Patent Description:
Composite pats are commonly used in applications where light weight and high strength are desired, such as in aircraft and vehicles. Typically, one or more machining or other processing operations are performed on the composite part, such as drilling holes, machining features, and trimming edges. However, composite parts, particularly large composite parts, may tend to deform once they are removed from a tool upon which they are cured. Such deformation may present challenges related to the accuracy of the machining operations. As such, post-machining operations, such as shimming, may be required due to differences between an as-built shape of the composite structure and a shape of the composite structure during machining. These challenges may also limit the capacity for determine assembly or predictive assembly of a manufactured structure that includes the composite part. Accordingly, those skilled in the art continue with research and development efforts in the field of composite manufacturing.

Patent document <CIT>, according to its abstract, states that a method and apparatus for use in manufacturing a composite part includes molding a composite part on a lay-up tool, machining a sacrificial portion of a first surface for securing a first hardware device with the composite part while the part is on the lay-up tool and cutting the part forming a peripheral edge while the part is on the lay-up tool. The method can further include positioning the first hardware device in contact with a machined interface of the composite part and machining the part including drilling a plurality of positioning holes through the hardware device and the part while the part is on the lay-up tool. The machining can include machining the sacrificial portion creating a machined interface and positioning the hardware device on the machined interface.

Patent document <CIT>, according to its abstract, states that a drill template includes a vacuum housing with a skirt having a CAD-formed contact surface formed to a fit with a mold line surface of a structure. The drill template includes a drill guide bushing extending through the vacuum housing from a top surface to an interior surface of the vacuum housing, a vacuum port integral to the vacuum housing, and an index hole for positioning and aligning the vacuum housing on the structure. Index holes extend from the top surface through to the CAD-formed contact surface of the vacuum housing. A CAD-formed edge of part locator is formed according to a CAD solid model of the aircraft fuselage and fits to a location of the structure for positioning the template on the structure. A vacuum port provides vacuum to the interior of the vacuum housing for removing drilling debris and dust.

Patent document <CIT>, according to its abstract, states a method and apparatus for manufacturing wings which includes a fixture that holds wing panels for drilling and edge trimming by numerically controlled machine tools using original numerical part definition records, utilizing spatial relationships between key features of detail parts or subassemblies as represented by coordination features machined into the parts and subassemblies, thereby making the parts and subassemblies intrinsically determinant of the dimensions and contour of the wing. Spars are attached to the wing panel using the coordination holes to locate the spars on the panel in accordance with the original engineering design, and in-spar ribs are attached to rib posts on the spar using drilled coordination holes in the ends of the rib and in the rib post. The wing contour is determined by the configuration of the spars and ribs.

Patent document <CIT>, according to its abstract, states that a machine head is positioned in a desired location relative to a material on a tool using a sensor connected to the machine head and calibrated to detect magnetic material in the tool. An operation is performed on the material using the machine head starting at the desired location.

Patent document <CIT>, according to its abstract, states that systems and methods provide for the determination and correction of tooling deviation by comparing two different three-dimensional surface scans of a composite panel after curing. Such methods and systems may allow for less accurate post-cure fixturing, while still maintaining a sufficient amount of precision for predictive shimming and shimless techniques. Methods include performing a first three-dimensional surface scan, performing a second three-dimensional surface scan, and comparing the two to determine a deformation function corresponding to tooling deviation. In some systems, a header structure is used to hold the composite panel in a nominal configuration for the second three-dimensional surface scan. In some systems, scanning devices perform mirrored scanning on either side of the composite panel, using a common reference frame.

Disclosed are examples of a system for post-cure processing of a composite workpiece according to independent system claim <NUM>, a tool for post-cure processing of a composite workpiece, and a method for post-cure processing of a composite workpiece according to independent method claim <NUM>.

In an example, the disclosed system includes a tool. The tool includes a tool surface. The tool surface supports a composite workpiece located on the tool. The system also includes a drill template. The drill template defines a drilling location for drilling a hole through the composite workpiece while the composite workpiece is on the tool.

In an example, the disclosed tool includes a tool surface that supports a composite workpiece located on the tool. The tool also includes a recess formed in the tool surface. The tool further includes a sacrificial material within the recess and having a top surface that is substantially flush with the tool surface. A portion of a drill bit penetrates the recess, drilling the sacrificial material, when drilling a hole through the composite workpiece while the composite workpiece is on the tool.

In another example, the disclosed system includes a tool. The tool includes a tool surface that supports the composite workpiece located on the tool. The tool also includes a sacrificial portion disposed on the tool surface. The system also includes a drill template that defines a drilling location on the composite workpiece. The system further includes a drill that includes a drill bit for drilling a hole through the composite workpiece at the drilling location, defined by the drill template, while the composite workpiece is on the tool. A portion of the drill bit penetrates the sacrificial portion of the tool after the drill bit passes through the composite workpiece.

In another example, the disclosed method includes steps of: (<NUM>) supporting a composite workpiece on a tool surface of a tool; (<NUM>) defining a drilling location on the composite workpiece while the composite workpiece is on the tool using a drill template; and (<NUM>) drilling a hole through the composite workpiece at the drilling location, defined by the drill template, while the composite workpiece is on the tool.

Other examples of the disclosed system, tool, and method will become apparent from the following detailed description, the accompanying drawings, and the appended claims.

Referring generally to <FIG>, by way of examples, the present disclosure is directed to a system <NUM> for post-cure processing of a composite workpiece <NUM>. The system <NUM> facilitates an initial operation in the post-cure processing, in which at least one machining operation is performed on the composite workpiece <NUM> while the composite workpiece <NUM> is on a tool <NUM> in its as-built shape. The system <NUM> advantageously improves the accuracy and precision of the machining operation, facilitates automated indexing of the composite workpiece <NUM> during subsequent machining or processing operations, and facilitates determinate or predictive assembly of a structure that includes the composite workpiece <NUM>.

For the purpose of the present disclosure, the term "composite workpiece" (e.g., composite workpiece <NUM>) refers to any object, article, item, or structure made of a cured composite material. In one or more examples, the composite workpiece <NUM> is, or forms, a part or a component of a larger manufactured article or structure, such as an aircraft or a component of an aircraft. As an example, the composite workpiece <NUM> is a wing panel <NUM> of an aircraft <NUM> (e.g., as shown in <FIG>).

For the purpose of the present disclosure, the term "post-cure" refers to a condition of a composite material after a curing operation, such as by application of heat and/or pressure, to cure, anneal, dry, and/or harden the composite material.

For the purpose of the present disclosure, the term "as-built," such as in reference to the as-built condition or shape of the composite workpiece <NUM>, refers to a condition of the composite workpiece <NUM> in which the composite workpiece <NUM> has a shape (e.g., geometry, profile, contour, and the like) as formed and/or cured on the tool <NUM>.

It can be appreciated that once a composite structure (e.g., the composite workpiece <NUM>) is removed from a cure tool upon which it is cured (e.g., tool <NUM>), the composite structure may tend to deform (e.g., change shape), for example, due to residual stresses in the composite structure or due to external forces applied to the composite structure during post-cure processing. The principles and implementations of the system <NUM> disclosed herein enable a machining operation to be performed on the composite workpiece <NUM> while the composite workpiece <NUM> is on the tool <NUM>. As such, the machining operation is performed on the composite workpiece <NUM> while the composite workpiece <NUM> is in the as-built condition or while having the as-built shape, thereby, reducing or eliminating inaccurate or inconsistent machining due to the machining operation being performed on a composite workpiece while the composite workpiece has a shape that is different than the as-built shape.

