Patent Description:
Large composite parts, such as those spanning tens of feet, occupy substantial space within a factory floor. Laminates for these parts are laid up on a mandrel in a stationary work cell. The mandrel is moved to another stationary work cell and the laminate is hardened into a composite part. Next, the composite part is separated from the mandrel. The manufacturing excess for a composite part is trimmed immediately after demolding. The composite part is then transported to a new stationary work cell to receive work, such as NDI inspection. Each time transportation occurs, the composite part must be aligned to the stationary work cell. Alignment to each stationary work cell adds time and complexity to the fabrication process.

Patent document <CIT>, according to its abstract, states: a semifinished arrangement for the production of a fiber composite component by forming a flat fiber composite semifinished product in a mold, comprising the fiber composite semifinished product and a plurality of holding elements extending beyond the edge of the fiber composite semifinished product. The holding elements are recessed in recesses of the fiber composite semifinished product in order to avoid a height-wise projection. This allows for the edge of the fiber composite semifinished product to extend at least partially within the molding tool during the reshaping. A method for producing a fiber composite component using a semifinished arrangement is also provided.

Patent document <CIT>, according to its abstract, states: 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: a method for manufacturing of a CFRP part comprising the following steps: laying out one or more pre-preg or composite plies, on a mould comprising a marking tool, forming an uncured laminate with a guiding mark on the uncured laminate using, curing the laminate giving the part the final shape with the guiding mark and, trimming and/or drilling the CFRP part taking as reverence the guiding mark. Further, a mould is provided for moulding and curing a CFRP part comprising a marking tool adapted to perform a guiding mark on a fresh CFRP part, and a system for manufacturing of a moulded CFRP part.

Present techniques for fabricating large composite parts result in large parts that require substantial amounts of time to probe and inspect each time the composite parts are moved.

Embodiments described herein provide systems and methods for fabricating indexing features into a composite part that resides at a mandrel. The mandrel, being a rigid tool, is already machined to a desired level of precision. By following indexing features placed in the mandrel, a machine may rapidly apply indexing features precisely to a composite part hardened thereon. After the composite part is removed, its integral indexing features are utilized to rapidly the index the composite part to one or more stations that perform work on the composite part as the composite part moves in a process direction.

One embodiment is a method for preparing a composite part for assembly. The method includes receiving a mandrel to which a composite part has been molded, and operating a work station to install an indexing feature into a manufacturing excess of the composite part.

A further embodiment is a system for preparing a composite part for assembly. The system includes a mandrel that moves in a process direction while transporting a composite part. The mandrel comprises a layup surface for the composite part, and indexing features disposed at predetermined locations. The system further includes a work station that indexes to the indexing features at the mandrel, and that installs an indexing feature onto the composite part that is offset from the indexing feature at the mandrel, and a downstream work station that indexes to the indexing feature installed onto the composite part.

A further embodiment is a method for processing a composite part. The method includes receiving a mandrel to which a composite part has been molded, and processing the composite part based on indexing features located in the mandrel.

Yet another embodiment is a non-transitory computer readable medium embodying programmed instructions which, when executed by a processor, are operable for performing a method of preparing a composite part for assembly. The method includes receiving a mandrel to which a composite part has been molded, and operating a work station to install an indexing feature into a manufacturing excess of the composite part.

According to an aspect of the present disclosure, a method for preparing a composite part for assembly is provided, the method comprising: placing a preform with a manufacturing excess upon a mandrel; hardening the preform into composite part with a hardened manufacturing excess while still upon mandrel; and installing an indexing feature into the manufacturing excess pre-hardening and/or post hardening prior to demolding from mandrel.

Advantageously, the method further comprises demolding the composite part from the mandrel advancing the composite part in a process direction and indexing the composite part to a downstream work station via the indexing feature installed into the composite part.

Preferably, the method further comprises operating a mandrel work station to install an indexing feature into the manufacturing excess of the composite part prior to demolding the composite part from the mandrel.

Preferably, the method further comprises separating flash edges from the composite part prior to demolding.

Preferably, the method further comprises indexing the mandrel work station to a mandrel indexing feature at the mandrel.

Preferably, in the method, the indexing feature installed into the manufacturing excess of the composite part is offset from a mandrel indexing feature.

Preferably, in the method, indexing the mandrel work station to the mandrel indexing feature at the mandrel comprises inserting a complementary key of the mandrel work station into a corresponding keyway at the mandrel.

Preferably, in the method, the mandrel work station follows a groove at the mandrel.

Preferably, in the method, the mandrel work station follows a track at the mandrel.

Preferably, in the method, operating the mandrel work station to install the indexing feature comprises subtractive fabrication using drilling, milling or trimming or by additive fabrication such as adding pins adding RFID tags or adding bar codes.

Preferably, in the method, the mandrel work station cuts through the composite part into a potted recess of the mandrel to install the indexing feature into composite part.

Preferably, in the method, installing the indexing feature comprises installing a notch in the bearing edge and/or edge at the mandrel of the composite part.

Preferably, in the method, installing the indexing feature comprises installing the indexing feature in a manufacturing excess selected from the group consisting of window manufacturing excess and/or door manufacturing excess, and antenna cut-out regions on the composite part.

Preferably, in the method, operating the mandrel work station to install the indexing feature comprises installing multiple types of indexing features, wherein different types of indexing features are utilized by different downstream work stations.

Preferably, in the method, the indexing features installed into the manufacturing excess of the composite part are selected from the group consisting of cup locating features, drill start locations, drill through locations, slots, installed pins RFID tags bar codes, formed indexing feature and notch.

Preferably, in the method, the indexing features installed into the manufacturing excess of the composite part using mandrel indexing features selected from the group consisting of indents, protrusions, ridges, grooves, notches, through-holes, blind holes, RFID tags, and bar code.

A portion of an aircraft assembled according to the method as described above is part of the present disclosure.

According to an aspect of the present disclosure, a system for preparing a composite part for assembly is provided, the system comprising: a mandrel that comprises: a layup surface for the composite part; and mandrel indexing features disposed at the mandrel; and a mandrel work station that indexes to the mandrel indexing features, and that installs an indexing feature onto the composite part that is offset from the mandrel indexing feature.

Advantageously, in the system, a downstream work station indexes to the indexing feature.

Preferably, in the system, a downstream work station receives the composite part after the composite part has been demolded from the mandrel.

Preferably, the system further comprises the mandrel moves in a process direction while transporting the composite part.

Preferably, in the system, the mandrel work station comprises an indexing feature tool that cuts into the composite part without cutting through the composite part.

Preferably, in the system, a complementary key of the mandrel work station is inserted into a corresponding keyway at the mandrel to index the mandrel work station to the mandrel indexing feature.

Fabricating a portion of an aircraft using the system described above is part of the present disclosure.

According to an aspect of the present disclosure, a method for processing a composite part is provided, the method comprising: receiving a mandrel to which a composite part has been molded; and processing the composite part based on indexing features located on the mandrel.

Advantageously, the method wherein processing the composite part comprises installing indexing features into the composite part prior to demolding.

Preferably, the method further comprises processing the composite part comprises separating flash edges from the composite part prior to demolding.

Preferably, the method further comprises demolding the composite part from the mandrel advancing the composite part in a process direction and indexing the composite part to a downstream work station via the indexing feature installed into the composite part.

Preferably, the method further comprises the indexing feature installed into the manufacturing excess of the composite part is offset from the mandrel indexing feature at the mandrel.

Preferably, the method further comprises indexing the mandrel work station to the mandrel indexing feature at the mandrel comprises inserting a complementary key of the mandrel work station into a corresponding keyway at the mandrel.

Preferably, the method further comprises the mandrel work station follows a groove and/or track at the mandrel.

Preferably, the method further comprises operating the mandrel work station to install the indexing feature comprises cutting into the composite part without cutting through the composite part.

Preferably, the method further comprises the mandrel work station cuts through the composite part into a potted recess of the mandrel to install the indexing feature.

Preferably, the method further comprises installing the indexing feature comprises installing a notch in the bearing edge and/or edge at the mandrel of the composite part.

Preferably, the method further comprises installing the indexing feature comprises installing a notch in a bearing edge of the composite part.

Preferably, the method further comprises installing the indexing feature comprises installing the indexing feature in a manufacturing excess, window manufacturing excess and/or door manufacturing excess.

Preferably, the method further comprises removing the manufacturing excess from the composite part.

Preferably, the method further comprises operating the mandrel work station to install the indexing feature comprises installing multiple types of indexing features, wherein different types of indexing features are utilized by different downstream work stations.

Preferably, the method further comprises the indexing features installed into the manufacturing excess, window manufacturing excess and/or door manufacturing excess of the composite part are selected from the group consisting of cup locating features, drill start locations, drill through locations, slots, installed pins RFID tags bar codes , formed indexing feature and notch.

A portion of an aircraft assembled according to the method described above is part of the present disclosure.

According to an aspect of the present disclosure, an apparatus for forming composite parts is provided, the apparatus comprising: a mandrel defining a contour for a composite part, the mandrel comprising: potted recesses disposed in a layup region for the composite part, beneath locations providing a layup region for a manufacturing excess of the composite part; and an index contour feature disposed within the layup region.

