alternatively, the first scanning device 212 and / or the second scanning device 214 may be, or include, contact scanning devices configured to physically contact the panel during scanning, such as coordinate measuring machines (CMMs), articulated arms suspended from a mobile carriage, and / or touch probes.

[0042] In use, the system 200 and / or the fixture 202 may be used, for example, in the manufacture of aircraft wing and / or fuselage panels. Additionally or alternatively, the system 200 and / or the fixture 202 may be used in shimless or predictive shimming applications. Referring to Figure 13, a mirror-type scanning method 300 for determining the deviation introduced to a panel (e.g., panel 204) during manufacturing may be performed using the system 200. Method 300 generally involves fixing the panel in 302 by holding the panel at at least two locations via a fixture (e.g., fixture 202). Once the panel is thus fixed, a first measurement scan may be performed in 304 on a first surface of the panel (e.g., outer surface 210) (e.g., a scan with a second scanning device 214), and a second measurement scan may be performed in 306 on a second surface of the panel (e.g., inner surface 208) (e.g., a scan with a first scanning device 212). Performing a first measurement scan in 304 is performed with respect to the same reference frame (e.g., reference frame 216) as performing a second measurement scan in 306. Performing a first measurement scan in 304 generates a first 3D surface scan of a first surface of the panel, and performing a second measurement scan in 306 generates a second 3D surface scan of a second surface of the panel. Method 300 also includes, during the first and second 3D surface scans, determining the IML surface relative to the OML surface of the panel in 308 (e.g., determining the inner surface relative to the outer surface, and / or vice versa). Thus, the tool deviation of the fixed tool used to form the panel can be characterized. Such determination of surfaces relative to each other and / or characterization of tool deviation in 308 may, in some examples, be performed by one or more processing units (e.g., processing unit 218).

[0043] In some methods 300, the first measurement scan performed in 304 may be performed substantially simultaneously with the second measurement scan performed in 306. In other examples, the first measurement scan in 304 may be performed before the second measurement scan in 306, or vice versa. In some examples, when both the first and second measurement scans are being performed, the first and second measurement scans may be staggered so that their durations overlap, with one measurement scan starting before the other, and / or the other measurement scan following the completion of the first measurement scan. The first and second measurement scans in 304 and 306 are generally performed while the panel is positioned on the fixtures that have been moved after curing, but in some examples, the first and / or second measurement scans in 304 and 306 may be performed while the panel is positioned on the mandrel or other molding tools used to manufacture the panel. In some examples, the mandrel itself may be scanned in 308 (for example, after the panel has been removed from the mandrel) to determine the IML plane relative to the OML plane. For example, a measurement scan may be performed in 306 to establish the IML plane of the panel, and then (in the case of an OML-controlled mandrel) the mandrel may be scanned to establish the OML plane.

[0044] Some methods 300 include using a first 3D surface scan in 310 to identify a set of reference geometric shapes. For example, the first 3D surface scan may be used to identify and position one or more reference features of the panel being scanned. Additionally or alternatively, a reference frame may be formed in 314 to align the first and second 3D surface scans. In some examples, forming a reference frame in 314 may involve using known references from the inner and outer surfaces of the panel.

[0045] In some methods 300, at least a portion of the panel may be machined in 312 after the IML surface has been determined relative to the OML surface in 308. For example, if it is determined that the IML surface of the panel will not engage properly with the assembly because tool deviation is converted into the finished IML surface, a suitable portion of the IML surface may be machined or sacrificial material added in 312 to bring the IML surface within an acceptable range and engage with the rest of the assembly.

[0046] Method 300 may include compensating for tool deviations identified by comparing first and second 3D surface scans in 316. For example, the first and second 3D surface scans may be analyzed in combination with known data analysis to correct for tool deviations observed in manufacturing. Correcting for tool deviations in 316 may include forming a dataset representing the offset distance between the IML surface and the OML surface. Additionally or alternatively, correcting for tool deviations in 316 may include analytically deforming the OML surface to an actual reference configuration.