Additionally, the principles and implementations of the system <NUM> disclosed herein enable a digital model to be generated, which is representative of the composite workpiece <NUM> having the as-built shape. The digital model of the composite workpiece <NUM> in the as-built shape is used to index the composite workpiece <NUM> before a subsequent processing operation is performed on the composite workpiece <NUM> from the tool <NUM>. The digital model of the composite workpiece <NUM> may also be used to conform the composite workpiece <NUM> to the as-built shape during a subsequent processing operation performed on the composite workpiece <NUM> off the tool <NUM>. As such, subsequent machining operations performed on the composite workpiece <NUM>, with the composite workpiece <NUM> off the tool <NUM> but in the as-built shape, reduces or eliminates inaccurate or inconsistent machining due to the machining operation being performed on a composite workpiece while the composite workpiece has a shape that is different than the as-built shape.

Moreover, the principles and implementations of the system <NUM> disclosed herein enable the digital model to be updated after a machining operation is performed, such that the digital model is representative of an as-machined condition of the composite workpiece <NUM>. For the purpose of the present disclosure, the term "as-machined," such as in reference to the as-machined condition the composite workpiece <NUM>, refers to a condition of the composite workpiece <NUM> after a machining operation is performed on the composite workpiece <NUM>. As such, the principles and implementations of the system <NUM> disclosed herein also enable determinate assembly or predictive assembly of the composite workpiece <NUM> based on the digital model of the composite workpiece <NUM>, which is updated throughout post-cure processing of the composite workpiece <NUM>.

Referring now to <FIG>, which schematically illustrates a manufacturing environment <NUM>. The manufacturing environment <NUM> facilitates post-cure processing of the composite workpiece <NUM>, such as machining, trimming, coating, painting, sub-assembly (e.g., assembly of other parts or components to the composite workpiece <NUM>), and the like. Generally, the manufacturing environment <NUM> includes a plurality of work cells <NUM>, identified individually as a first work cell <NUM>, a second work cell <NUM>, a third work cell <NUM>, a fourth work cell <NUM>, a fifth work cell <NUM>, etc. Each one of the work cells <NUM> facilitates or corresponds to a different post-cure processing operation associated with the manufacture of the composite workpiece <NUM>. In one or more examples, each one of the work cells <NUM> includes one or more systems, apparatuses, and/or machines that perform at least one post-cure processing operation. In one or more examples, the work cells <NUM> are interlinked (e.g., in series or parallel) and cooperate to automate at least a portion of the fabrication process.

The system <NUM> is associated with one of the work cells <NUM> and forms a sub-system of the manufacturing environment <NUM>. In one or more examples, the system <NUM> is associated with the first work cell <NUM> and facilitates an initial post-cure processing operation performed on the composite workpiece <NUM>. For example, after the composite workpiece <NUM> is cured (e.g., by a curing apparatus, such as an oven or autoclave), the composite workpiece <NUM> is transported to the first work cell <NUM> on the tool <NUM>, upon which it was cured.

Referring now to <FIG>, which schematically illustrates an example of the system <NUM>. In one or more examples, the system <NUM> includes the tool <NUM>. The tool <NUM> includes a tool surface <NUM>. The tool surface <NUM> supports the composite workpiece <NUM> located on the tool <NUM>. The system <NUM> also includes a drill template <NUM>. The drill template <NUM> defines a drilling location <NUM> for drilling a hole <NUM>, such as a dependent-determinant assembly hole, through the composite workpiece <NUM> while the composite workpiece <NUM> is on the tool <NUM>. Generally, the drilling location <NUM> is a desired location of the hole <NUM> to be drilled through the composite workpiece <NUM>.

The drill template <NUM> enables the hole <NUM> to be drilled through the composite workpiece <NUM> at the drilling location <NUM>, as desired or as predetermined based on manufacturing design, while the composite workpiece <NUM> is on the tool <NUM> and while in the as-built condition (e.g., having the as-built shape).

In one or more examples, the hole <NUM> is intended for use as, or serves as, any one of various types of holes. In one or more examples, the hole <NUM> is a determinate assembly hole that is used for a subsequent assembly operation to couple another component or structure to the composite workpiece <NUM> or to couple the composite workpiece <NUM> to another structure. In one or more examples, the hole <NUM> is used as an indexing feature for indexing the composite workpiece <NUM> in a subsequent one of the plurality of work cells <NUM> for performance of a subsequent post-cure processing operation. In one or more examples, the hole <NUM> is used as a carrying feature, such for attachment of the composite workpiece <NUM> to a material handler (e.g., an overhead material handler <NUM> as illustrated in <FIG> and <FIG>).

In one or more examples, the tool <NUM> includes a sacrificial portion <NUM>. The sacrificial portion <NUM> of the tool <NUM> is disposed on, or forms a portion of, the tool surface <NUM>. The drill template <NUM> indexes the drilling location <NUM> to the sacrificial portion <NUM> of the tool <NUM>.

In one or more examples, the system <NUM> also includes a drill <NUM> to drill the hole <NUM> through the composite workpiece <NUM> at the drilling location <NUM>, defined by the drill template <NUM>, while the composite workpiece <NUM> is on the tool <NUM>. The drill <NUM> includes a drill bit <NUM>. The sacrificial portion <NUM> of the tool <NUM> receives (e.g., is penetrated by) a portion of the drill bit <NUM> after the drill bit <NUM> passes through the composite workpiece <NUM> when drilling the hole <NUM> through the composite workpiece <NUM>. In other words, the sacrificial portion <NUM> defines a portion (e.g., a drill-penetration portion) of the tool <NUM> that is designed or that is intended to be drilled while the hole <NUM> is being drilled through the composite workpiece <NUM>. For example, a portion of the drill bit <NUM> extends into the sacrificial portion <NUM> when drilling the hole <NUM> through the composite workpiece <NUM>.

Referring to <FIG>, which schematically illustrates an example of the tool <NUM>. Generally, the sacrificial portion <NUM> is formed in, is disposed on, or otherwise forms a portion of the tool surface <NUM>. In one or more examples, the tool <NUM> includes a plurality of sacrificial portions <NUM>. The sacrificial portion <NUM> (e.g., any one of a plurality of sacrificial portions <NUM>) may be located at any suitable location on the tool surface <NUM>. Generally, the sacrificial portion <NUM> corresponds to a desired location of the hole <NUM> to be drilled through the composite workpiece <NUM>.

The sacrificial portion <NUM> may have any geometry and/or dimensions suitable to receive, or to be penetrated by, a portion of the drill bit <NUM> when drilling the hole <NUM> through the composite workpiece <NUM>. For example, the sacrificial portion <NUM> includes a two-dimensional geometry in plan view (e.g., as shown in <FIG>) and a two-dimensional geometry in section view (e.g., as shown in <FIG>). The two-dimensional geometry of the sacrificial portion <NUM> in plan view defines a width dimension and length dimension of the sacrificial portion <NUM>. The two-dimensional geometry of the sacrificial portion <NUM> in section view defines a depth dimension of the sacrificial portion <NUM>.

The illustrative examples show the sacrificial portion <NUM> as being configured to receive a portion of the drill bit <NUM> during a drilling operation, for example, as having a circular shape in plan view and approximately rectangular shape in section view. However, the principles and implementation of the sacrificial portion <NUM> may be applied to other machining operations performed on the composite workpiece <NUM>, while on the tool <NUM>, by other types of machining tools. For example, the sacrificial portion <NUM> may have an elongate (e.g., long and narrow) rectangular shape in plan view and be configured to receive a router bit or cutting blade during a milling, cutting, or trimming operation. Alternatively, in one or more examples, the sacrificial portion <NUM> may have the elongate rectangular shape in plan view and be configured to receive a portion of the drill bit <NUM> during a drilling operation. In these examples, the desired location of the hole <NUM> to be drilled through the composite workpiece <NUM> (e.g., the drilling location <NUM>) is located along the sacrificial portion <NUM>.