Advantageously, in the apparatus, the mandrel further comprises keyways disposed beyond the layup region.

Advantageously, in the apparatus, the mandrel further comprises grooves disposed beyond the layup region that guide a mandrel work station.

Fabricating a portion of an aircraft using the apparatus described above is part of the present disclosure.

According to an aspect of the present disclosure, a system for preparing a composite part for assembly is provided, the system comprising: a mandrel that comprises a layup region for the composite part; a composite part placed upon the layup region; and mandrel indexing features disposed at the mandrel.

Advantageously, the system further comprises a mandrel work station that indexes to the mandrel indexing features.

Preferably, the system further comprises the mandrel work station installs an indexing feature onto the composite part that is offset from the mandrel indexing feature.

Preferably, the system further comprises a potted recess disposed in a layup region, beneath locations providing a layup region for a manufacturing excess of the composite part.

Preferably, the system further comprises the mandrel further comprises keyways disposed beyond the layup region.

Preferably, in the system, the mandrel further comprises grooves disposed beyond the layup region that guide a mandrel work station.

Preferably, the system further comprises the flash edge and manufacturing excess is separated from the composite part prior to demolding.

Preferably, in the system, the separated flash edge and separated manufacturing excess are collected in chute system.

According to an aspect of the present disclosure, an indexing feature installer is provided, comprising: a mandrel work station; and a feature creator coupled to the mandrel work station.

Advantageously, the indexing feature installer further comprises a transmitter coupled to the mandrel work station.

Preferably, the indexing feature installer further comprises an indexing key coupled to the mandrel work station.

Preferably, in the indexing feature installer, the indexing key comprises a complementary key.

Preferably, in the indexing feature installer, the feature creator is selected from the group consisting of a blade, a drill, a mill, a pin installer, an RFID tag installer, a bar code installer and a fastener installer.

Preferably, in the indexing feature installer, the mandrel work station is coupled to a mandrel.

Preferably, in the indexing feature installer, the mandrel work station is coupled to the mandrel by a groove in the mandrel.

Preferably, in the indexing feature installer, the mandrel work station is transportable relative to manufacturing excess by slide-ably engaging the groove.

Preferably, in the indexing feature installer, the mandrel work station is transportable relative to manufacturing excess by slide-ably engaging the groove via a roller system.

Preferably, in the indexing feature installer, the mandrel work station is coupled to the mandrel by a track on the mandrel.

Preferably, in the indexing feature installer, the mandrel work station is transportable relative to manufacturing excess by slide-ably engaging the track.

Preferably, in the indexing feature installer, the mandrel work station is transportable relative to manufacturing excess by slide-ably engaging the track via a roller system.

Preferably, the indexing feature installer further comprises the complementary key configured to complementarily mate with a mandrel indexing feature.

Preferably, the indexing feature installer further comprises the blade selected from the group consisting of a reciprocating blade or a circular blade.

Preferably, in the indexing feature installer, the mandrel work station comprising a controller.

Other illustrative embodiments (e.g., methods and computer-readable media relating to the foregoing embodiments) may be described below. The features, functions, and advantages that have been discussed can be achieved independently in various embodiments or may be combined in yet other embodiments further details of which can be seen with reference to the following description and drawings.

The figures and the following description provide specific illustrative embodiments of the disclosure. It will thus be appreciated that those skilled in the art will be able to devise various arrangements that, although not explicitly described or shown herein, embody the principles of the disclosure and are included within the scope of the disclosure. Furthermore, any examples described herein are intended to aid in understanding the principles of the disclosure, and are to be construed as being without limitation to such specifically recited examples and conditions. As a result, the disclosure is not limited to the specific embodiments or examples described below, but by the claims.

Composite parts, such as Carbon Fiber Reinforced Polymer (CFRP) parts, are initially laid-up in multiple layers that together are referred to as a preform or laminate. Individual fibers within each layer of the preform are aligned parallel with each other, but different layers exhibit different fiber orientations in order to increase the strength of the resulting composite part along different dimensions. The preform includes a viscous resin that solidifies in order to harden the preform into a composite part (e.g., for use in an aircraft). Carbon fiber that has been impregnated with an uncured thermoset resin or a thermoplastic resin is referred to as "prepreg". Other types of carbon fiber include "dry fiber" which has not been impregnated with thermoset resin but may include a tackifier or binder. Dry fiber is infused with resin prior to curing. For thermoset resins, the hardening is a one-way process referred to as curing, while for thermoplastic resins, the resin reaches a viscous form if it is re-heated.

Turning now to <FIG>, an illustration of an aircraft is depicted in which an illustrative embodiment may be implemented. Aircraft <NUM> is an example of an aircraft which can be formed caul plate <NUM>, <NUM>-<NUM> of <FIG>, <FIG> <FIG>, respectively. Aircraft <NUM> is an example of an aircraft <NUM> which is formed of half barrel sections <NUM> of fuselage <NUM>.

In this illustrative example, aircraft <NUM> has wing <NUM> and wing <NUM> attached to body <NUM>. Aircraft <NUM> includes engine <NUM> attached to wing <NUM> and engine <NUM> attached to wing <NUM>.

Body <NUM> has tail section <NUM>. Horizontal stabilizer <NUM>, horizontal stabilizer <NUM>, and vertical stabilizer <NUM> are attached to tail section <NUM> of body <NUM>.

Fuselage <NUM> is fabricated from half barrel sections <NUM> with an upper half barrel section <NUM> joined to a lower half barrel section <NUM> to form a full barrel section <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-n. There are n numbers of full barrel sections as illustrated by <NUM>-n. The full barrel sections are joined serially, such as end to end, to form fuselage <NUM>.

Wing <NUM> and <NUM> are formed of wing panels <NUM> comprising upper wing panel <NUM> and a lower wing panel <NUM> joined together. Section cut <NUM> is a cut through of upper wing panel <NUM> and corresponds to unhardened preform <NUM>, <NUM>-<NUM> (<FIG> and <FIG>). Section cut <NUM> is orientated chord wise roughly perpendicular to upper wing panel <NUM>.

Section cut <NUM> is a cut through composite part <NUM> and corresponds to half barrel section preform <NUM>-<NUM> (<FIG>) prior to hardening. Half barrel section preform <NUM>-<NUM> corresponds to preform <NUM>. Section cut <NUM> is orientated longitudinally <NUM> through a contour <NUM>-<NUM> along a stringer.

<FIG>, <FIG> is a block diagram of a fabrication environment <NUM>, <NUM>-<NUM> for installing indexing features <NUM>, B126 into and/or onto composite parts <NUM>, <NUM>-<NUM> in an illustrative embodiment. In prior systems, manufacturing excess for a composite part is trimmed immediately after demolding. Fabrication environment <NUM>, <NUM>-<NUM> is unique in that it utilizes material during subsequent assembly that is traditionally immediately trimmed from a composite part <NUM>, <NUM>-<NUM> after demolding. Fabrication environment <NUM>, <NUM>-<NUM> comprises any system, device, or component operable to install indexing features <NUM>, B126 onto a composite part <NUM>, <NUM>-<NUM> that resides on a layup surface <NUM>, <NUM>-<NUM> (e.g., defining a curved or flat contour) in a layup region <NUM>, <NUM>-<NUM> of a mandrel <NUM>, <NUM>-<NUM> (e.g., a rigid tool, such as a steel tool, composite tool, Invar tool, aluminum tool, etc., that is capable of withstanding heat and pressure applied during hardening of the composite part <NUM>, <NUM>-<NUM>, such as a half barrel section <NUM> or wing panel <NUM>-<NUM>). As used herein, an indexing feature <NUM>, B126 comprises a physical, electrical, optical, or other sensory feature that is integrated into the mandrel or the composite part <NUM>, <NUM>-<NUM>, and characterizes a portion of the composite part <NUM>, <NUM>-<NUM> (or mandrel) within the purview <NUM>-<NUM> of a work station <NUM>-<NUM>.

The mandrel <NUM>, <NUM>-<NUM> that carries the composite part <NUM>, <NUM>-<NUM> proceeds in a process direction <NUM>, <NUM>-<NUM> during fabrication. In this embodiment, the mandrel <NUM>, <NUM>-<NUM> proceeds along a track <NUM>, <NUM>-<NUM> (e.g., a series of discrete stanchions having rollers, a rail or set of rails, etc.) during fabrication, and may be pulsed incrementally such as its entire length, several feet to several inches in the process direction <NUM>, <NUM>-<NUM>, in what is known as a micro pulse <NUM>. In further embodiments, the mandrel <NUM>, <NUM>-<NUM> proceeds continuously in the process direction <NUM>, <NUM>-<NUM>. The mandrel <NUM>, <NUM>-<NUM> defines a contour for the placed composite part <NUM>, <NUM>-<NUM>, such as a half barrel section <NUM> of an aircraft fuselage <NUM>, or a wing panel <NUM>-<NUM> for a wing <NUM>. A half barrel section preform <NUM>-<NUM> is placed upon mandrel <NUM>, <NUM>-<NUM> during layup and then is hardened into composite part <NUM>, <NUM>-<NUM>.

