Dynamic indexing for moving parts in a fabrication environment

Patent metadata

Field	Value
Publication number	US-11953880-B2
Application number	US-202117454252-A
Country	US
Kind code	B2
Filing date	Nov 10, 2021
Priority date	Nov 18, 2020
Publication date	Apr 9, 2024
Grant date	Apr 9, 2024

Abstract

Systems and methods are provided for indexing a layup mandrel. 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, 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.

First claim

What is claimed is:

1. A method for indexing a layup mandrel for a composite part, the method comprising:
identifying a first side surface and a layup surface of the layup mandrel, wherein the layup mandrel travels in a process direction between serially arranged workstations during fabrication of the composite part;
placing a lamination head in contact with the first side surface;
traversing the first side 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 first side 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 on the layup surface at the layup mandrel, based on a difference between an alignment of the layup mandrel and a nominal alignment of the layup mandrel.

2. The method of claim 1 wherein:
traversing the first side surface comprises holding a roller of the lamination head in contact with the first side surface, the roller traversing the first side surface in accordance with an indexing NC program that directs the roller to follow a nominal path along the layup mandrel, the roller deflecting when the first side surface deviates from the nominal path;
comparing the acquired stream of 3D coordinates to the nominal path to determine differences in position from the nominal path; and wherein
altering comprises integrating the differences into the NC program that directs the layup of the fiber reinforced material at the layup mandrel.

3. The method of claim 1 wherein acquiring the stream of 3D coordinates of the lamination head comprises measuring positional offsets of components of a suspension that enable a roller of the lamination head to deflect for later comparison to a nominal path.

4. The method of claim 1 further comprising:
laying up a laminate onto the layup mandrel in accordance with the NC program;
acquiring a second stream of 3D coordinates of a roller of the lamination head during the laying up;
transporting the layup mandrel in the process direction to a downstream lamination head;
passing the second stream of 3D coordinates to a controller of the downstream lamination head; and
determining an alignment of the layup mandrel at the downstream lamination head based on the second stream of 3D coordinates.

5. The method of claim 4 further comprising:
placing the roller in contact with a second side surface of the layup mandrel;
traversing the second side surface with the roller of the lamination head; and
acquiring the second stream of 3D coordinates of the roller as the roller traverses the second side surface.

6. The method of claim 5 further comprising:
operating the lamination head in accordance with the NC program to lay up fiber reinforced material in a layup region between the first side surface and the second side surface.

7. The method of claim 1 further comprising altering the NC program in real time to accommodate a thickness of fiber reinforced material already placed upon the layup mandrel.

8. A method for indexing a rigid tool for a composite part, the method comprising:
identifying a groove formed in the rigid tool and that extends in a process direction, wherein the rigid tool travels in the process direction during fabrication of the composite part;
placing an indexing head with respect to the groove;
traversing the indexing head along the groove;
acquiring a stream of 3D coordinates of the indexing head as the indexing head traverses the groove;
determining an alignment of the rigid tool based on the stream of 3D coordinates; and
altering a Numerical Control (NC) program that directs work at the rigid tool, based on a difference between the alignment of the rigid tool and a nominal alignment of the rigid tool.

9. The method of claim 8 wherein the groove includes a non-repeating series of unique curves, the method further comprising identifying a position of the indexing head at the rigid tool, based on 3D coordinates in the stream that are indicative of one of the unique curves in the non-repeating series.

10. The method of claim 8 wherein:
identifying the groove upon the rigid tool comprises one or more of:
identifying a continuous protrusion upon the rigid tool; and
identifying one or more lines upon the rigid tool; and

placing the indexing head with respect to the groove comprises one or more of:
mating rollers of the indexing head with the continuous protrusion; and
tracking the one or lines using one or more cameras.

11. The method of claim 8 wherein the rigid tool includes a first groove and a second groove that both extend in a process direction, and wherein:
traversing the indexing head comprises traversing both the first groove and the second groove using at least one indexing head;
acquiring a stream of 3D coordinates comprises acquiring a stream of 3D coordinates for each of the first groove and the second groove; and
determining an alignment of the rigid tool comprises determining the alignment of the rigid tool based on both streams of 3D coordinates.

12. The method of claim 8 wherein placing the indexing head with respect to the groove comprises pressing an indexing end of the indexing head into the groove.

13. The method of claim 12 wherein traversing the indexing head along the groove comprises moving the indexing head along a nominal path, with the indexing end remaining in the groove.

14. The method of claim 13 wherein acquiring the stream of 3D coordinates of the indexing head comprises determining deflections of the indexing head from the nominal path as the indexing end travels along the groove.

15. The method of claim 8 further comprising:
replacing the indexing head with a lamination head; and
performing layup by dispensing fiber reinforced material from the lamination head.

16. The method of claim 8 wherein traversing the indexing head along the groove comprises rolling an indexing end of the indexing head along the groove.

17. The method of claim 8 wherein acquiring the stream of 3D coordinates of the indexing head comprises determining an arc and an orientation of the arc of the indexing head as the indexing head traverses the groove.

18. The method of claim 8 wherein traversing the indexing head comprises traversing the groove in accordance with an indexing NC program that directs the indexing head to follow a nominal path along the rigid tool, an indexing end of the indexing head pressed into the groove during the traversing.

19. The method of claim 18 wherein determining the alignment of the rigid tool comprises comparing the stream of 3D coordinates from the indexing head to the 3D coordinates of the nominal path to determine deviations of the groove from the nominal path.

20. The method of claim 19 wherein altering the Numerical Control (NC) program comprises integrating the deviations into the NC program that lays up composite on the rigid tool.

21. A system for indexing a layup mandrel for a composite part, the system comprising:
a lamination head comprising:
a roller;
a suspension that enables deflection of the roller;
a position sensor that measures deflection of the roller; and
a dispenser that dispenses tows of fiber-reinforced material; and

a controller that identifies a first side surface and a layup surface of the layup mandrel, wherein the layup mandrel travels in a process direction between serially arranged workstation

Assignees

• Boeing Co

Inventors

• Erickson Jordan Seth
• Louie Michael Kenneth-Que

Classifications

• B32B2309/72

  For measuring or regulating, e.g. systems with feedback loops · CPC title

• B32B37/0053

  Constructional details of laminating machines comprising rollers; Constructional features of the rollers · CPC title

• B32B38/1841

  during laying up · CPC title

• G05B2219/49114

  Go to coarse programmed reference, detector for fine alignment · CPC title

• G05B19/4099 Primary

  Surface or curve machining, making three-dimensional [3D] objects, e.g. desktop manufacturing · CPC title