Referring to <FIG>, which schematically illustrates an example of a portion of the tool <NUM> and a portion of the composite workpiece <NUM> on the tool <NUM> before the hole <NUM> is drilled through the composite workpiece <NUM>. In one or more examples, the sacrificial portion <NUM> of the tool <NUM> includes a recess <NUM> formed in the tool surface <NUM>, for example, formed in the tool <NUM> and depending from the tool surface <NUM>. The sacrificial portion <NUM> also includes a sacrificial material <NUM> located within the recess <NUM>. The sacrificial material <NUM> includes, or forms, a top surface <NUM> of the sacrificial portion <NUM>. The top surface <NUM> of the sacrificial portion <NUM> is substantially flush with, or forms a portion of, the tool surface <NUM>. In one or more examples, a portion of the drill bit <NUM> penetrates the recess <NUM>, drilling the sacrificial material <NUM>, when drilling the hole <NUM> through the composite workpiece <NUM>, according to the drill template <NUM>, while the composite workpiece <NUM> is on the tool <NUM>.

The sacrificial material <NUM> includes, or is made from, any material suitable for application within the recess <NUM> and for use as a curing surface for a composite layup that is cured on the tool <NUM>. For example, the sacrificial material <NUM> fills the recess <NUM> and hardens such that the top surface <NUM> of the sacrificial portion <NUM> is compatible with and forms a portion of the tool surface <NUM>. In one or more examples, the sacrificial material <NUM> is a potting compound. However, any one of various other types of materials may be used for the sacrificial material <NUM>.

As illustrated in <FIG>, the composite workpiece <NUM> includes a first surface <NUM> and a second surface <NUM>, which is opposite the first surface <NUM>. In one or more examples, the first surface <NUM> defines an outer mold line of the composite workpiece <NUM> and the second surface <NUM> defines an inner mold line of the composite workpiece <NUM>. In one or more examples, the first surface <NUM> defines the inner mold line of the composite workpiece <NUM> and the second surface <NUM> defines the outer mold line of the composite workpiece <NUM>.

The tool surface <NUM> supports, or is in contact with, the first surface <NUM> of the composite workpiece <NUM>. Additionally, the top surface <NUM> of the sacrificial portion <NUM> is in contact with a portion of the first surface <NUM> of the composite workpiece <NUM>. The drilling location <NUM> (e.g., the desired location for the hole <NUM> to be drilled through the composite workpiece <NUM>) is located over the sacrificial portion <NUM> of the tool <NUM>.

Referring now to <FIG>, which schematically illustrates an example of the tool <NUM> and the composite workpiece <NUM> on the tool <NUM> before the hole <NUM> is drilled through the composite workpiece <NUM>. Generally, the composite workpiece <NUM> is fabricated from a composite layup (e.g., a composite laminate or composite preform) that is cured on the tool <NUM>. As such, in one or more examples, in addition to the tool <NUM> serving as a support structure for machining the composite workpiece <NUM>, the tool <NUM> also serves as a cure tool and the tool surface <NUM> serves as a cure surface that supports the composite layup during cure.

Generally, the composite layup includes a plurality of plies (e.g., layers) of a composite material. Each ply of composite material may take the form of a composite sheet or a series of lengths of composite tape. The composite material includes a reinforcement material (e.g., carbon fiber, glass fiber, aramid fiber, and the like) that is embedded in a matrix binding material (e.g., a polymeric matrix, a thermoset plastic, a thermoplastic, a resin, and the like).

In one or more examples, the composite layup is formed on the tool <NUM>. As such, in one or more examples, the tool <NUM> also serves as a layup tool or mandrel and the tool surface <NUM> serves as a layup surface that supports the composite layup during fabrication and that shapes the composite layup. However, in other examples, the composite layup may be fabricated on a dedicated layup tool and transferred to the tool <NUM> for cure and subsequent machining on the tool <NUM> after cure.

As illustrated in <FIG>, in one or more examples, the composite workpiece <NUM> includes a plurality of drilling locations <NUM>. The drilling location <NUM> (e.g., any one of the plurality of drilling locations <NUM>) may be located at any suitable location on the composite workpiece <NUM>, as defined by the drill template <NUM>. The drilling location <NUM> (e.g., any one of the plurality of drilling locations <NUM>) is aligned with or indexed to the sacrificial portion <NUM> (e.g., a corresponding one of the plurality of sacrificial portions <NUM>) of the tool <NUM>.

Referring now to <FIG>, which schematically illustrates an example of the tool <NUM> and the composite workpiece <NUM> on the tool <NUM> after the hole <NUM> is drilled through the composite workpiece <NUM>. In one or more examples, the composite workpiece <NUM> includes a plurality of holes <NUM>. The hole <NUM> (e.g., any one of the plurality of holes <NUM>) is located at any suitable location on the composite workpiece <NUM> according to the drilling location <NUM> (e.g., a corresponding one of the plurality of drilling locations <NUM>) defined by the drill template <NUM>.

Referring now to <FIG>, which schematically illustrates an example of the tool <NUM>, the composite workpiece <NUM> on the tool <NUM>, and the drill template <NUM> used to locate the drilling location <NUM> relative to the composite workpiece <NUM>. In one or more examples, the drill template <NUM> is a physical template, which is coupled to the tool <NUM>. In one or more examples, the drill template <NUM> includes a template body <NUM>. The template body <NUM> is coupled to the tool <NUM>. The drill template <NUM> also includes a drill guide <NUM> formed in the template body <NUM>. The drill guide <NUM> defines, or locates, the drilling location <NUM> relative to the composite workpiece <NUM>. For example, the drill guide <NUM> locates a drilling axis of the drill bit <NUM> relative to the composite workpiece <NUM>. With the drill template <NUM> coupled to the tool <NUM>, the template body <NUM> is indexed relative to the tool <NUM>. The template body <NUM> thereby indexes the drill guide <NUM> relative to the composite workpiece <NUM> and relative to the tool <NUM> such that the drilling location <NUM> is aligned with the sacrificial portion <NUM> of the tool <NUM>.

In one or more examples, the drill guide <NUM> includes, or is formed by, a template hole <NUM>. The template hole <NUM> is formed, or extends, through the template body <NUM>. The drill guide <NUM> (e.g., the template hole <NUM>) receives and guides the drill bit <NUM> when drilling the hole <NUM> through the composite workpiece <NUM> on the tool <NUM>.

In one or more examples, the template body <NUM> locates the drill guide <NUM> (e.g., the template hole <NUM>) relative to the second surface <NUM> of the composite workpiece <NUM>. With the drill template <NUM> coupled to the tool <NUM>, the template body <NUM> indexes the drill guide <NUM> (e.g., the template hole <NUM>) relative to the tool <NUM> and to the composite workpiece <NUM> such that the drilling location <NUM> is at the desired location on the composite workpiece <NUM> and is aligned with the sacrificial portion <NUM> of the tool <NUM>.

In one or more examples, the drill guide <NUM> includes a plurality of template holes <NUM>. Each one of the plurality of template holes <NUM> corresponds to, or defines, a corresponding one of the plurality of drilling locations <NUM>. Each one of the plurality of template holes <NUM> is indexed to or is aligned with a corresponding one of the plurality of sacrificial portions <NUM> of the tool <NUM>.