The mandrel <NUM>, <NUM>-<NUM> has mandrel indexing features <NUM>, B114, such as indents <NUM>-<NUM>, B114-<NUM>, protrusions <NUM>-<NUM>, B114-<NUM>, ridges <NUM>-<NUM>, B114-<NUM>, grooves <NUM>-<NUM>, B114-<NUM>, notches <NUM>-<NUM>, B114-<NUM>, through-holes <NUM>-<NUM>, B114-<NUM>, blind holes <NUM>-<NUM>, B114-<NUM>, RFID tags <NUM>-<NUM>, B114-<NUM>, bar code <NUM>-<NUM>, B114-<NUM> , etc. While all of mandrel indexing features <NUM>, <NUM>-<NUM> through <NUM>-<NUM> and B114, B114-<NUM> through B114-<NUM> are illustrated in <FIG>, it is not uncommon to have only one or a couple types of mandrel indexing features <NUM>, B114 used on each half barrel section <NUM> or on wing panel <NUM>-<NUM>. While all of mandrel indexing features <NUM>, <NUM>-<NUM> through <NUM>-<NUM> and B114, B114-<NUM> through B114-<NUM> are illustrated as rectangular, each mandrel indexing feature <NUM> has the shape commensurate with the shape of that mandrel index feature <NUM>, B114, such as indents <NUM>-<NUM>, B114-<NUM>, protrusions <NUM>-<NUM>, B114-<NUM>, ridges <NUM>-<NUM>, B114-<NUM>, grooves <NUM>-<NUM>, B114-<NUM>, notches <NUM>-<NUM>, B114-<NUM>,through-holes <NUM>-<NUM>, B114-<NUM>, blind holes <NUM>-<NUM>, B114-<NUM>, RFID tags <NUM>-<NUM>, B114-<NUM>, bar code <NUM>-<NUM>, B114-<NUM>. Mandrel indexing features <NUM>, B114 are capable of being used directly to place indexing features <NUM>, B126 onto the half barrel section <NUM> or wing panel <NUM>-<NUM> while others accommodate trimming of manufacturing excess <NUM>, <NUM>-<NUM>. The trimming of manufacturing excess <NUM>, <NUM>-<NUM> creates separated flash edge <NUM>-<NUM>, <NUM>-<NUM> from flash edge <NUM>, <NUM>-<NUM> and creates bearing edge <NUM> and edge <NUM>-<NUM> at the mandrel <NUM>, <NUM>-<NUM>. Drilling and/or milling of the half barrel section <NUM> or wing panel <NUM>-<NUM> at the mandrel <NUM> add indexing feature <NUM>, B126 to composite part <NUM>, <NUM>-<NUM>, respectively. Separated flash edge <NUM>-<NUM>, <NUM>-<NUM> and separated manufacturing excess <NUM>-<NUM>, <NUM>-<NUM> are collected in chute system <NUM>. Chute system <NUM> facilitates removing the trimmed off materials, such as separated flash edge <NUM>-<NUM>, <NUM>-<NUM> and separated manufacturing excess <NUM>-<NUM>, <NUM>-<NUM>, from the removed material location prior to demold from the mandrel <NUM>, <NUM>-<NUM>. Further, index contour features <NUM> on mandrel <NUM> are recesses, indents, dimple, bumps or ridges that are filled with resin and reinforcing fibers or displaces resin and reinforcing fibers, respectively, thus imparting a indexing feature <NUM>-<NUM>, B126-<NUM> into manufacturing excess <NUM>-<NUM>, <NUM>-<NUM>, <NUM> prior to hardening which is made permanent by the hardening process. <FIG> shows the index contour features <NUM> through cut through view <NUM>-<NUM> of manufacturing excess <NUM>-<NUM>. Index contour features <NUM> on mandrel <NUM>, <NUM>-<NUM> also convey indexing features <NUM>, B126 into window manufacturing excess <NUM> and/or door manufacturing excess <NUM>-<NUM>. Trim edge <NUM>-<NUM> remains after window manufacturing excess <NUM> is separated. Potted recesses <NUM> (<FIG>) are recesses filled with potting compound and finished to a mandrel <NUM>, <NUM>-<NUM> surface contour <NUM>. Overshoot during drilling or trimming through composite part <NUM>, <NUM>-<NUM> and into the mandrel <NUM>, <NUM>-<NUM> into potted recess <NUM> and piercing surface contour <NUM> and result in a need to restore the surface contour <NUM> prior to the reuse of the mandrel <NUM>. That is, surface contour <NUM> of the mandrel <NUM>, <NUM>-<NUM> after piercing due to drilling or cutting and contour <NUM> is restored to account for any overshoot in cuts or drilling that occurred prior to demold. Piercing of the surface contour <NUM> into potted recesses <NUM> during drilling, milling and/or trimming saves the mandrel and the drilling, milling and/or trimming device from unrepairable damage. Potted recess <NUM> is easily returned to surface contour <NUM> by adding potting compound. Actuators <NUM> and <NUM> adjust the position of the key complementary <NUM> and indexing feature tool <NUM>.

A mandrel work station <NUM>, <NUM>-<NUM>, <NUM>-<NUM> aligns itself to mandrel indexing features <NUM> in mandrel <NUM>, which are precisely machined and located into the mandrel <NUM>. After alignment to the mandrel <NUM>, the mandrel work station <NUM>, <NUM>-<NUM>, <NUM>-<NUM> installs indexing features <NUM>, B126 onto the composite part <NUM>, <NUM>-<NUM>. These indexing features <NUM>, B126 are installed at locations on the composite part <NUM>, <NUM>-<NUM> with the assistance of mandrel work station <NUM>, <NUM>-<NUM>, <NUM>-<NUM> and mandrel index feature <NUM>, <NUM>-<NUM> through <NUM>-<NUM> and B114, B114-<NUM> through B114-<NUM>. The indexing features <NUM> are installed at manufacturing excess <NUM>-<NUM> or within window manufacturing excess <NUM>. The indexing features B126 are installed at manufacturing excess <NUM>-<NUM> or in other words between edge <NUM>-<NUM> and final trim <NUM>-<NUM>. The precision of the mandrel <NUM>, <NUM>-<NUM> and the layup upon the mandrel <NUM>, <NUM>-<NUM> is leveraged to locate the indexing features <NUM>, B126 relative to composite part <NUM>, <NUM>-<NUM> such as half barrel section <NUM> and/or <NUM>-<NUM>. The composite part <NUM>, <NUM>-<NUM> is precisely laid-up onto the mandrel <NUM> during fabrication. Indexing feature <NUM>, B126 carries the precision of the mandrel indexing features <NUM>, B114 into the composite part <NUM>, <NUM>-<NUM> and carries it through the post demold fabrication process until manufacturing excess <NUM>-<NUM>, <NUM>-<NUM> and <NUM> are finally separated. The mandrel indexing features <NUM>, B114 at the mandrel <NUM>, <NUM>-<NUM> enable precise alignment of the mandrel work station <NUM>, <NUM>-<NUM>, <NUM>-<NUM> to the mandrel <NUM>, <NUM>-<NUM>. The indexing features <NUM>, B126 facilitate indexing <NUM>, <NUM>-<NUM> of the composite part <NUM>, <NUM>-<NUM> to downstream work stations <NUM>, <NUM>-<NUM>, such as work station <NUM>, <NUM>-<NUM> after the composite part <NUM>, <NUM>-<NUM> has been removed from the mandrel <NUM>, <NUM>-<NUM>. Indexing features <NUM>, B126 comprise cup locating features <NUM>-<NUM>, B126-<NUM> for a cup and cone arrangement (<FIG>), drill start locations <NUM>-<NUM>, B126-<NUM> (<FIG>), drill through locations <NUM>-<NUM>, B126-<NUM> (<FIG>) , slots <NUM>-<NUM>, B126-<NUM> (<FIG>), installed pins <NUM>-<NUM>, B126-<NUM> (<FIG>), RFID tags <NUM>-<NUM>, B126-<NUM> (<FIG>), bar codes <NUM>-<NUM>, B126-<NUM> (<FIG>), formed indexing feature <NUM>-<NUM>, B126-<NUM> (<FIG>), notch <NUM>-<NUM>, B126-<NUM> (<FIG>). Installing the notch <NUM>-<NUM>, B126-<NUM> in the bearing edge <NUM>, edge <NUM> and/or edge <NUM>-<NUM> at the mandrel <NUM>, <NUM>-<NUM> of the composite part (<NUM>, <NUM>-<NUM>) to install an indexing feature <NUM>, B126. While all of these indexing features are illustrated, typically only a plurality of the different types will be present on composite part <NUM>, such as half barrel section <NUM> or wing panel <NUM>-<NUM>. Some of the mandrel indexing features <NUM>, B114 of the mandrel <NUM>, <NUM>-<NUM> are located beneath or beyond a final trim <NUM>, <NUM>-<NUM> of the composite part <NUM>, while the indexing features <NUM>, B126 are installed above a bearing edge <NUM> or between edge <NUM>-<NUM> and final trim <NUM>-<NUM> of the composite part <NUM>, <NUM>-<NUM>, respectively. Bearing edge <NUM> is an edge of the composite part <NUM> that bears a weight of the composite part <NUM> after demolding. Formed indexing feature <NUM>-<NUM>, B126-<NUM> is created during layup and hardening due to forming over an index contour feature <NUM> shaping the composite part <NUM>, <NUM>-<NUM> before hardening occurs and which is made permanent by the hardening process. The formed indexing feature <NUM>-<NUM> is present in the hardened composite part <NUM>, <NUM>-<NUM>. Each indexing feature <NUM>, B126 in the composite part <NUM>, <NUM>-<NUM> may be common to (i.e., used by) one or more stations <NUM>, <NUM>-<NUM> at an assembly line <NUM>, <NUM>-<NUM> after demolding, and the precision of each indexing feature <NUM>, <NUM>-<NUM> through <NUM>-<NUM> and B126, B126-<NUM> through B126-<NUM> is tailored to a tolerance determined for the work station <NUM>, <NUM>-<NUM> that utilizes the indexing feature <NUM>, <NUM>-<NUM> through <NUM>-<NUM> and B126, B126-<NUM> through B126-<NUM>. For example, work stations <NUM>, <NUM>-<NUM> that require precision operations may require more tightly toleranced indexing features <NUM>, B126. Furthermore, different arrangements, positions, or patterns of indexing features <NUM>, B126 relative to half barrel section <NUM> or wing panel <NUM>-<NUM> can indicate instructions to be performed by work stations <NUM>, <NUM>-<NUM>, respectively. Mandrel work stations <NUM>-<NUM>, <NUM>-<NUM> are block representations of mandrel work station <NUM>. Mandrel work station <NUM>-<NUM> is also capable of creating separated flash edge <NUM>-<NUM>. Mandrel work stations <NUM>-<NUM>, <NUM>-<NUM> have the same capabilities as mandrel work station <NUM> and <NUM>-<NUM> except it traverses mandrel <NUM>-<NUM> on track <NUM> without using groove <NUM>. Another possibility is to have the mandrel work station <NUM>-<NUM> and mandrel work station <NUM>-<NUM> carried along upon both a track <NUM> and a groove <NUM> to trim along edge <NUM>-<NUM> and to install indexing features B126. Another possibility is to have the mandrel work station <NUM> installing the indexing features <NUM> and also cutting the bearing edge <NUM> in a single work station in a single or multiple passes along mandrel <NUM>, <NUM>-<NUM>. Indexing features <NUM> through <NUM>-<NUM> and indexing features B126 through B126-<NUM> are coupled to composite part <NUM>, <NUM>-<NUM>, respectively, by subtractive fabrication using drilling, milling or trimming or by additive fabrication such as adding pins <NUM>-<NUM>, B126-<NUM>, adding RFID tags <NUM>-<NUM>, B126-<NUM>, or adding bar codes <NUM>-<NUM>, B126-<NUM>. While each mandrel work station <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM> type is shown along one edge only, it is possible to have one type of the work stations serving multiple edges. Four mandrel work stations <NUM>-<NUM> can service each of the four edges or two mandrel work stations <NUM>-<NUM> and two mandrel work stations <NUM>-<NUM> could each work an edge or three or four mandrel work stations <NUM>-<NUM> could each work an edge and a mandrel work station <NUM>-<NUM> can work an edge. Therefore, any combination of mandrel work stations <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM> are able to be used to service a particular edge.