[0047] This disclosure generally describes methods, systems, and header structures in light of the manufacture of aircraft panel skins, but the disclosed methods, systems, and header structures may be useful in the manufacture of panel skins for other applications and / or other composite structures. For example, this disclosure is not limited to aircraft and aircraft applications. Other devices that may consist of composite panel skins include, but are not limited to, spacecraft, ships, land vehicles, wind turbines, structural towers and masts. Furthermore, although aircraft 14 is shown as a fixed-wing passenger aircraft in Figure 1, aircraft 14 may take any suitable form, including commercial aircraft, military aircraft, civilian aircraft, helicopters, or any other suitable aircraft.

[0048] Exemplary and non-limiting examples of the subject matter of the inventions described herein are listed in the following paragraphs. A1. A method for calibrating a fixed tool to determine the deviations introduced to a panel, including its outer and inner surfaces, during manufacturing, Performing a first scan to generate a first three-dimensional (3D) surface scan of the inner surface of the panel while the panel is fixed to a fixing tool, wherein the fixing tool is configured to support the panel during its formation so that the outer surface of the panel faces the fixing tool. This involves removing the panel from the fixing tool after performing the first 3D surface scan, The panel is fixed to a header structure configured to hold the panel in a standard configuration, thereby holding the panel in the standard configuration, wherein the standard configuration corresponds to the size and shape of the panel as designed, and the panel is fixed and thereby held. While the panel is held in a base configuration by the header structure, a second scan is performed to generate a second 3D surface scan of the inner surface of the panel, To determine the deformation function corresponding to the deviation between the first 3D surface scan and the second 3D surface scan. A method that includes this. A1.1. The method according to paragraph A1, wherein determining the transformation function is performed by at least one processing unit. A2. The method described in paragraph A1 or A1.1, wherein the fixing tool includes a layup mandrel. A3. The method described in any of paragraphs A1-A2, wherein the panel includes a composite panel. A4. The method described in any of paragraphs A1-A3, wherein the header structure includes multiple foam headers. A5. The method according to any of paragraphs A1-A4, wherein the header structure is configured to hold the panels in their OML base configuration at the positions of the panel ribs and spars. A6. The method according to any of paragraphs A1-A5, wherein holding the panel in a reference configuration includes drawing it into a vacuum, thereby pressing the panel against the header structure until the panel is in a reference configuration. A7. The method according to any of paragraphs A1-A6, wherein fixing involves deforming the inner and / or outer surfaces of the panel. A8. Forming the header structure from multiple foam headers, Ensure that the header structure is configured to hold the panel in the base configuration. The method described in any of paragraphs A1-A7, further including the method described in any of paragraphs A1-A7. A9. The method according to paragraph A8, comprising positioning a foam header such that it forms a header structure that supports all important joint surfaces of the panel. A10. The method according to any of paragraphs A1-A9, wherein performing a first scan involves scanning a panel using a 3D scanning device, and performing a second scan involves scanning a panel using a 3D scanning device. A10.1. The method according to paragraph A10, wherein the 3D scanning device includes a non-contact scanning device that is spaced apart from the panel. A10.2. The method according to paragraph A10.1, wherein the 3D scanning device includes a time-of-flight 3D laser scanner, a triangulation-based 3D laser scanner, a handheld laser scanner, a stereoscopic illumination 3D scanner, a modulated light 3D scanner, a stereoscopic video camera system, a photometric camera system, a laser pulse-based 3D scanner, a laser phase-shift 3D scanner, and / or a lidar system. A10.3. The method according to paragraph A10, comprising a contact scanning device configured to physically contact a panel during scanning. A10.4. The method according to any of paragraph A10.3, wherein the 3D scanning device includes a coordinate measuring machine (CMM), an articulated arm suspended from a traveling carriage, and / or a touch probe. A11. The method according to any of paragraphs A1-A10.4, wherein performing a first scan includes laser scanning (e.g., 3D laser scanning), optical scanning, computed tomography scanning, stereoillumination scanning, conoscopy holography, photogrammetry, contact-based 3D scanning, and / or laser pulse scanning, and performing a second scan includes laser scanning (e.g., 3D laser scanning), optical scanning, computed tomography scanning, stereoillumination scanning, conoscopy holography, photogrammetry, contact-based 3D scanning, and / or laser pulse scanning. A12. A method according to any of paragraphs A1-A11, wherein determining the transformation function involves mapping the transformation function. A12.1. The method described in paragraph A12, wherein the mapping of the transformation function is performed by at least one processing unit. A13. The method according to any of paragraphs A1-A12.1, further comprising using a first 3D surface scan and a second 3D surface scan to establish an IML surface of a panel relative to an OML surface of the panel. A13.1. The method according to paragraph A13, wherein establishing the IML plane of a panel relative to the OML plane of a panel is performed by at least one processing unit. A14. Use a deformation function to compensate for any deviation of the outer surface compared to the panel's standard configuration. The method described in any of paragraphs A1-A13.1, further including the method described in any of paragraphs A1-A13.1. A15. Use a transformation function to compensate for any deviations in the inner surface compared to the standard configuration of the panel. The method described in any of paragraphs A1-A14, further including the method described in any of paragraphs A1-A14. A16. Applying a deformation function to compensate for tool deviation of the fixed tool during the fabrication of the second panel of the fixed tool. The method described in any of paragraphs A1-A15, further including the method described in any of paragraphs A1-A15. A17. The method according to any of paragraphs A1-A16, further comprising using a deformation function to compensate for machining of holes in the second panel. A18. The method according to any of paragraphs A1-A17, further comprising performing a first 3D surface scan and a second 3D surface scan on a pair of panel casings to characterize the pair of panel casings and generating a dataset of offset distances between the IML surface of each panel casing of the pair of panel casings and the OML surface of each panel casing of the pair of panel casings. A19. The method described in any of paragraphs A1-A18, further comprising using a transformation function in combination with known data analysis to perform predictive shimming. A20. The method described in any of paragraphs A1-A19, further comprising using a deformation function to actually bend the panel to its OML base configuration.