In one or more examples, the system <NUM> includes a plurality of drill templates <NUM>. In one or more examples, each one of the plurality of drill templates <NUM> is coupled to the tool <NUM>. Each one of the plurality of drill templates <NUM> is designed or configured to index the drill guide <NUM> to a corresponding one of the plurality of sacrificial portions <NUM>, for example, based on the design and/or geometry of the tool <NUM> and/or of the composite workpiece <NUM>.

Referring now to <FIG>, which schematically illustrates an example of a portion of the tool <NUM>, a portion of the composite workpiece <NUM> on the tool <NUM>, and the drill template <NUM> coupled to the tool <NUM> and used to locate the drilling location <NUM> relative to the composite workpiece <NUM>. In one or more examples, the drill template <NUM> is indexed relative to the tool <NUM> such that the drill guide <NUM> is aligned with (e.g., over) the sacrificial portion <NUM> of the tool <NUM>. Indexing the drill template <NUM> enables the drill template <NUM> to be repeatably and consistently used with the tool <NUM> to locate the drill guide <NUM> over the sacrificial portion <NUM> of the tool <NUM>.

In one or more examples, the tool <NUM> includes a first template-indexing feature <NUM>. The drill template <NUM> includes a second template-indexing feature <NUM>. The second template-indexing feature <NUM> mates with the first template-indexing feature <NUM> to index the drill template <NUM> relative to the tool <NUM> and to index the drill guide <NUM> relative to the tool <NUM> and to the composite workpiece <NUM> at the drilling location <NUM>. For example, the mating of the first template-indexing feature <NUM> and the second template-indexing feature <NUM> locates the template hole <NUM> adjacent to the second surface <NUM> of the composite workpiece <NUM> and aligns the template hole <NUM> with the sacrificial portion <NUM> of the tool <NUM>.

In one or more examples, one of the first template-indexing feature <NUM> or the second template-indexing feature <NUM> is a male feature and the other one of the first template-indexing feature <NUM> or the second template-indexing feature <NUM> is a female feature that receives and mates with the male feature. For example, one of the first template-indexing feature <NUM> or the second template-indexing feature <NUM> is a pin, protrusion, or other projection and the other one of the first template-indexing feature <NUM> or the second template-indexing feature <NUM> is an aperture, recess, or other opening.

In one or more examples, the drill template <NUM> is coupled to the tool <NUM> using the first template-indexing feature <NUM> and the second template-indexing feature <NUM>. In one or more examples, one of the first template-indexing feature <NUM> or the second template-indexing feature <NUM> is first component of a mechanical fastener, such as a threaded bolt, and the other one of the first template-indexing feature <NUM> or the second template-indexing feature <NUM> is a second component of the mechanical fastener, such as a nut or internally threaded aperture.

Referring now to <FIG> and <FIG>, which schematically illustrate examples of a portion of the tool <NUM>, a portion of the composite workpiece <NUM> on the tool <NUM>, and the drill template <NUM> used to locate the drilling location <NUM> relative to the composite workpiece <NUM>. In one or more examples, the tool <NUM> also includes a side surface <NUM>. The side surface <NUM> extends from the tool surface <NUM>. In one or more examples, the drill template <NUM> is coupled to the side surface <NUM> and extends over the second surface <NUM> of the composite workpiece <NUM> while the composite workpiece <NUM> is on the tool <NUM>. For example, the template body <NUM> is coupled to the side surface <NUM> of the tool <NUM> and extends over the second surface <NUM> of the composite workpiece <NUM> to locate the drill guide <NUM> over the sacrificial portion <NUM> of the tool <NUM>.

In one or more examples, the template body <NUM> of the drill template <NUM> includes a first template-portion <NUM>, a second template-portion <NUM>, and a third template-portion <NUM>. The first template-portion <NUM> is coupled to the tool <NUM>, such as to the side surface <NUM> of the tool <NUM>. The second template-portion <NUM> extends approximately perpendicular from the first template-portion <NUM>. The third template-portion <NUM> extends from the second template-portion <NUM>. The second template-portion <NUM> is located over the second surface <NUM> of the composite workpiece <NUM> while the composite workpiece <NUM> is on the tool <NUM>. The third template-portion <NUM> is located proximate to the second surface <NUM> of the composite workpiece <NUM> while the composite workpiece <NUM> is on the tool <NUM>. The drill guide <NUM> is formed by, or forms a portion of, the third template-portion <NUM>. In an example, the template hole <NUM> is formed through the third template-portion <NUM>.

Referring now to <FIG>, which schematically illustrates an example of a portion of the composite workpiece <NUM>, the drill template <NUM>, and the drill <NUM>. In one or more examples, the drill guide <NUM> of the drill template <NUM> includes a drill bushing <NUM>. The drill bushing <NUM> forms, or is located in, the template hole <NUM>. In an example, the drill bushing <NUM> is coupled to the third template-portion <NUM>. The drill bushing <NUM> receives a portion of the drill bit <NUM> and guides the drill bit <NUM> when drilling the hole <NUM> through the composite workpiece <NUM> while the composite workpiece <NUM> is on the tool <NUM>.

Referring now to <FIG>, which schematically illustrates an example of the system <NUM> and the first work cell <NUM> to which the system <NUM> is associated. In one or more examples, the system <NUM> includes a scanner <NUM>. The scanner <NUM> scans and digitizes at least a portion of the composite workpiece <NUM> while the composite workpiece <NUM> is on the tool <NUM>. In one or more examples, the scanner <NUM> scans and digitizes at least the second surface <NUM> of the composite workpiece <NUM> while the composite workpiece <NUM> is on the tool <NUM>.

The scanner <NUM> is any one of various types of three-dimensional (3D) scanners. In one or more examples, the scanner <NUM> includes, or is, a photogrammetric scanner <NUM> (e.g., as shown in <FIG>), such as a photogrammetric camera. In other examples, the scanner <NUM> includes, or is, one of a laser triangulation scanner, a structured light scanner, other laser-based scanners or metrology systems, and the like.

The scanner <NUM> captures the geometry (e.g., size and shape), contour (e.g., curvature), physical features (e.g., holes, edges, etc.), and other details of the composite workpiece <NUM>. Scan data <NUM> generated the scanner <NUM> is used by a computer to form a workpiece model <NUM>. The workpiece model <NUM> is a digital three-dimensional representation of the composite workpiece <NUM>.

Referring to <FIG> and <FIG>, in one or more examples, the system <NUM> also includes a computing device <NUM>. The computing device <NUM> is adapted to generate and/or manipulate the workpiece model <NUM> based on the scan data <NUM> generated by the scanner. The workpiece model <NUM> is representative of at least a portion of the composite workpiece <NUM> in the as-built shape.

The computing device <NUM> may include a single computer or several interconnected computers. For example, the computing device <NUM> may include any collection of computing devices that individually or jointly execute a set (or multiple sets) of instructions to implement any one or more of the operations discussed herein. The computing device <NUM> includes a processor <NUM> (e.g., at least one processing unit) that is coupled to memory <NUM>. The memory <NUM> includes program code <NUM> that is executable by the processor <NUM> to perform one or more operations. Generally, as used herein, the phrase "the computing device <NUM> is adapted to" refers to the computing device <NUM> being configured or otherwise operable to perform a function, such as the program code <NUM> being executed by the processor <NUM> to perform a desired operation or function. The program code <NUM> is any coded instructions that is (e.g., computer readable and/or machine readable. The memory <NUM> is any a non-transitory computer readable and/or machine readable medium, such as a hard disk drive, flash memory, read-only memory, a compact disk, a digital versatile disk, a cache, random-access memory, and/or any other storage device or storage disk in which information is stored for any duration (e.g., for extended time periods, permanently, for brief instances, for temporarily buffering, and/or for caching of the information).