In further embodiments, mandrel indexing features <NUM>, B114 are implemented as Radio Frequency Identifier (RFID) tags <NUM>-<NUM>, B114-<NUM> that are coupled to the mandrel <NUM>, <NUM>-<NUM>. In such embodiments, mandrel work stations <NUM>, <NUM>-<NUM>, <NUM>-<NUM> interact with information provided by the mandrel indexing features <NUM>, B114 to characterize the mandrel <NUM>, <NUM>-<NUM>, and use this information to determine locations for receiving indexing features <NUM>, B126. In still further embodiments, the mandrel work station <NUM>, <NUM>-<NUM>, <NUM>-<NUM> installs indexing features <NUM>, B126 in the form of RFID tags <NUM>-<NUM> that each characterize a portion of the composite part <NUM>, <NUM>-<NUM> within the purview <NUM>, <NUM>-<NUM> of work station <NUM>, <NUM>-<NUM>.

After hardening, the composite part <NUM>, <NUM>-<NUM> is rough-trimmed to form a bearing edge <NUM> of the manufacturing excess <NUM>-<NUM>. For example, rough-trimming may remove the flash edge <NUM>, such as the rough edge of the layup including portions with resin and reinforcing fibers or just one or the other, from the composite part <NUM>. The rough trimming creates the bearing edge <NUM> and edge <NUM>-<NUM> prior to demold from mandrel <NUM>. The removed material is a separated flash edge <NUM>-<NUM>, <NUM>-<NUM> from manufacturing excess <NUM>, <NUM>-<NUM>. Window manufacturing excess <NUM> are typically removed after installation of window surrounds, and windows are installed at a downstream work station <NUM>. While illustrated as being installed in manufacturing excess <NUM>, <NUM>-<NUM>, in further embodiments, the indexing features <NUM>, B126 are installed into other forms of manufacturing excess, such as window manufacturing excess <NUM> door cut-out regions (not shown), or antenna cut-out regions (not shown).

Mandrel work station <NUM>, <NUM>-<NUM>, <NUM>-<NUM> includes a feature creator <NUM>, such as blade <NUM>, drill, mill, pin installer, RFID tag installer, bar code installer, fastener installer or other machine tool to install the indexing features <NUM>, B126 by removing material, adding material or scannable device to the composite part <NUM>. Looking at <FIG>, <FIG> and <FIG>, the feature creator <NUM> trims portions of a composite part <NUM>, <NUM>-<NUM> that is disposed at the mandrel <NUM>, <NUM>-<NUM>. The cutting operation is typically performed prior to demolding of the composite part <NUM>, <NUM>-<NUM> from the mandrel <NUM>, <NUM>-<NUM>, and leaves a sufficient amount of manufacturing excess <NUM>-<NUM>, <NUM>-<NUM> to include indexing features <NUM>, B126 and bearing edge <NUM> for use by work stations <NUM>, <NUM>-<NUM> in an assembly line <NUM>, <NUM>-<NUM>, respectively. Feature creator <NUM> is employed to apply a preliminary cut that provides a bearing edge <NUM> or edge <NUM>-<NUM> to the composite part <NUM>, <NUM>-<NUM> during the manufacturing process, prior to trimming the edge to a final trim <NUM>, <NUM>-<NUM>. Cutter <NUM> provides all of the trimming, milling or drilling to create separated flash edge <NUM>-<NUM>, <NUM>-<NUM> from manufacturing excess <NUM>-<NUM>, <NUM>-<NUM>. Trimming prior to demold saves the non-value added time of placing the composite part <NUM>, <NUM>-<NUM>, such as half barrel section <NUM> and/or wing panel <NUM>-<NUM>, into a cell dedicated only to trimming the composite part <NUM>, <NUM>-<NUM>. In the dedicated cell scenario, the composite part <NUM>, <NUM>-<NUM> is indexed to the cell and the trimming equipment including the cutter prior to trimming to produce a final trim and then indexing the composite structure <NUM> to each successive cell in a repetitive process to scan the part perimeter and contour. It is noted that the terms composite structure <NUM> and composite part <NUM> are used interchangeably throughout the application. Using the manufacturing excess <NUM>-<NUM> and <NUM> to convey indexing features <NUM> saves much if not all of the repetitive part perimeter and contour scan-able process when moving from work station to work station through the assembly process. Also, using the bearing edge <NUM> as part of the transport process in assembly line <NUM>, <NUM>-<NUM> protects the final trim <NUM>, <NUM>-<NUM> edge from bump damage until manufacturing excess <NUM>-<NUM>, including bearing edge <NUM> and manufacturing excess <NUM>-<NUM> is separated. Any damage to bearing edge <NUM>, particularly after demolding, can be rough patched to restore transportation capabilities on assembly line <NUM> as needed before being trimmed off with manufacturing excess <NUM>-<NUM>.