[0049] B1. A mirror-type scanning method for determining deviations introduced to a panel, including its outer and inner surfaces, during manufacturing, The panel is secured by holding it in at least two places via fasteners, With respect to the reference frame, a first measurement scan is performed on the outer surface of the panel, thereby generating a first 3D surface scan of the outer surface of the panel. With respect to the reference frame, a second measurement scan is performed on the inner surface of the panel, thereby generating a second 3D surface scan of the inner surface of the panel, opposite to the outer surface. Using the first and second 3D surface scans, the IML surface is determined relative to the OML surface, thereby characterizing the tool deviation of the fixing tool used to form the panel. A method that includes this. B1.1. The method according to paragraph B1, wherein determining the IML plane relative to the OML plane is performed by at least one processing unit. B2. The method according to paragraph B1 or B1.1, further comprising using a first 3D surface scan to identify a set of reference geometric shapes. B3. The method according to any of paragraphs B1-B2, further comprising machining a portion of the panel after determining the IML surface relative to the OML surface. B4. The method of any of paragraphs B1-B3, further comprising analytically transforming the OML surface into an actual reference configuration. B5. The method described in any of paragraphs B1-B4, wherein the first measurement scan and the second measurement scan are performed substantially simultaneously. B6. The method according to any of paragraphs B1-B5, further comprising generating a reference frame and aligning a first 3D surface scan and a second 3D surface scan using known criteria from the inner and outer surfaces. B7. The method according to any of paragraphs B1-B6, further comprising using a first 3D surface scan and a second 3D surface scan in combination with known data analysis to correct for tool deviations observed in manufacturing and generate a dataset that displays the offset distance between the IML surface and the OML surface. B8. Performing a first measurement scan and / or a second measurement scan is performed while the panel is positioned on the mandrel used in the manufacture of the panel, as described in any of paragraphs B1-B7.