In one or more examples, the workpiece model <NUM> is representative of the geometry of the second surface <NUM> of the composite workpiece <NUM> as on the tool <NUM> (e.g., with the composite workpiece <NUM> having the as-built shape). For example, the workpiece model <NUM> is representative of the size, the shape, and the contour of the second surface <NUM> of the composite workpiece <NUM> as on the tool <NUM> (e.g., in the as-built condition on the tool <NUM>) relative to a reference frame <NUM> (e.g., as shown in <FIG>). In one or more examples, the reference frame <NUM> is a workpiece reference frame.

In one or more examples, the composite workpiece <NUM> is digitized, the scan data <NUM> is generated, and the workpiece model <NUM> is created before the hole <NUM> is drilled through the composite workpiece <NUM>. In one or more examples, the composite workpiece <NUM> is digitized, the scan data <NUM> is generated, and the workpiece model <NUM> is created, or modified, after the hole <NUM> is drilled through the composite workpiece <NUM>. As such, in one or more examples, the workpiece model <NUM> is also representative of a location and geometry of the hole <NUM> relative to the reference frame <NUM>.

Referring now to <FIG>, which schematically illustrates an example of the tool <NUM>, the composite workpiece <NUM> on the tool <NUM>, and an automated drilling machine <NUM>. In one or more examples, the system <NUM> automatically or semi-automatically drills the hole <NUM> through the composite workpiece <NUM> at the drilling location <NUM> while the composite workpiece <NUM> is on the tool <NUM>. In such examples, the system <NUM> includes the automated drilling machine <NUM>.

In one or more examples, the automated drilling machine <NUM> includes a robotic arm <NUM> or other programmable movement mechanism. The drill <NUM> is coupled to an end (e.g., an end effector) of the robotic arm <NUM>. The robotic arm <NUM> selectively and controllably moves the drill <NUM> in three-dimensional space, for example, relative to the tool <NUM> and relative to the composite workpiece <NUM>. The automated drilling machine <NUM> receives instructions from the computing device <NUM>. For example, the automated drilling machine <NUM> may operate according to a numerical control (NC) program (e.g., program code <NUM>) executed by the computing device <NUM> to automatically locate the drill <NUM> at the drilling location <NUM> and to drill the hole <NUM> through the composite workpiece <NUM> at the drilling location <NUM>.

Referring now to <FIG>, which schematically illustrates an example of the workpiece model <NUM>. In one or more examples, such as examples in which the drilling operation is performed automatically using the automated drilling machine <NUM>, the drill template <NUM> is, or takes the form of, a virtual template <NUM> (e.g., a no-physical template). For example, the virtual template <NUM> is carried out, accessed, and/or stored by means of the computing device <NUM>, such as made by software (e.g., the program code <NUM>). The workpiece model <NUM> and the virtual template <NUM> are used by the computing device <NUM> to determine the drilling location <NUM> on the composite workpiece <NUM>.

In one or more examples, the computing device <NUM> is adapted to locate the virtual template <NUM> relative to the workpiece model <NUM> such that a virtual drill guide <NUM> of the virtual template <NUM> is indexed to the sacrificial portion <NUM> of the tool <NUM>. The computing device <NUM> is also adapted to determine the drilling location <NUM> relative to the reference frame <NUM> based on the virtual drill guide <NUM>. The computing device <NUM> is further adapted to instruct the automated drilling machine <NUM> to drill the hole <NUM> at the drilling location <NUM>.

In one or more examples, the computing device <NUM> is adapted to perform various transforms (e.g., rigid body transforms and/or coordinate frame transforms) and/or other data manipulation operations to virtually locate the workpiece model <NUM> relative to a tool model <NUM> that represents the location of the composite workpiece <NUM> relative to the tool <NUM>. The computing device <NUM> is also adapted to perform various transforms and/or other data manipulation operations to virtually locate the virtual template <NUM> relative to the tool model <NUM> such that the virtual drill guide <NUM> is aligned with the location of the sacrificial portion <NUM> of the tool <NUM> represented by the tool model <NUM>. With the workpiece model <NUM> and the virtual template <NUM> located relative to the tool model <NUM>, the computing device <NUM> determines the drilling location <NUM> (e.g., XYZ-coordinates) relative to the reference frame <NUM>. The computing device <NUM> is also adapted to modify the NC program and/or compensate an NC machine reference frame based on the drilling location <NUM>.

The tool model <NUM> is representative of the geometry, contour, and physical features of the tool <NUM>, such as the geometry and location of the sacrificial portion <NUM>, relative to a tool reference frame. In one or more examples, the tool <NUM> is digitized by the scanner <NUM> before the composite workpiece <NUM> is located on the tool surface <NUM>.

Referring again to <FIG>, in one or more examples, the automated drilling machine <NUM> is indexed to the tool <NUM> before being instructed to drill the hole <NUM> through the composite workpiece <NUM> on the tool <NUM>. In one or more examples, the tool <NUM> includes a tool-indexing feature <NUM>. The automated drilling machine <NUM> includes a machine-indexing feature <NUM>. The machine-indexing feature <NUM> is configured to mate with the tool-indexing feature <NUM> to index the automated drilling machine <NUM> relative to the tool <NUM>.

In one or more examples, the machine-indexing feature <NUM> includes at least one projection (e.g., a fork) and the tool-indexing feature <NUM> includes at least one opening (e.g., a mouse hole) that is configured to receive the machine-indexing feature <NUM>. However, in other examples, the machine-indexing feature <NUM> and the tool-indexing feature <NUM> may include, or take the form of, any one of various other physical indexing structures (e.g., probes, indexing pins, etc.) or visual indexing features (e.g., optical targets and vision-based or laser-based detectors).

Referring now to <FIG>, which schematically illustrates an example of the composite workpiece <NUM> and the second work cell <NUM> of the manufacturing environment <NUM>, in which a subsequent post-cure processing operation is performed on the composite workpiece <NUM>. In one or more examples, the workpiece model <NUM> is used to index the composite workpiece <NUM> to the second work cell <NUM> for a subsequent processing operation.

In one or more examples, the composite workpiece <NUM> is loaded in the second work cell <NUM>. For example, the composite workpiece <NUM> is mounted to or is otherwise secured a tooling fixture <NUM>. The composite workpiece <NUM> (e.g., as held by the tooling fixture <NUM>) is then measured, scanned, or otherwise digitized in the second work cell <NUM> and a second workpiece model (e.g., a second three-dimensional model) of the composite workpiece <NUM> is generated that represents the position (e.g., location and orientation) and shape (e.g., contour) of the composite workpiece <NUM> in the second work cell <NUM> (e.g., relative to a work-cell reference frame <NUM>). The second three-dimensional model is compared to the workpiece model <NUM> at an indexed position relative to the work-cell reference frame <NUM> and the composite workpiece <NUM> is conformed to the indexed position based on this comparison.

Referring to <FIG> and <FIG>, in one or more examples, the system <NUM> includes a material loader <NUM> (e.g., as shown in <FIG>). The material loader <NUM> removes (e.g., separates and demolds) the composite workpiece <NUM> from the tool <NUM>. In one or more examples, the system <NUM> also includes an overhead material handler <NUM>. The overhead material handler <NUM> receives the composite workpiece <NUM> from the material loader <NUM> and transports the composite workpiece <NUM> from the first work cell <NUM> (e.g., as shown in <FIG>) to the second work cell <NUM> for the subsequent processing operation. The overhead material handler <NUM> may also transport the composite workpiece <NUM> from the second work cell <NUM>, following the processing operation, to the third work cell <NUM> for performance of a subsequent processing operation, and so on.