Mandrel work station <NUM> further comprises a support <NUM> (e.g., a rigid bar, an actuated linkage such as a robot arm, kinematic chain, or other component, etc.) that is capable of aligning the feature creator <NUM> in position. Mandrel work stations <NUM>-<NUM>, <NUM>-<NUM> are block representations of mandrel work station <NUM>. Mandrel work stations <NUM>-<NUM>, <NUM>-<NUM> have the same capabilities as mandrel work station <NUM> and <NUM>-<NUM> except it traverses mandrel <NUM>-<NUM> on track <NUM> without using groove <NUM>. Another possibility is to have the mandrel work station <NUM>-<NUM> and mandrel work station <NUM>-<NUM> carried along upon both a track <NUM> and a groove <NUM> to trim along edge <NUM>-<NUM> and to install indexing features B126. Another possibility is to have the mandrel work station <NUM> installing the indexing features <NUM> and also cutting the bearing edge <NUM> in a single work station in a single or multiple passes along mandrel <NUM>, <NUM>-<NUM>. Mandrel work station <NUM> still further comprises indexing key <NUM>, which complementarily mates with mandrel indexing features <NUM>, such as indents <NUM>-<NUM>, protrusions <NUM>-<NUM>, ridges <NUM>-<NUM>, grooves <NUM>-<NUM>, notches <NUM>-<NUM>, through-holes <NUM>-<NUM>, blind holes <NUM>-<NUM> to lock the feature creator <NUM> in place relative to the mandrel <NUM>. Mandrel work station <NUM>, through <NUM>-<NUM> comprises an indexing feature installer and indexing key <NUM>. The complementary mating of the indexing key <NUM> with the indents <NUM>-<NUM>, protrusions <NUM>-<NUM>, ridges <NUM>-<NUM>, grooves <NUM>-<NUM>, notches <NUM>-<NUM>, through-holes <NUM>-<NUM>, blind holes <NUM>-<NUM> conveys a message from the mandrel <NUM> regarding placement and type of indexing feature <NUM> relative to composite part <NUM>. The Mandrel work station <NUM> places the message conveyed by the mating of the indexing key <NUM> from the mandrel indexing feature <NUM> into operation to locate and install the indexing features <NUM>, <NUM>-<NUM> through <NUM>-<NUM> and B126, B126-<NUM> through B126-<NUM> into or onto manufacturing excess <NUM>-<NUM>. In one embodiment, mandrel work station <NUM> includes a blade <NUM>, such as a reciprocating or circular blade, and/or a mill and/or a drill and a control system that drives the blade <NUM> to trim, mill or drill portions of a composite part <NUM> at the mandrel <NUM>. This trimming, milling or drilling operation are performed prior to demolding of the composite part <NUM> from the mandrel <NUM>, and leaves indexing features <NUM>, B126 including cup locating features <NUM>-<NUM>, B126-<NUM> for a cup and cone arrangement, drill start locations <NUM>-<NUM>, B126-<NUM>, drill through locations <NUM>-<NUM>, B126-<NUM>, slots <NUM>-<NUM>, B126-<NUM>, installed pins <NUM>-<NUM>, B126-<NUM> for use by work stations <NUM>, <NUM> in an assembly line <NUM>, <NUM>-<NUM>. The RFID tags <NUM>-<NUM>, and bar codes <NUM>-<NUM> are also placed by the mandrel work station <NUM>. RFID tags <NUM>-<NUM> and bar code <NUM>-<NUM> are placed RFID tags and/or bar code placer <NUM> (<FIG>).

Groove <NUM> is used to guide and for transport of the cutter <NUM> relative to manufacturing excess <NUM>-<NUM>, <NUM> with support <NUM>-<NUM> slide-ably engaging it with roller system <NUM>-<NUM>. This embodiment is cantilever mounted into groove <NUM> and is guided along groove <NUM> to facilitate installing indexing features <NUM>, <NUM>-<NUM> through <NUM>-<NUM> and B126, B126-<NUM> through B126-<NUM> into manufacturing excess <NUM>-<NUM>, <NUM>. The cutter <NUM> is cantilevered from groove <NUM> with one or more roller systems <NUM> slide-ably engaging and propelling the cutter <NUM> along mandrel <NUM> to facilitate creating indexing features <NUM>, <NUM>-<NUM> through <NUM>-<NUM> and B126, B126-<NUM> through B126-<NUM>. The mandrel indexing features <NUM>, such as indents <NUM>-<NUM>, protrusions <NUM>-<NUM>, ridges <NUM>-<NUM>, grooves <NUM>-<NUM>, notches <NUM>-<NUM>, through-holes <NUM>-<NUM>, blind holes <NUM>-<NUM>, RFID tags <NUM>-<NUM>, bar code <NUM>-<NUM> are engaged by indexing key <NUM> such as a complementary key <NUM> (<FIG>) and/or RFID tag reader <NUM> and/or bar code reader <NUM>-<NUM>. Installed pins <NUM>-<NUM> are placed by pin installer <NUM> (<FIG> and <FIG>) into the hole created by blade <NUM> (<FIG>). Mandrel work station <NUM>, through <NUM>-<NUM> comprises an indexing feature installer and complementary key <NUM>. A cutter <NUM> has a transverse mount <NUM>-<NUM> travelling in transverse direction <NUM> to the feature creator <NUM>. The cutter <NUM> includes the blade <NUM> which is a reciprocating blade or a circular blade or a mill type cutter blade to separate flash edge <NUM>, <NUM>-<NUM> and create bearing edge <NUM> or edge <NUM>-<NUM>, respectively. The transverse mount <NUM>-<NUM> travelling in transverse direction <NUM> of the cutter <NUM> comes into play when locating indexing features <NUM> in a transverse direction <NUM> relative to track <NUM>. This can be accomplished by using the same cutter <NUM>-<NUM> to install index features <NUM>, B126 into manufacturing excess <NUM>, <NUM>-<NUM> at different distances from bearing edge <NUM> and/or edge <NUM>-<NUM>. The complementary key <NUM> complementarily engages with mandrel indexing feature <NUM>, such as indents <NUM>-<NUM>, protrusions <NUM>-<NUM>, ridges <NUM>-<NUM>, grooves <NUM>-<NUM>, notches <NUM>-<NUM>, through-holes <NUM>-<NUM>, blind holes <NUM>-<NUM>, RFID tags <NUM>-<NUM>, and bar code <NUM>-<NUM>. Indexing the mandrel work station <NUM> to the mandrel indexing feature <NUM> at the mandrel <NUM>, <NUM>-<NUM> comprises inserting a complementary key <NUM> of the mandrel work station <NUM> into a corresponding keyway <NUM> at the mandrel <NUM>, <NUM>-<NUM>. Mandrel work station <NUM>, through <NUM>-<NUM> comprises an indexing feature installer and keyway <NUM>.

The wheels <NUM> enable longitudinal <NUM>-<NUM> movement relative to mandrel <NUM> along groove <NUM> to the next in mandrel indexing features <NUM>, and the complementary key <NUM> facilitates fine alignment of the indexing feature tool <NUM> to mandrel indexing features <NUM>, such as indents <NUM>-<NUM>, protrusions <NUM>-<NUM>, ridges <NUM>-<NUM>, grooves <NUM>-<NUM>, notches <NUM>-<NUM>, through-holes <NUM>-<NUM>, blind holes <NUM>-<NUM> when complementary key <NUM> mates to mandrel indexing feature <NUM>. Sensor <NUM> senses the mandrel indexing features <NUM>, such as indents <NUM>-<NUM>, protrusions <NUM>-<NUM>, ridges <NUM>-<NUM>, grooves <NUM>-<NUM>, notches <NUM>-<NUM>, through-holes <NUM>-<NUM>, blind holes <NUM>-<NUM> and rough positions the mandrel work station <NUM> such that complementary key <NUM> is mate-able with mandrel indexing feature <NUM>. The sensor <NUM> is an optical sensor or some other type of sensor that detects mandrel indexing feature <NUM>. The mandrel <NUM> indexing feature <NUM>, such as RFID tags <NUM>-<NUM>, bar code <NUM>-<NUM> conveys the locations of the mandrel indexing features <NUM> to mandrel work station <NUM> to help with locating each and then using the sensor <NUM> to mate the complementary key <NUM> with the mandrel indexing feature <NUM>. An embodiment has groove <NUM> engaging with wheels <NUM> in a rack and pinion arrangement that can also be used to convey position data relative to mandrel <NUM> and/or propel the mandrel work station <NUM> relative to mandrel <NUM>. Thus, in one embodiment the mandrel work station <NUM> follows one or more grooves <NUM> at the mandrel <NUM>, pausing and mating with mandrel indexing features <NUM>. Other embodiments of mandrel work station <NUM> use multiple tracks <NUM> with groove <NUM> or multiple tracks <NUM> only without groove <NUM>.

A flex track type of device with a cutter moveably attached to two tracks removeably attached to the composite part <NUM> such as half barrel section <NUM>. The tracks <NUM> are shown removably attached to composite part <NUM> such as half barrel section <NUM> and mandrel <NUM>. The tracks <NUM> are vacuum coupled or by some other means of removable attaching to composite part <NUM>. The housing <NUM> spans between the track <NUM> and groove <NUM> and transports along the track <NUM> and groove <NUM>. A cutter <NUM> has a transverse mount <NUM>-<NUM> travelling in transverse direction <NUM> to the feature creator <NUM>. The cutter <NUM> includes the blade <NUM> which is a reciprocating blade or a circular blade or a mill type cutter blade to separate flash edge <NUM>, <NUM>-<NUM> and create bearing edge <NUM> and edge <NUM>-<NUM>. The transverse mount <NUM>-<NUM> travelling in transverse direction <NUM> of the cutter <NUM> comes into play when locating indexing features <NUM> in a transverse direction relative to track <NUM>. An embodiment of the roller system <NUM> has a rack and pinion connection between the feature creator <NUM> and the tracks <NUM>. An embodiment has a rack and pinion connection between the feature creator <NUM> and the groove <NUM>. Another embodiment has the mandrel work station <NUM> carried directly upon track <NUM>.

