Assembly line fabrication and assembly of aircraft wings

A system configured to install an indexing feature into a composite part, such that the system comprises:

• a work station that comprises an indexing unit;
• a cutter;
• and
• a layup mandrel that is separate from the work station and configured to receive a preform, wherein the layup mandrel comprises:
• a layup region that defines a contour for the composite part, wherein dimensions of the layup region correspond with dimensions of the composite part and wherein an entire surface of the layup region comprises a contour that corresponds to an entire surface of the composite part;
• a manufacturing excess region that at least partially encompasses the layup region, wherein the manufacturing excess region comprises a shape corresponding to the indexing unit;
• and
• a flash edge region that at least partially encompasses the manufacturing excess region and comprises a recess that comprises a shape that defines a path for the cutter, wherein the path comprises a shape configured to trim material beyond, from the layup region, the manufacturing excess region.

A method for installing an indexing feature into a composite part, the method comprising:

• providing an apparatus comprising:
• a cutter, and a work station comprising an indexing unit;
• forming a layup mandrel separate from the work station and comprising:
• a layup region configured to lay up a preform of a composite part, wherein dimensions of the layup region correspond with dimensions of the composite part and wherein an entire surface of the layup region comprises a contour that corresponds to an entire surface of the composite part;
• a final perimeter that defines an outermost boundary of the layup region;
• a manufacturing excess region disposed beyond the final perimeter such that the manufacturing excess region at least partially encompasses the layup region and comprises a shape complementary to the indexing unit on the work station;
• and
• a flash edge region that at least partially encompasses the manufacturing excess region and comprises a guide that comprises a shape that defines a path for the cutter;
• laying up a preform comprising a manufacturing excess and a flash edge onto the layup mandrel with the manufacturing excess of the preform aligned onto the manufacturing excess region of the layup mandrel and the flash edge of the preform aligned onto the flash edge region of the layup mandrel;
• embedding at least one of:
• an electronic chip, or a graphic code, into the manufacturing excess region of the preform;
• hardening the preform and forming the composite part;
• hardening the manufacturing excess of the preform and forming the indexing feature therein;
• cutting, using the cutter, the flash edge away from the manufacturing excess;
• and
• demolding the composite part from the layup mandrel while retaining on the composite part the manufacturing excess including the indexing feature.

A method for installing an indexing feature into a composite part, the method comprising:

• providing an apparatus comprising:
• a cutter, and a work station comprising an indexing unit;
• forming a layup mandrel separated from the work station and comprising:
• a layup region configured to lay up a preform of the composite part, wherein dimensions of the layup region correspond with dimensions of the composite part and wherein an entire surface of the layup region comprises a contour that corresponds to an entire surface of the composite part;
• a final perimeter that defines an outermost boundary of the layup region;
• a manufacturing excess region disposed beyond the final perimeter such that the manufacturing excess region at least partially encompasses the layup region and comprises a shape complementary to the indexing unit on the work station;
• and
• a flash edge region that at least partially encompasses the manufacturing excess region and comprises a guide that comprises a shape that defines a path for the cutter;
• executing, by a processor, a non-transitory computer readable medium comprising programmed instructions controlling the following steps:
• laying up a preform comprising a manufacturing excess and a flash edge onto the layup mandrel with the manufacturing excess of the preform onto the manufacturing excess region of the layup mandrel;
• embedding at least one of:
• an electronic chip, or a graphic code, formed therein;
• hardening the preform into the composite part;
• guiding, prior to demolding the composite part, the cutter along the guide and cutting off a flash edge of the preform;
• and
• demolding the composite part from the layup mandrel while retaining on the composite part the manufacturing excess including the indexing feature.

A method for installing indexing features into a composite part, the method comprising:

• providing an apparatus comprising:
• a cutter, and a work station comprising an indexing unit;
• forming a layup mandrel separated from the work station and comprising:
• a layup region configured to lay up a preform of the composite part, wherein dimensions of the layup region correspond with dimensions of the composite part and wherein an entire surface of the layup region comprises a contour that corresponds to an entire surface of the composite part;
• a final perimeter that defines an outermost boundary of the layup region;
• a manufacturing excess region disposed beyond the final perimeter such that the manufacturing excess region at least partially encompasses the layup region and comprises a shape complementary to the indexing unit on the work station;
• and
• a flash edge region that at least partially encompasses the manufacturing excess region and comprises a guide that comprises a shape that defines a path for the cutter;
• laying up a preform onto the layup mandrel;
• hardening the preform into the composite part and forming the indexing unit in a manufacturing excess of the preform;
• cutting, prior to demolding the composite part and using the cutter in the guide, a flash edge away from a manufacturing excess;
• and
• demolding the composite part from the layup mandrel while retaining the manufacturing excess that includes the indexing features, wherein the indexing features comprise readable identifying means.

A method for installing indexing features into a composite part, the method comprising:

• providing an apparatus comprising:
• a cutter, and a work station comprising an indexing unit;
• forming a layup mandrel separated from the work station and comprising:
• a layup region configured to lay up a preform of the composite part, wherein dimensions of the layup region correspond with dimensions of the composite part and wherein an entire surface of the layup region comprises a contour that corresponds to an entire surface of the composite part;
• a final perimeter that defines an outermost boundary of the layup region;
• a manufacturing excess region disposed beyond the final perimeter such that the manufacturing excess region at least partially encompasses the layup region and comprises a shape complementary to the indexing unit on the work station;
• and
• a flash edge region that at least partially encompasses the manufacturing excess region and comprises a guide that comprises a shape that defines a path for the cutter;
• laying up a preform comprising a manufacturing excess and a flash edge onto the layup mandrel;
• hardening the preform into the composite part with the indexing features formed in the manufacturing excess of the preform;
• and
• prior to demolding the composite part, removing, using the cutter in the guide, material forming the flash edge away from the composite part while retaining the manufacturing excess that includes the indexing features.