Referring to <FIG>, in one or more examples, the material loader <NUM> is indexed to the tool <NUM> before removing the composite workpiece <NUM> from the tool <NUM>. In one or more examples, the material loader <NUM> includes a loader-indexing feature <NUM>. The loader-indexing feature <NUM> is configured to mate with the tool-indexing feature <NUM> to index the material loader <NUM> relative to the tool <NUM>.

In one or more examples, the loader-indexing feature <NUM> includes at least one projection (e.g., a fork) and the tool-indexing feature <NUM> includes at least one opening (e.g., a mouse hole) that is configured to receive the loader-indexing feature <NUM>. However, in other examples, the loader-indexing feature <NUM> and the tool-indexing feature <NUM> may include, or take the form of, any one of various other physical indexing structures (e.g., probes, indexing pins, etc.) or visual indexing features (e.g., optical targets and vision-based or laser-based detectors).

Referring to <FIG>, in one or more examples, the overhead material handler <NUM> includes a support beam <NUM>. The overhead material handler <NUM> also includes a hanger <NUM>. The hanger <NUM> is connected to the support beam <NUM> and to the composite workpiece <NUM> such that the composite workpiece <NUM> is suspended from the support beam <NUM>. In one or more examples, the hanger <NUM> is connected to the composite workpiece <NUM> at, or using, the hole <NUM> such that the composite workpiece <NUM> is suspended from the hanger <NUM> by the hole <NUM>.

The present disclosure is also directed to a method for post-cure processing the composite workpiece <NUM> using the system <NUM>. The present disclosure is also directed to a composite workpiece <NUM> that includes the hole <NUM>, or the plurality of holes <NUM>) formed while the composite workpiece <NUM> is on the tool <NUM> using the system <NUM>.

Referring now to <FIG>, which illustrates an example of a method <NUM> for post-cure processing of the composite workpiece <NUM>. In one or more examples, the method <NUM> is implemented using the system <NUM>.

In one or more examples, the method <NUM> includes a step of (block <NUM>) forming the sacrificial portion <NUM> of the tool <NUM>. In one or more examples, step of (block <NUM>) forming the sacrificial portion <NUM> includes a step of filling the recess <NUM> formed in the tool surface <NUM> of the tool <NUM> with the sacrificial material <NUM> such that the top surface <NUM> of the sacrificial material <NUM> (e.g., of the sacrificial portion <NUM>) is flush with and forms a portion of the tool surface <NUM>.

In one or more examples, the method <NUM> includes a step of (block <NUM>) forming the composite layup on the tool surface <NUM> of the tool <NUM>. Alternatively, the method includes a step of forming the composite layup on a dedicate layup tool and a step of transferring the composite layup to the tool <NUM> for curing.

In one or more examples, the method <NUM> includes a step of (<NUM>) curing the composite layup (e.g., an uncured or "green" composite) on the tool <NUM> to form the composite workpiece <NUM> (e.g., a cured composite).

In one or more examples, the method <NUM> includes a step of (block <NUM>) supporting the composite workpiece <NUM> on the tool surface <NUM> of the tool <NUM>.

In one or more examples, the method <NUM> includes a step of (block <NUM>) defining the drilling location <NUM> on the composite workpiece <NUM> while the composite workpiece <NUM> is on the tool <NUM> using the drill template <NUM>. In one or more examples, the step of (block <NUM>) defining the drilling location <NUM> is performed (e.g., determined) physically using the template body <NUM>, coupled to the tool <NUM>, and the drill guide <NUM>, located over the sacrificial portion <NUM> of the tool <NUM>. In one or more examples, step of (block <NUM>) defining the drilling location <NUM> is performed (e.g., determined) virtually using the virtual template <NUM>.

In one or more examples, the method <NUM> includes a step of (block <NUM>) indexing the drilling location <NUM> to the sacrificial portion <NUM> of the tool <NUM>. In one or more examples, step of (block <NUM>) indexing the drilling location <NUM> to the sacrificial portion <NUM> is performed physically by coupling the template body <NUM> to the tool <NUM>. In one or more examples, step of (block <NUM>) indexing the drilling location <NUM> to the sacrificial portion <NUM> is performed virtually using the workpiece model <NUM>, the tool model <NUM>, and the virtual template <NUM>.

In one or more examples, the step of (block <NUM>) indexing the drilling location <NUM> to the sacrificial portion <NUM> of the tool <NUM> includes a step of indexing the drill template <NUM> to the tool <NUM> (e.g., coupling the template body <NUM> to the tool <NUM>) to align the drill guide <NUM> (e.g., the template hole <NUM>) of the drill template <NUM> with the sacrificial portion <NUM> of the tool <NUM>.

In one or more examples, the step of (block <NUM>) indexing the drilling location <NUM> to the sacrificial portion <NUM> of the tool <NUM> includes a step of indexing the virtual template <NUM> relative to the workpiece model <NUM> such that the virtual drill guide <NUM> is aligned with the sacrificial portion <NUM> of the tool <NUM> and a step of determining the drilling location <NUM> relative to the reference frame <NUM> based on the virtual drill guide <NUM>.

In one or more examples, the method <NUM> includes a step of (block <NUM>) drilling the hole <NUM> through the composite workpiece <NUM> at the drilling location <NUM>, defined by the drill template <NUM>, while the composite workpiece <NUM> is on the tool <NUM>. In one or more examples, step of (block <NUM>) drilling the hole <NUM> through the composite workpiece <NUM> is performed manually using the drill <NUM>. In one or more examples, the step of (block <NUM>) drilling the hole <NUM> through the composite workpiece <NUM> is performed automatically or semi-automatically using the automated drilling machine <NUM>, such as by instructing the automated drilling machine <NUM> to automatically drill the hole <NUM> through the composite workpiece <NUM> on the tool <NUM> at the drilling location <NUM>.

In one or more examples, the method <NUM> includes a step of (block <NUM>) drilling the sacrificial portion <NUM> of the tool <NUM> while drilling the hole <NUM> through the composite workpiece <NUM> while the composite workpiece <NUM> is on the tool <NUM>. In one or more examples, the step of (block <NUM>) drilling the sacrificial portion <NUM> of the tool <NUM> includes a step of drilling the sacrificial material <NUM> of the sacrificial portion <NUM> and a step of penetrating the recess <NUM> of the sacrificial portion <NUM>.

In one or more examples, the method <NUM> includes a step of (block <NUM>) digitizing at least a portion the composite workpiece <NUM> while the composite workpiece <NUM> is on the tool <NUM>.

In one or more examples, the step of (block <NUM>) digitizing the composite workpiece <NUM> is performed before the step of (block <NUM>) drilling the hole <NUM> through the composite workpiece <NUM> on the tool <NUM>. In these examples, the workpiece model <NUM> is representative of at least the contour of the second surface <NUM> of the composite workpiece <NUM> relative to the reference frame <NUM>.

In one or more examples, the step of (block <NUM>) digitizing the composite workpiece <NUM> is performed (or is performed again) after the step of (block <NUM>) drilling the hole <NUM> through the composite workpiece <NUM>. In these examples, the workpiece model <NUM> is also representative of the location of the hole <NUM> relative to the reference frame <NUM>.