Looking at <FIG> and <FIG>, mandrel work station <NUM>-<NUM> includes a feature creator <NUM>-<NUM>, such as blade, drill, mill, pin installer, RFID tag installer, bar code installer or fastener installer other machine tool to install the indexing features <NUM> by removing material, adding material or scannable device to the composite part <NUM>. The feature creator <NUM>-<NUM> trims portions of a composite part <NUM> that is disposed at the mandrel <NUM>. The cutting operation is typically performed prior to demolding of the composite part <NUM> from the mandrel <NUM>, and places an indexing features <NUM> in manufacturing excess <NUM> for use by work stations <NUM> in an assembly line <NUM>, <NUM>-<NUM>. Trimming prior to demold saves the non-value added time of placing the composite part <NUM> such as half barrel section <NUM> into a cell dedicated to only trimming and indexing to the cell and the cutter prior to trimming to a production perimeter and then indexing the composite structure <NUM> to each successive cell in a repetitive part perimeter and contour scan-able process. Using the manufacturing excess <NUM> to convey indexing features <NUM> saves much if not all of the repetitive part perimeter and contour scan-able process time when moving through the assembly process from work station to work station.

Mandrel work station <NUM>-<NUM> further comprises a receiver <NUM>-<NUM> that receives coordinating information from mandrel work station <NUM> transmitter <NUM>-<NUM>. Mandrel work station <NUM> comprises indexing key <NUM> and specifically complementary key <NUM>, which complementarily mates with mandrel indexing features <NUM>, such as indents <NUM>-<NUM>, protrusions <NUM>-<NUM>, ridges <NUM>-<NUM>, grooves <NUM>-<NUM>, notches <NUM>-<NUM>, through-holes <NUM>-<NUM>, blind holes <NUM>-<NUM> to lock the feature creator <NUM> in place relative to the mandrel <NUM>. The complementary mating of the complementary key <NUM> with the indents <NUM>-<NUM>, protrusions <NUM>-<NUM>, ridges <NUM>-<NUM>, grooves <NUM>-<NUM>, notches <NUM>-<NUM>, through-holes <NUM>-<NUM>, blind holes <NUM>-<NUM> conveys a message from the mandrel <NUM> regarding placement and type of indexing feature <NUM>. The mandrel work station <NUM> transmits the message, via transmitter <NUM>-<NUM> to receiver <NUM>-<NUM> conveyed by the mating of the complementary key <NUM> with the mandrel indexing feature <NUM> into operation to locate and install the indexing features <NUM>, <NUM>-<NUM> through <NUM>-<NUM> and B126, B126-<NUM> through B126-<NUM> into or onto manufacturing excess <NUM>. In one embodiment, mandrel work station <NUM>-<NUM> includes a blade <NUM>, such as a reciprocating or circular blade, and/or a mill and/or a drill and a controller <NUM> that drives the blade <NUM> to trim, mill or drill portions of manufacturing excess <NUM> at the mandrel <NUM> to install indexing feature <NUM>, <NUM>-<NUM> through <NUM>-<NUM>. This trimming, milling or drilling operation are performed in manufacturing excess <NUM> prior to demolding of the composite part <NUM> from the mandrel <NUM>, and leaves indexing features <NUM>, locating features <NUM>-<NUM>, drill start locations <NUM>-<NUM>, drill through locations <NUM>-<NUM>, slots <NUM>-<NUM>, installed pins <NUM>-<NUM> for use by work stations <NUM> in an assembly line <NUM>, <NUM>-<NUM>. The RFID tags <NUM>-<NUM> and bar codes <NUM>-<NUM> are also placed by the mandrel work station <NUM>. RFID tags <NUM>-<NUM> and bar code <NUM>-<NUM> are placed RFID tags and/or bar code placer <NUM>.

A flex track type of device with a cutter moveably attached to two tracks removeably attached to the composite part <NUM> such as half barrel section <NUM>. The tracks <NUM> are shown removably attached to composite part <NUM> such as half barrel section <NUM> and mandrel <NUM>. The tracks <NUM> are vacuum coupled or by some other means of removable attaching to composite part <NUM>. The housing <NUM>-<NUM> spans between the tracks <NUM> and transports along the track <NUM> by a roller system <NUM> and/or also couples the tracks <NUM> to housing <NUM>-<NUM>. A cutter <NUM>-<NUM> has a transverse mount <NUM>-<NUM> travelling in transverse direction <NUM> to the feature creator <NUM>-<NUM>. The cutter <NUM>-<NUM> includes the blade <NUM> which is a reciprocating blade or a circular blade or a mill type cutter blade to separate flash edge <NUM>, <NUM>-<NUM> and create bearing edge <NUM> or edge <NUM>-<NUM>, respectively. The transverse mount <NUM>-<NUM> travelling in transverse direction <NUM> of the cutter <NUM>-<NUM> comes into play when locating indexing features <NUM> in a transverse direction relative to track <NUM>. This can be accomplished by using the same cutter <NUM>-<NUM> to install index features <NUM> into manufacturing excess <NUM> at different distances from bearing edge <NUM>. An embodiment of the roller system <NUM> has a rack and pinion connection between the feature creator <NUM>-<NUM> and the tracks <NUM>.

Looking at <FIG>, <FIG> and <FIG>, mandrel work station <NUM>-<NUM> includes a cutter <NUM>-<NUM> with a blade <NUM>, such as blade, drill, mill, to create separated manufacturing excess <NUM>-<NUM> from manufacturing edge <NUM>-<NUM> and bearing edge <NUM>. The cutting operation is typically performed prior to demolding the composite part <NUM> from the mandrel <NUM>, and leaves a sufficient amount of manufacturing excess <NUM>-<NUM> to include indexing features <NUM> for use by work stations <NUM> in an assembly line <NUM>. The trimming also creates the bearing edge <NUM> used to transport composite part <NUM> on track <NUM> through work stations <NUM> on assembly line <NUM>. Trimming prior to demold saves the non-value added time of placing the composite part <NUM>, such as half barrel section <NUM>, into a cell dedicated to only trimming and indexing to the cell and indexing to a edge <NUM>-<NUM> final trim <NUM>, <NUM>-<NUM> trim line <NUM>-<NUM> prior to trimming to a final trim <NUM> and then indexing the composite structure <NUM> to each successive cell in a repetitive part perimeter and contour scan-able process. Using the manufacturing excess <NUM>-<NUM> to convey indexing features <NUM> saves much if not all of the repetitive part perimeter and contour scan-able process time needed to index to each cell when moving through the assembly process.

Groove <NUM> is used to guide and enable longitudinal <NUM>-<NUM> transport of the cutter <NUM>-<NUM> relative to manufacturing excess <NUM>-<NUM> with support <NUM>-<NUM> slide-ably engaging it with roller system <NUM>-<NUM>. A version of mandrel work station <NUM>-<NUM>, <NUM>-<NUM> is cantilever mounted into groove <NUM>. The mandrel work station <NUM>-<NUM> is guided along groove <NUM> to facilitate creating separated flash edge <NUM>-<NUM> from manufacturing excess <NUM>. The cutter <NUM>-<NUM> is cantilevered from groove <NUM> with one or more roller systems <NUM> slide-ably engaging and propelling the cutter <NUM>-<NUM> along mandrel <NUM>. Groove <NUM> is illustrated having a rectangular cross section, but other cross sections are possible. The groove <NUM> also provides cutter <NUM>-<NUM> guidance during the creation of bearing edge <NUM>. In another version, the track <NUM> as well as groove <NUM> is used to enable longitudinal <NUM>-<NUM> transport of the cutter <NUM>-<NUM> relative to manufacturing excess <NUM>-<NUM>. In yet another version, the track <NUM> instead of groove <NUM> is used to enable longitudinal <NUM>-<NUM> movement.

This means that the wheels <NUM> enable longitudinal <NUM>-<NUM> movement relative to mandrel <NUM> along groove <NUM> relative to bearing edge <NUM> and trim line <NUM>-<NUM> from one end of mandrel <NUM> to the other. A version has groove <NUM> engaging with wheels <NUM> in a rack and pinion arrangement that can also be used to convey position data relative to mandrel <NUM> and/or propel the mandrel work station <NUM>-<NUM> relative to mandrel <NUM>. Thus, in one embodiment the mandrel work station <NUM>-<NUM> follows one or more grooves <NUM> at the mandrel <NUM>. In another embodiment, as shown, one end <NUM> of the feature creator <NUM>-<NUM> is coupled via roller system <NUM> and track <NUM> to composite part <NUM> as part of a flex track type of device and the other end <NUM>-<NUM> of the feature creator <NUM>-<NUM> is coupled via support <NUM> and roller system <NUM>-<NUM> to groove <NUM>. In yet another embodiment, as shown, one end <NUM> of the feature creator <NUM>-<NUM> is coupled via roller system <NUM> and track <NUM> to composite part <NUM>, <NUM>-<NUM> as part of a flex track type of device and the other end <NUM>-<NUM> of the feature creator <NUM>-<NUM> is coupled via roller system <NUM> and track <NUM>, <NUM> to mandrel <NUM> as part of a flex track type of device without using a connection to groove <NUM>. In still another embodiment, as shown, one end <NUM> of the feature creator <NUM>-<NUM> is coupled via roller system <NUM> and track <NUM> to composite part <NUM> as part of a flex track type of device and the other end <NUM>-<NUM> of the feature creator <NUM>-<NUM> is coupled via roller system <NUM> and track <NUM> to mandrel <NUM> as part of a flex track type of device and other end <NUM>-<NUM> of the feature creator <NUM>-<NUM> is coupled via support <NUM> and roller system <NUM>-<NUM> to groove <NUM>.