[0050] C1. A fastener for holding composite components, At least a first and a second mounting point configured to hold a composite component for machining after hardening, the first and second mounting points being selectively controlled relative to each other and configured to hold a composite component. Fixing devices including a fastener. C1.1 The fastener described in paragraph C1, wherein the fastener is configured to hold a composite component in its basic configuration. C2. The fastener described in paragraph C1 or C1.1, wherein the fastener comprises multiple foam headers. C3. The fastener according to any of paragraphs C1-C2, wherein the fastener is configured to hold a composite component, and the first surface and the second surface of the composite component are simultaneously surface-scanned, with the first surface on the opposite side of the second surface. C4. A fixture according to any of paragraphs C1-C3, wherein the fixture is configured to hold the composite component in its OML standard configuration at the locations of the ribs and spars of the composite component. C5. The fixture according to any of paragraphs C1-C4, comprising a vacuum system configured to press the composite component against a first mounting point and a second mounting point so that the composite component becomes its basic configuration.

[0051] D1. A system for calibrating fixtures to determine deviations introduced into composite panels during manufacturing, A fixing tool configured to support a composite panel during its formation such that the outer surface of the composite panel faces the fixing tool when the composite panel is supported by the fixing tool, A scanning device configured to perform a first 3D surface scan of the inner surface opposite the outer surface of the composite panel while the composite panel is supported by a fixing tool, A header structure configured to hold a composite panel in a standard configuration, wherein the standard configuration corresponds to the size and shape of the composite panel as designed, and the header structure is configured to hold the composite panel so that a scanning device can perform a second 3D surface scan on the inner surface of the composite panel while the composite panel is held by the header structure. A processing unit configured to determine a deformation function corresponding to the deviation between a first 3D surface scan and a second 3D surface scan. A system that includes this. D2. The system described in paragraph D1, configured to perform any of the methods described in paragraphs A1-A20. D3. A system described in any of paragraphs D1-D2, wherein the fixing tool includes a layup mandrel. D4. A system described in any of paragraphs D1-D3, wherein the header structure includes a fastener described in any of paragraphs C1-C5. D5. The system according to any of paragraphs D1-D4, wherein the scanning device includes a non-contact scanning device that is spaced apart from the composite panel. D6. A system as described in any of paragraphs D1-D5, wherein the scanning device includes a time-of-flight 3D laser scanner, a triangulation-based 3D laser scanner, a handheld laser scanner, a stereoscopic illumination 3D scanner, a modulated light 3D scanner, a stereoscopic video camera system, a photometric camera system, a laser pulse-based 3D scanner, a laser phase-shift 3D scanner, and / or a lidar system. D7. The system according to any of paragraphs D1-D6, including a contact scanning device configured to physically contact a composite panel during scanning. D8. The system according to any of paragraphs D1-D7, wherein the scanning device includes a coordinate measuring machine (CMM), an articulated arm suspended from a traveling carriage, and / or a touch probe. D9. The system according to any of paragraphs D1-D8, further comprising a vacuum system configured to press the composite panel into a header structure until the composite panel is in its basic configuration.

[0052] E1. A mirror-type scanning system for determining deviations introduced to a panel during manufacturing, A fixture configured to hold the panel in at least two locations such that the inner and outer surfaces of the panel are configured to be subjected to 3D surface scanning, wherein the inner surface is on the opposite side of the outer surface, With respect to the reference frame, a first scanning device is configured to perform and generate a first 3D surface scan on the inner surface of the panel, With respect to the reference frame, a second scanning device is configured to perform and generate a second 3D surface scan on the outer surface of the panel, A processing unit configured to determine an IML surface relative to an OML surface using a first 3D surface scan and a second 3D surface scan, further configured to characterize the tool deviation of a fixed tool used to form a panel. A system that includes this. E2. The system described in paragraph E1, configured to perform any of the methods described in paragraphs B1-B8. E3. The system according to any one of paragraphs E1-E2, wherein the first scanning device and / or the second scanning device includes a non-contact scanning device spaced apart from the panel. E4. A system according to any of paragraphs E1-E3, wherein the first scanning device and / or the second scanning device includes a time-of-flight 3D laser scanner, a triangulation-based 3D laser scanner, a handheld laser scanner, a stereoscopic illumination 3D scanner, a modulated light 3D scanner, a stereoscopic video camera system, a photometric camera system, a laser pulse-based 3D scanner, a laser phase-shift 3D scanner, and / or a lidar system. E5. The system according to any of paragraphs E1-E4, wherein the first scanning device and / or the second scanning device include a contact scanning device configured to physically contact the panel during scanning. E6. The system according to any of paragraphs E1-E5, wherein the first scanning device and / or the second scanning device includes a coordinate measuring machine (CMM), an articulated arm suspended from a traveling carriage, and / or a touch probe.