In one or more examples, the method <NUM> includes a step of (block <NUM>) generating the workpiece model <NUM> that is representative of at least a portion of the composite workpiece <NUM>, such as of at least the contour of the composite workpiece <NUM> as on the tool <NUM>.

In one or more examples, the method <NUM> includes a step of (block <NUM>) demolding the composite workpiece <NUM> from the tool <NUM>. In one or more examples, the step of (block <NUM>) demolding the composite workpiece <NUM> includes a step of separating the composite workpiece <NUM> from the tool surface <NUM> and a step of removing the composite workpiece <NUM> from the tool <NUM>. In one or more examples, the step of (block <NUM>) is preformed automatically or semi-automatically using the material loader <NUM>. In one or more examples, the step of (block <NUM>) is performed manually.

In one or more examples, the method <NUM> includes a step of (block <NUM>) transferring the composite workpiece <NUM> to a subsequent work cell (e.g., the second work cell <NUM>) for performance of a subsequent post-cure processing operation. In one or more examples, the step of (block <NUM>) transferring the composite workpiece <NUM> includes a step of transferring the composite workpiece <NUM> from the tool <NUM> to the overhead material handler <NUM> and a step of moving the composite workpiece <NUM> to the subsequent work cell using the overhead material handler <NUM>. In one or more examples, the step of transferring the composite workpiece <NUM> from the tool <NUM> to the overhead material handler <NUM> is performed using the material loader <NUM>. In one or more examples, transferring the composite workpiece <NUM> from the tool <NUM> to the overhead material handler <NUM> is performed manually. In one or more examples, the step of transferring the composite workpiece <NUM> to the overhead material handler <NUM> includes a step of coupling the hanger <NUM> of the overhead material handler <NUM> to the composite workpiece <NUM> using the hole <NUM> drilled through the composite workpiece <NUM> and a step of suspending the composite workpiece <NUM> from the support beam <NUM> of the overhead material handler <NUM>.

In one or more examples, the method <NUM> includes a step of transferring the composite workpiece <NUM> from the overhead material handler <NUM> to the tooling fixture <NUM> located in the subsequent work cell (e.g., the second work cell <NUM> as shown in <FIG>). In one or more examples, the method <NUM> includes a step of performing the subsequent processing operation (e.g., a machining operation, a trimming operation, a coating operation, and the like) on the composite workpiece <NUM> while the composite workpiece <NUM> is on, or is being held by, the tooling fixture <NUM>.

In one or more examples, the method <NUM> includes a step of (block <NUM>) indexing the composite workpiece <NUM> to the subsequent work cell (e.g., the second work cell <NUM>) for the subsequent processing operation by conforming the workpiece model <NUM> to the work-cell reference frame <NUM>. In one or more examples, the step of (block <NUM>) indexing the composite workpiece <NUM> includes a step of conforming the composite workpiece <NUM> to the workpiece model <NUM>.

In one or more examples, the method <NUM> includes a step of reforming (e.g., replacing or repairing) the sacrificial portion <NUM> of the tool <NUM> after the hole <NUM> is drilled through the composite workpiece <NUM>, after the composite workpiece <NUM> is removed (e.g., demolded) from the tool <NUM>, and before a subsequent composite workpiece is located on the tool <NUM>. For example, remnants of the sacrificial material <NUM> are removed and/or cleaned from within the recess <NUM> and the sacrificial material <NUM> is replaced to fill the recess <NUM>.

The present disclosure is also directed to a system of post-cure processing the composite workpiece <NUM> implemented according to the method <NUM>. The present disclosure is further directed to the composite workpiece <NUM> that includes the hole <NUM> or the plurality of holes <NUM> formed while the composite workpiece <NUM> is on the tool <NUM> according to the method <NUM>.

Referring now to <FIG> and <FIG>, examples of the system <NUM>, the method <NUM>, and the composite workpiece <NUM> may be related to, or used in the context of, an aircraft manufacturing and service method <NUM>, as shown in the flow diagram of <FIG> and the aircraft <NUM>, as schematically illustrated in <FIG>. For example, the aircraft <NUM> and/or the aircraft production and service method <NUM> may utilize the composite workpiece <NUM> that is machined using the system <NUM>, described herein and illustrated in <FIG>, and/or according to the method <NUM>, described herein and illustrated in <FIG>.

Referring to <FIG>, examples of the aircraft <NUM> may include an airframe <NUM> having the interior <NUM>. The aircraft <NUM> also includes a plurality of high-level systems <NUM>. Examples of the high-level systems <NUM> include one or more of a propulsion system <NUM>, an electrical system <NUM>, a hydraulic system <NUM>, and an environmental system <NUM>. In other examples, the aircraft <NUM> may include any number of other types of systems, such as a communications system, a flight control system, a guidance system, a weapons system, and the like. In one or more examples, the composite workpiece <NUM> made (e.g., machined and/or processed) using the system <NUM> and/or according to the method <NUM> forms a component of the airframe <NUM>, such as a wing <NUM>, a fuselage <NUM>, a panel, a stringer, a spar, and the like.

Referring to <FIG>, during pre-production, the service method <NUM> includes specification and design of the aircraft <NUM> (block <NUM>) and material procurement (block <NUM>). During production of the aircraft <NUM>, component and subassembly manufacturing (block <NUM>) and system integration (block <NUM>) of the aircraft <NUM> take place. Thereafter, the aircraft <NUM> goes through certification and delivery (block <NUM>) to be placed in service (block <NUM>). Routine maintenance and service (block <NUM>) includes modification, reconfiguration, refurbishment, etc. of one or more systems of the aircraft <NUM>.

Each of the processes of the service method <NUM> illustrated in <FIG> may be performed or carried out by a system integrator, a third party, and/or an operator (e.g., a customer). For the purposes of this description, a system integrator may include, without limitation, any number of spacecraft manufacturers and major-system subcontractors; a third party may include, without limitation, any number of vendors, subcontractors, and suppliers; and an operator may be an airline, leasing company, military entity, service organization, and so on.

Examples of the system <NUM> and the method <NUM> shown and described herein may be employed during any one or more of the stages of the manufacturing and service method <NUM> shown in the flow diagram illustrated by <FIG>. In an example, manufacture of the composite workpiece <NUM> in accordance with the method <NUM> and/or using the system <NUM> may form a portion of component and subassembly manufacturing (block <NUM>) and/or system integration (block <NUM>). Further, the composite workpiece <NUM> manufactured in accordance with the method <NUM> and/or using the system <NUM> may be utilized in a manner similar to components or subassemblies prepared while the aircraft <NUM> is in service (block <NUM>). Also, the composite workpiece <NUM> manufactured in accordance with the method <NUM> and/or using the system <NUM> may be utilized during system integration (block <NUM>) and certification and delivery (block <NUM>). Similarly, manufacture of the composite workpiece <NUM> in accordance with the method <NUM> and/or using the system <NUM> may be utilized, for example and without limitation, while the aircraft <NUM> is in service (block <NUM>) and during maintenance and service (block <NUM>). For example, spare and or replacement composite parts may be fabricated in accordance with the method <NUM> and/or using the system <NUM>, which may be installed due to a prescribed maintenance cycle or after a realization of damage to a composite part.

In can be appreciated that performing at least a portion of the post-cure processing operation on the composite workpiece <NUM> while the composite workpiece <NUM> is on the tool <NUM>, using the workpiece model <NUM> to index the composite workpiece <NUM> in one or more of the plurality of work cells <NUM>, and updating the workpiece model <NUM> after each subsequent processing operation may improve the accuracy and speed of the processing operation and enable determinate or predictive assembly of the composite workpiece <NUM>.

