Dynamic Indexing for Moving Parts In a Fabrication Environment

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 of a layup mandrel that travels in a process direction during fabrication of a composite part, directs the lamination head to place the roller in contact with the first side surface, directs the lamination head to traverse the first side surface with the roller, acquires a stream of 3D coordinates of the roller as the roller traverses the first side surface, determines an alignment of the layup mandrel based on the stream of 3D coordinates, and alters 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.

A lamination machine for a composite part, the lamination machine 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 operable to use the measured deflections to index the lamination head with respect to a layup mandrel that travels in a process direction during fabrication of the composite part.

A method for indexing a rigid tool for a composite part, the method comprising:

• identifying a groove upon a rigid tool and that extends in a process direction traveled by the rigid tool 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.

A system for indexing a rigid tool with respect to a lamination machine, the system comprising:

• an indexing head comprising an indexing end;
• position sensors that measure 3D coordinates of the indexing end of the indexing head;
• and
• a controller that:
• directs placement of the indexing end into a groove formed in a rigid tool, the groove extending in a process direction traveled by the rigid tool during fabrication of a composite part;
• directs the indexing head to traverse the groove;
• acquires a stream of 3D coordinates of the indexing head via the position sensors as the indexing head traverses the groove with the indexing end therein;
• determines an alignment of the rigid tool based on the acquired stream of 3D coordinates;
• and
• alters a Numerical Control (NC) program that directs work at the rigid tool, based on a difference between the determined alignment of the rigid tool and a nominal alignment of the rigid tool.

A method for indexing an arcuate tool for a composite part, the method comprising:

• identifying a groove associated with the arcuate tool that extends along a portion of the arcuate tool;
• placing an indexing head with respect to the groove;
• rotating the arcuate tool relative to the indexing head such that the indexing head traverses the groove;
• acquiring a stream of 3D coordinates of the indexing head as the indexing head traverses the groove;
• determining an alignment of the arcuate tool based on the acquired stream of 3D coordinates;
• and
• altering a Numerical Control (NC) program that directs work at the arcuate tool, based on a difference between the alignment of the arcuate tool and a nominal alignment of the arcuate tool.

A system for indexing an arcuate tool for composite part fabrication, the system comprising:

• an indexing head comprising an indexing end and position sensors that measure 3D coordinates of the indexing head with respect to the indexing end;
• an arcuate tool comprising at least one groove about an arcuate portion of the arcuate tool;
• a rotatable support that is configured to retain the arcuate tool, and further configured to rotate the arcuate tool relative to the indexing head such that the indexing end traverses the groove;
• and
• a controller that directs placement of the indexing head with respect to the arcuate tool, directs the rotatable support to rotate the arcuate tool, acquires a stream of 3D coordinates indicative of a position of the indexing head as the indexing end traverses the groove, determines an alignment of the arcuate tool with respect to a nominal tool alignment based on the acquired stream of 3D coordinates, and alters a Numerical Control (NC) program that directs composite layup work at the arcuate tool, based on a difference between the determined alignment of the arcuate tool and the nominal alignment of the arcuate tool.

An apparatus for indexing a lamination head with respect to an arcuate tool for a composite part, the apparatus comprising:

• an indexing head comprising an indexing end and position sensors that provide 3D coordinates of the indexing end;
• and
• a rotatable support for the arcuate tool;
• and
• a controller having an NC program configured to position the indexing head with respect to a groove in the arcuate tool and further configured to rotate the arcuate tool relative to the indexing head such that the indexing end traverses the groove.