[0053] F1. Use of fasteners described in any of paragraphs C1-C5 for the fabrication of aircraft wing and / or fuselage panels. F2. Use of any of the fixtures described in paragraphs C1-C5 for shimless or predictive shimming applications. F3. Use of fasteners described in any of paragraphs D1-D9 for the fabrication of aircraft wing and / or fuselage panels. F4. Use of any of the fixtures described in paragraphs D1-D9 for shimless or predictive shimming applications. F5. Use of fasteners described in any of paragraphs E1-E6 for the fabrication of aircraft wing and / or fuselage panels. F6. Use of any of the fixtures described in paragraphs E1-E6 for shimless or predictive shimming applications.

[0054] In this specification, the terms “selective” and “selectively” mean that, when modifying the operation, movement, configuration, or other function of one or more components of the device, or the characteristics of one or more components of the device, the particular operation, movement, configuration, or other function is a direct or indirect result of the user operating one aspect of the device or one or more components.

[0055] In this specification, the terms “adapted” and “configured” mean that an element, component, or other object is designed and / or intended to perform a given function. Therefore, the use of the terms “adapted” and “configured” should not be interpreted as meaning that a given element, component, or other object is merely “capable of” performing a given function, but rather as meaning that these elements, components, and / or other objects are specifically selected, produced, implemented, utilized, programmed, and / or designed for the purpose of performing that function. The scope of this disclosure also includes the possibility that an element, component, and / or other object described as adapted to perform a particular function may be described as configured to perform that function additionally or alternatively, and vice versa. Similarly, an object described as configured to perform a particular function may also be described as operable to perform that function additionally or alternatively.

[0056] When used herein, a processing unit may be any suitable one or more devices configured to perform the functions of a processing unit as described herein. For example, a processing unit may include one or more electronic controllers, dedicated controllers, special-purpose controllers, personal computers, special-purpose computers, display devices, logic devices, memory devices, and / or memory devices having a computer-readable medium suitable for storing computer-executable instructions for implementing aspects of the systems and / or methods described herein.

[0057] Additionally or alternatively, the processing unit may include, or be configured to read, non-transient, computer-readable storage or memory, media suitable for storing computer-executable instructions or software for implementing the methods or steps of the methods disclosed herein. Examples of such media include CD-ROMs, disks, hard drives, flash memory, and the like. When used herein, the computer-executable instructions, as well as the storage, memory, devices, and media having computer implementation methods and other methods, as disclosed herein are deemed to fall within the scope of subject matter that may be patented pursuant to Title 35, Section 101 of the U.S. Federal Code.

[0058] As used herein, the expression "at least one" relating to one or more item lists means at least one item selected from one or more items in the item list, but it should be understood that this does not necessarily mean that it must include at least one of each item specifically listed in the item list, nor does it exclude any combination of items in the item list. This provision also acknowledges that, regardless of whether the expression "at least one" relates to or does not relate to these specifically identified items, there may optionally be items other than those specifically identified in the item list. Therefore, as a non-restrictive example, “at least one of A and B” (or similarly, “at least one of A or B,” or similarly, “at least one of A and / or B”) means, in one embodiment, at least one, optionally including two or more A's and no B (and optionally including items other than B); in another embodiment, at least one, optionally including two or more B's and no A (and optionally including items other than A); and in yet another embodiment, at least one, optionally including two or more A's, and at least one, optionally including two or more B's (and optionally including other items). In other words, the expressions “at least one,” “one or more,” and “and / or” are conjunctive and separable non-restrictive expressions in their function. For example, the expressions "at least one of A, B, and C", "at least one of A, B, or C", "one or more of A, B, and C", "one or more of A, B, or C", and "A, B, and / or C" can mean A only, B only, C only, A and B together, A and C together, B and C together, A, B, and C together, and optionally, any of the above combined with at least one other item.