Although an aerospace example is shown, the examples and principles disclosed herein may be applied to other industries, such as the automotive industry, the space industry, the construction industry, and other design and manufacturing industries. Accordingly, in addition to aircraft, the examples and principles disclosed herein may apply to composite structures, systems, and methods of making the same for other types of vehicles (e.g., land vehicles, marine vehicles, space vehicles, etc.) and stand-alone structures.

The preceding detailed description refers to the accompanying drawings, which illustrate specific examples described by the present disclosure. Other examples having different structures and operations do not depart from the scope of the present disclosure. Like reference numerals may refer to the same feature, element, or component in the different drawings. Throughout the present disclosure, any one of a plurality of items may be referred to individually as the item and a plurality of items may be referred to collectively as the items and may be referred to with like reference numerals. Moreover, as used herein, a feature, element, component or step preceded with the word "a" or "an" should be understood as not excluding a plurality of features, elements, components or steps, unless such exclusion is explicitly recited.

Illustrative, non-exhaustive examples, which may be, but are not necessarily, claimed, of the subject matter according to the present disclosure are provided above. Reference herein to "example" means that one or more feature, structure, element, component, characteristic, and/or operational step described in connection with the example is included in at least one aspect, embodiment, and/or implementation of the subject matter according to the present disclosure. Thus, the phrases "an example," "another example," "one or more examples," and similar language throughout the present disclosure may, but do not necessarily, refer to the same example. Further, the subject matter characterizing any one example may, but does not necessarily, include the subject matter characterizing any other example. Moreover, the subject matter characterizing any one example may be, but is not necessarily, combined with the subject matter characterizing any other example.

Unless otherwise indicated, the terms "first," "second," "third," etc. are used herein merely as labels, and are not intended to impose ordinal, positional, or hierarchical requirements on the items to which these terms refer. Moreover, reference to, e.g., a "second" item does not require or preclude the existence of, e.g., a "first" or lower-numbered item, and/or, e.g., a "third" or highernumbered item.

For the purpose of the present disclosure, the term "position" of an item refers to a location of the item in three-dimensional space relative to a fixed reference frame and an angular orientation of the item in three-dimensional space relative to the fixed reference frame.

For the purpose of this disclosure, the terms "coupled," "coupling," and similar terms refer to two or more elements that are joined, linked, fastened, attached, connected, put in communication, or otherwise associated (e.g., mechanically, electrically, fluidly, optically, electromagnetically) with one another. In various examples, the elements may be associated directly or indirectly. As an example, element A may be directly associated with element B. As another example, element A may be indirectly associated with element B, for example, via another element C. It will be understood that not all associations among the various disclosed elements are necessarily represented. Accordingly, couplings other than those depicted in the figures may also exist.

As used herein, the term "approximately" refers to or represent a condition that is close to, but not exactly, the stated condition that still performs the desired function or achieves the desired result. As an example, the term "approximately" refers to a condition that is within an acceptable predetermined tolerance or accuracy, such as to a condition that is within <NUM>% of the stated condition. However, the term "approximately" does not exclude a condition that is exactly the stated condition. As used herein, the term "substantially" refers to a condition that is essentially the stated condition that performs the desired function or achieves the desired result.

<FIG> and <FIG>, referred to above, may represent functional elements, features, or components thereof and do not necessarily imply any particular structure. Accordingly, modifications, additions and/or omissions may be made to the illustrated structure. Additionally, those skilled in the art will appreciate that not all elements, features, and/or components described and illustrated in <FIG> and <FIG>, referred to above, need be included in every example and not all elements, features, and/or components described herein are necessarily depicted in each illustrative example. Accordingly, some of the elements, features, and/or components described and illustrated in <FIG> and <FIG>may be combined in various ways without the need to include other features described and illustrated in <FIG> and <FIG>, other drawing figures, and/or the accompanying disclosure, even though such combination or combinations are not explicitly illustrated herein. Similarly, additional features not limited to the examples presented, may be combined with some or all of the features shown and described herein. Unless otherwise explicitly stated, the schematic illustrations of the examples depicted in <FIG> and <FIG>, referred to above, are not meant to imply structural limitations with respect to the illustrative example. Rather, although one illustrative structure is indicated, it is to be understood that the structure may be modified when appropriate. Accordingly, modifications, additions and/or omissions may be made to the illustrated structure. Furthermore, elements, features, and/or components that serve a similar, or at least substantially similar, purpose are labeled with like numbers in each of <FIG> and <NUM>, and such elements, features, and/or components may not be discussed in detail herein with reference to each of <FIG> and <FIG>. Similarly, all elements, features, and/or components may not be labeled in each of <FIG> and <FIG>, but reference numerals associated therewith may be utilized herein for consistency.

In <FIG> and <FIG>, referred to above, the blocks may represent operations, steps, and/or portions thereof and lines connecting the various blocks do not imply any particular order or dependency of the operations or portions thereof. It will be understood that not all dependencies among the various disclosed operations are necessarily represented. <FIG> and <FIG> and the accompanying disclosure describing the operations of the disclosed methods set forth herein should not be interpreted as necessarily determining a sequence in which the operations are to be performed. Rather, although one illustrative order is indicated, it is to be understood that the sequence of the operations may be modified when appropriate. Accordingly, modifications, additions and/or omissions may be made to the operations illustrated and certain operations may be performed in a different order or simultaneously. Additionally, those skilled in the art will appreciate that not all operations described need be performed.

Further, references throughout the present specification to features, advantages, or similar language used herein do not imply that all of the features and advantages that may be realized with the examples disclosed herein should be, or are in, any single example. Rather, language referring to the features and advantages is understood to mean that a specific feature, advantage, or characteristic described in connection with an example is included in at least one example. Thus, discussion of features, advantages, and similar language used throughout the present disclosure may, but do not necessarily, refer to the same example.

Claim 1:
A system (<NUM>) for post-cure processing of a composite workpiece (<NUM>), the system (<NUM>) comprising:
a tool (<NUM>) comprising a tool surface (<NUM>), wherein the tool surface (<NUM>) supports the composite workpiece (<NUM>) located on the tool (<NUM>), and the tool (<NUM>) further comprises a sacrificial portion (<NUM>) disposed on the tool surface (<NUM>);
a drill template (<NUM>) that defines a drilling location (<NUM>) for drilling a hole (<NUM>) through the composite workpiece (<NUM>) while the composite workpiece (<NUM>) is on the tool (<NUM>), wherein the drill template (<NUM>) indexes the drilling location (<NUM>) to the sacrificial portion (<NUM>);
a scanner (<NUM>) to digitize at least a portion the composite workpiece (<NUM>) while the composite workpiece (<NUM>) is on the tool (<NUM>); and
a computing device (<NUM>) adapted to generate a workpiece model (<NUM>) representative of the composite workpiece (<NUM>), wherein:
the workpiece model (<NUM>) is representative of a contour of the composite workpiece (<NUM>) as on the tool (<NUM>);
the drill template (<NUM>) is a virtual template (<NUM>); and
the computing device (<NUM>) is further adapted to:
locate the virtual template (<NUM>) relative to the workpiece model (<NUM>) such that a virtual drill guide (<NUM>) is indexed to the sacrificial portion (<NUM>) of the tool (<NUM>);
determine the drilling location (<NUM>) relative to a reference frame (<NUM>) based on the virtual drill guide (<NUM>); and
instruct an automated drilling machine (<NUM>) to drill the hole (<NUM>) at the drilling location (<NUM>).