A flex track type of device with a cutter moveably attached to two tracks removeably attached to the composite part <NUM> such as half barrel section <NUM>. The tracks <NUM> are shown removably attached to composite part <NUM> and mandrel <NUM>. The tracks <NUM> are vacuum coupled or by some other means of removable attaching to composite part <NUM> and/or mandrel <NUM>. The cutter housing <NUM>-<NUM> spans between the tracks <NUM> and transports along the track <NUM> by a roller system <NUM> and/or also couples the tracks <NUM> to housing <NUM>-<NUM>. A cutter <NUM>-<NUM> has a transverse mount <NUM>-<NUM> travelling in transverse direction <NUM> to the feature creator <NUM>-<NUM>. The cutter <NUM>-<NUM> includes the blade <NUM> which is a reciprocating blade or a circular blade or a mill type cutter blade to separate manufacturing excess <NUM> and create bearing edge <NUM>. The transverse mount <NUM>-<NUM> travelling in transverse direction <NUM> of the cutter <NUM>-<NUM> comes into play within feature creator <NUM>-<NUM> when locating indexing features <NUM> in a transverse direction relative to track <NUM>. This can be accomplished by using the same cutter <NUM>-<NUM> to create bearing edge <NUM>. An embodiment of the roller system <NUM> has a rack and pinion connection between the feature creator <NUM>-<NUM> and the tracks <NUM>. Groove <NUM> is used to guide cutter <NUM>-<NUM> relative to bearing edge <NUM> and for transport of the cutter <NUM>-<NUM> relative to manufacturing excess <NUM>-<NUM>, <NUM> with support <NUM>-<NUM> slide-ably engaging it with roller system <NUM>-<NUM>. This embodiment is cantilever mounted into and guided along groove <NUM>-<NUM> to facilitate creating bearing edge <NUM> within manufacturing excess <NUM>. The cutter <NUM>-<NUM> is cantilevered from groove <NUM> with one or more roller systems <NUM> slide-ably engaging and propelling the cutter <NUM>-<NUM> along mandrel <NUM> either autonomously or manually.

Groove <NUM>-<NUM> in another embodiment is used to guide the cutter <NUM>-<NUM> relative to bearing edge <NUM> with support <NUM> slide-ably engaging it with roller system <NUM>-<NUM>. This embodiment does not use tracks <NUM> and roller system <NUM>, but is instead cantilever mounted into groove <NUM> and is guided along groove <NUM>-<NUM> to facilitate cutting bearing edge <NUM>. The feature creator <NUM>-<NUM> and cutter <NUM>-<NUM> is cantilevered from groove <NUM>-<NUM> with one or more roller systems <NUM>-<NUM> slide-ably engaging and propelling the feature creator <NUM>-<NUM> and cutter <NUM>-<NUM> along mandrel <NUM> to facilitate creating bearing edge <NUM>. This may result in a rougher cut than for final trim and provides a consistent bearing edge <NUM> to the composite part <NUM> for use during the manufacturing process, prior to trimming off the bearing edge <NUM> to a final trim <NUM>.

Looking at <FIG>, <FIG> and <FIG>, mandrel work station <NUM>-<NUM> and mandrel work stations <NUM>-<NUM>, <NUM>-<NUM> includes a cutter <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM> with a blade <NUM>, such as blade, drill and/or mill, to create separated manufacturing excess <NUM>-<NUM>, <NUM>-<NUM> from manufacturing edge <NUM>-<NUM>, trim line <NUM>-<NUM> leaving edge <NUM>, <NUM>-<NUM>, respectively. The cutting operation is typically performed prior to demolding of the composite part <NUM> from the mandrel <NUM>, and creating a final trim edge <NUM> or edge <NUM>-<NUM> prior to processing through work stations <NUM>, <NUM>-<NUM> in an assembly line <NUM>, <NUM>-<NUM>. Trimming prior to demold saves the non-value added time of placing the composite part <NUM>, <NUM>-<NUM> into a cell dedicated to only trimming and indexing to the cell and indexing to a edge <NUM>-<NUM> final trim <NUM>, <NUM>-<NUM> trim line <NUM>-<NUM> prior to trimming to a final trim <NUM>, <NUM>-<NUM> and then indexing the composite structure <NUM>, <NUM>-<NUM> to each successive cell in a repetitive part perimeter and contour scan-able process prior to beginning work in the cell. Using the manufacturing excess <NUM>-<NUM>, <NUM>-<NUM> to convey indexing features <NUM>, B126 saves much if not all of the repetitive part perimeter and contour scan-able process time needed to index to each cell when moving through the assembly process.

Mandrel work stations <NUM>-<NUM> and mandrel work stations <NUM>-<NUM> correspond to mandrel work station <NUM>-<NUM> and trims off flash edge <NUM>-<NUM> in a manner similar to flash edge <NUM>. Mandrel work stations <NUM>-<NUM>, <NUM>-<NUM> could be substituted for by mandrel work station <NUM>-<NUM> in some versions depending upon location, or lack thereof, of groove B352 and/or track B354. Mandrel work station <NUM>-<NUM> is sized to facilitate placement of housing <NUM> with halfway point <NUM>-<NUM> roughly directly above track B354 to help balance mandrel work station <NUM>-<NUM> relative to the one groove B352. Likewise, mandrel work station <NUM>-<NUM> is sized to facilitate placement of housing <NUM> with halfway point <NUM>-<NUM> roughly directly above groove B352 to help balance mandrel work station <NUM>-<NUM> above the one groove B352. Trimming prior to demold saves the non-value added time of placing the composite part <NUM>, <NUM>-<NUM> such as half barrel section <NUM> and/or wing panel <NUM>-<NUM> into a cell dedicated to only trimming and indexing to the cell and indexing to a edge <NUM>-<NUM> final trim <NUM>, <NUM>-<NUM> trim line <NUM>-<NUM> prior to trimming to a final trim <NUM>, <NUM>-<NUM> and then indexing the composite structure <NUM>, <NUM>-<NUM> to each successive cell in a repetitive part perimeter and contour scan-able process. Using the manufacturing excess <NUM>-<NUM>, <NUM>-<NUM> to convey indexing features <NUM>, B126 saves much if not all of the repetitive part perimeter and contour scan-able process time needed to index to each cell when moving through the assembly process.

Groove <NUM>-<NUM>, B352 is used to guide and enable longitudinal <NUM>-<NUM> transport of the cutter <NUM>-<NUM> relative to final trim edge <NUM> with support <NUM>-<NUM> slide-ably engaging it with roller system <NUM>-<NUM>. Groove B352 is used to guide and enable transport of the cutter <NUM>-<NUM>, <NUM>-<NUM> relative to edge <NUM>-<NUM> with support <NUM>-<NUM> slide-ably engaging it with roller system <NUM>-<NUM>. Groove <NUM>, B352 is illustrated having a rectangular cross section, but other cross sections are possible. The mandrel work station <NUM>-<NUM>, <NUM>-<NUM> is mounted into groove <NUM>-<NUM>, B352 and is guided along groove <NUM>-<NUM>, B352 to facilitate creating separated manufacturing excess <NUM>-<NUM> or separated flash edge <NUM>-<NUM> from composite part <NUM>, <NUM>-<NUM>. The cutter <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM> has one or more roller systems <NUM> slide-ably engaging and propelling the cutter <NUM>-<NUM> along mandrel <NUM>. The groove <NUM>-<NUM>, B352 also provides cutter <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM> guidance during the creation of bearing edge <NUM> or edge <NUM>-<NUM>, respectively. This means that the wheels <NUM> enable movement relative to mandrel <NUM>, <NUM>-<NUM> along groove <NUM>-<NUM>, B352 relative to edge <NUM>-<NUM>, trim line <NUM>-<NUM> leaving final trim edge <NUM> or edge <NUM>-<NUM> from one end of mandrel <NUM>, <NUM>-<NUM> to the other end. An embodiment has groove <NUM>-<NUM>, B352 engaging with wheels <NUM> in a rack and pinion arrangement that can also be used to convey position data relative to mandrel <NUM> and/or propel the mandrel work station <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM> relative to mandrel <NUM>, <NUM>-<NUM>. Thus, in one embodiment the mandrel work station <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM> follows one or more grooves <NUM>-<NUM>, B352 at the mandrel <NUM>, <NUM>-<NUM>. In another embodiment, as shown, one end <NUM> of the feature creator <NUM>-<NUM> is coupled via roller system <NUM> and track <NUM> to composite part <NUM> as part of a flex track type of device and the other end <NUM>-<NUM> of the feature creator <NUM>-<NUM> is coupled via support <NUM> and roller system <NUM>-<NUM> to groove <NUM>-<NUM>. In yet another embodiment, as shown, one end <NUM> of the feature creator <NUM>-<NUM> is coupled via roller system <NUM> and track <NUM> to composite part <NUM> as part of a flex track type of device and the other end <NUM>-<NUM> of the feature creator <NUM>-<NUM> is coupled via support <NUM> and <NUM>-<NUM> to groove <NUM>-<NUM>, B352. Another embodiment not illustrated has one end <NUM> of the feature creator <NUM>-<NUM> is coupled via roller system <NUM> and track <NUM> to composite part <NUM>, <NUM>-<NUM> as part of a flex track type of device and the other end <NUM>-<NUM> of the feature creator <NUM>-<NUM> is coupled via roller system <NUM> and track <NUM> to mandrel <NUM> as part of a flex track type of device without using a connection to groove <NUM>-<NUM>, B352. In still another embodiment, as shown, one end <NUM> of the feature creator <NUM>-<NUM> is coupled via roller system <NUM> and track <NUM> to composite part <NUM> as part of a flex track type of device and the other end <NUM>-<NUM> of the feature creator <NUM>-<NUM> is coupled via roller system <NUM> and track <NUM> to mandrel <NUM>, <NUM>-<NUM> as part of a flex track type of device and other end <NUM>-<NUM> of the feature creator <NUM>-<NUM> is coupled via support <NUM> and roller system <NUM>-<NUM> to groove <NUM>-<NUM>, B352.