[0059] The various elements and steps of the apparatus disclosed herein are not required for all of the apparatuses and methods disclosed herein, and this disclosure includes all novel and inventive combinations and partial combinations of the various elements and steps disclosed herein. Furthermore, one or more of the various elements and steps disclosed herein may constitute an independent subject matter separate from the entire disclosed apparatus or method. Accordingly, such subject matter does not need to be related to any specific apparatus or method explicitly disclosed herein, and such subject matter may provide usefulness in apparatuses and / or methods not explicitly disclosed herein.

[0060] As used herein, when the expressions “for example,” “as an example,” and / or the term “example” are used in relation to one or more components, features, details, structures, embodiments, and / or methods provided herein, they are intended to convey that the aforementioned components, features, details, structures, embodiments, and / or methods are illustrative and non-limiting examples of the components, features, details, structures, embodiments, and / or methods provided herein. Therefore, the aforementioned components, features, details, structures, embodiments, and / or methods are not intended to be limiting, required, or restrictive / exclusive. Other components, features, details, structures, embodiments, and / or methods, including structurally and / or functionally similar and / or equivalent components, features, details, structures, embodiments, and / or methods, are also included within the scope of this disclosure.

Claims

1. A mirror-type scanning method (300) for determining deviations introduced to a panel (70) including an outer surface (73) and an inner surface (72) during manufacturing, The panel (70) is fixed (302) by holding the panel (70) at at least two locations via fasteners, With respect to one shared reference frame (216), a first measurement scan is performed on the outer surface (73) of the panel (70) (304) to generate a first 3D surface scan of the outer surface (73) of the panel (70), With respect to one shared reference frame (216), a second measurement scan is performed on the inner surface (72) of the panel (70) (306) to generate a second 3D surface scan of the inner surface (72) of the panel (70) opposite to the outer surface (73), Using the first 3D surface scan and the second 3D surface scan, the inner surface (72) is determined relative to the outer surface (73) as data characterizing the tool deviation of the fixture (308) Includes, Method (300), wherein the fastener is a fastening tool used to form the panel (70).

2. A mirror-type scanning method (300) for determining a deviation introduced to a panel (70) including an outer surface (73) and an inner surface (72) during manufacturing, The panel (70) is fixed (302) by holding the panel (70) at at least two locations via fasteners, With respect to one shared reference frame (216), a first measurement scan is performed on the outer surface (73) of the panel (70) (304) to generate a first 3D surface scan of the outer surface (73) of the panel (70), With respect to one shared reference frame (216), a second measurement scan is performed on the inner surface (72) of the panel (70) (306) to generate a second 3D surface scan of the inner surface (72) of the panel (70) opposite to the outer surface (73), Using the first 3D surface scan and the second 3D surface scan, determine the inner surface (72) relative to the outer surface (73) as data characterizing the deviation caused by the fixture (308) A method including (300).

3. The method according to claim 1 or 2 (300), further comprising machining a part of the panel (70) (312) after determining the inner surface (72) with respect to the outer surface (73) (308).

4. The method according to any one of claims 1 to 3 (300), further comprising analytically deforming the outer surface (73) to an actual standard configuration.

5. The method according to any one of claims 1 to 4 (300), wherein performing the first measurement scan (304) and performing the second measurement scan (306) are performed substantially simultaneously.

6. The method according to any one of claims 1 to 5 (300), further comprising generating a shared reference frame (216) (314) and aligning the first 3D surface scan and the second 3D surface scan using known references from the inner surface (72) and the outer surface (73).

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