A flex track type of device, such as but not limited to mandrel work station <NUM>-<NUM>, <NUM>-<NUM>, with a cutter moveably attached to two tracks removeably attached to the composite part <NUM>, <NUM>-<NUM> such as half barrel section <NUM>. The tracks <NUM> are shown removably attached to composite part <NUM>, <NUM>-<NUM> such as half barrel section <NUM> and/or wing panel <NUM>-<NUM> and mandrel <NUM>, <NUM>-<NUM>. The tracks <NUM>, B354, B354-<NUM> are vacuum coupled or by some other means of removable attaching to composite part <NUM>, <NUM>-<NUM> and/or mandrel <NUM>, <NUM>-<NUM>. The cutter housing <NUM>-<NUM> spans between the track <NUM>, B354-<NUM> and the groove <NUM>-<NUM>, B352 and transports cutter housing <NUM>-<NUM> along the track <NUM>, B354-<NUM> and groove <NUM>-<NUM>, B352 by a roller system <NUM> and rollers <NUM>-<NUM>, respectively. A cutter <NUM>-<NUM> has a transverse mount <NUM>-<NUM> travelling in transverse direction <NUM> to the feature creator <NUM>-<NUM>. The cutter <NUM>-<NUM> includes the blade <NUM> which is a reciprocating blade or a circular blade or a mill type cutter blade to separate manufacturing excess <NUM>-<NUM> and final trim edge <NUM> or edge <NUM>-<NUM>. An embodiment of the roller system <NUM> has a rack and pinion connection between the feature creator <NUM>-<NUM> and the tracks <NUM>, B354-<NUM>.

Looking at <FIG>, <FIG> and <FIG>, mandrel work station <NUM>-<NUM> includes a cutter <NUM>-<NUM> with a blade <NUM>, such as blade, drill, mill, to create separated manufacturing excess <NUM>-<NUM> from manufacturing edge <NUM>-<NUM> leaving final trim edge <NUM>. The cutting operation is typically performed prior to demolding of the composite part <NUM> from the mandrel <NUM>, and creating a final trim edge <NUM> prior to processing through work stations <NUM> in an assembly line <NUM>, <NUM>-<NUM>. Trimming prior to demold saves the non-value added time of placing the composite part <NUM> such as half barrel section <NUM> into a cell dedicated to only trimming and indexing to the cell and indexing to edge <NUM>-<NUM> or final trim <NUM>, <NUM>-<NUM> or trim line <NUM>-<NUM> prior to trimming final trim <NUM>, <NUM>-<NUM> and then indexing the composite structure <NUM>, <NUM>-<NUM> to each successive cell in a repetitive part perimeter and contour scan-able process. Using the manufacturing excess <NUM>-<NUM>, <NUM>-<NUM> to convey indexing features <NUM>, B126 saves much if not all of the repetitive part perimeter and contour scan-able process time needed to index to each cell when moving through the assembly process.

While a groove <NUM>-<NUM> is used in some embodiments to guide and enable longitudinal <NUM>-<NUM> transport of the cutter <NUM>-<NUM> relative to final trim edge <NUM> with support <NUM>-<NUM> slide-ably engaging it with roller system <NUM>-<NUM>, it is not illustrated in this embodiment.

In the illustrated embodiment, as shown, one end <NUM> of the feature creator <NUM>-<NUM> is coupled to blade <NUM> while mid-span <NUM>-<NUM> of feature creator <NUM>-<NUM> is coupled via roller system <NUM> and track <NUM> to composite part <NUM> as part of a flex track type of device and the other end <NUM>-<NUM> of the feature creator <NUM>-<NUM> is coupled via roller system <NUM> and track <NUM> to mandrel <NUM> as part of a flex track type of device without using a connection to groove <NUM>-<NUM>. The blade <NUM> is cantilevered over the composite part <NUM> relative to the tracks <NUM>. The controller <NUM> guides the blade <NUM> relative to the final trim edge <NUM> to create separate manufacturing edge <NUM>-<NUM>.

A flex track type of device (mandrel work station <NUM>-<NUM>) with a cutter moveably attached to two tracks removeably attached to the composite part <NUM> such as half barrel section <NUM>. The tracks <NUM> are shown removably attached to composite part <NUM> such as half barrel section <NUM> and mandrel <NUM>. The tracks <NUM> are vacuum coupled or by some other means of removable attaching to composite part <NUM> and/or mandrel <NUM>. The cutter housing <NUM>-<NUM> spans between the track <NUM> and the groove <NUM>-<NUM> and transports along the track <NUM> and groove <NUM>-<NUM> by a roller system <NUM> and rollers <NUM>-<NUM>, respectively. A cutter <NUM>-<NUM> has a transverse mount <NUM>-<NUM> travelling in transverse direction <NUM> to the feature creator <NUM>-<NUM>. The cutter <NUM>-<NUM> includes the blade <NUM> which is a reciprocating blade or a circular blade or a mill type cutter blade to separate manufacturing excess <NUM>-<NUM> and final trim edge <NUM>. An embodiment of the roller system <NUM> has a rack and pinion connection between the cutter feature creator <NUM>-<NUM> and the tracks <NUM>. A The flex track type of device is embodied as mandrel work stations <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>,.

The mandrel work stations <NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM> and mandrel <NUM> are capable of being coupled with either grooves <NUM>, <NUM>-<NUM> or tracks <NUM> or a combination of the two as illustrated in <FIG>, <FIG>, <FIG>, <FIG>, <FIG>, <FIG>. As illustrated, mandrel work stations <NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM> and mandrel <NUM> cover several different ways to couple these together. One or more of the several coupling methods could be used for the embodiments of cutter <NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>. Therefore, <NUM>-<NUM> is coupleable to mandrel <NUM> by a groove <NUM>, <NUM>-<NUM> similar to cutter <NUM>, <NUM>-<NUM>. Similarly method of coupling of mandrel work stations <NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM> and mandrel <NUM> are capable of use on cutter <NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>.

A controller <NUM> manages the operations of the mandrel work station <NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>. In this embodiment, the controller <NUM> includes an interface, such as an ethernet interface, Universal Serial Bus (USB) interface, wireless interface, etc., for communicating with the mandrel work station <NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, and includes a memory that stores one or more Numerical Control (NC) programs for operating the mandrel work station <NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>. Controller <NUM> may further process feedback from mandrel work station <NUM>, and provide instructions based on such feedback. Controller <NUM> may be implemented, for example, as custom circuitry, as a hardware processor executing programmed instructions, or some combination thereof.

Track <NUM> guides the mandrel <NUM> in the process direction <NUM>, and may comprise rollers <NUM>, rails, or other components that facilitate movement of the mandrel <NUM>. In one embodiment, the track <NUM> comprises a discretized series of stanchions that are separated in the process direction <NUM>, and to which rollers are mounted. The track <NUM> includes a drive <NUM> (e.g., a chain drive or other component) to move the mandrel <NUM> in one embodiment, while in further embodiments an Autonomous Guided Vehicle (AGV) (not shown) is used to move the mandrel <NUM>. In one embodiment, the track <NUM> is also used to move the composite part <NUM>, after the composite part <NUM> has been demolded from the mandrel <NUM> while <FIG> has the composite part <NUM> carried on into assembly line <NUM>, <NUM>-<NUM> on track <NUM>. The feature creator <NUM> is carried by the track <NUM>, or by another rail or groove system.

After the indexing features <NUM>, B126 have been installed, the composite part <NUM>, <NUM>-<NUM> may be demolded, placed onto track <NUM>, and moved in the process direction <NUM>, <NUM>-<NUM> to a downstream work station <NUM>, <NUM>-<NUM>, while the mandrel <NUM>, <NUM>-<NUM> is returned to a cleaning and/or reconditioning station. For example, the mandrel <NUM>, <NUM>-<NUM> may be sent to a pulsed line or dedicated station, such as assembly line <NUM>, <NUM>-<NUM> and work station <NUM>, <NUM>-<NUM>, where it is processed for reuse, and potted recesses <NUM> are recesses within mandrel <NUM>, <NUM>-<NUM> that are filled with potting compound and finished to a mandrel <NUM>, <NUM>-<NUM> surface contour <NUM> before reused to receive another laminate for hardening into a composite part <NUM>, <NUM>-<NUM>. The downstream work station <NUM>, <NUM>-<NUM> utilizes the indexing features <NUM>, B126 in the demolded composite part <NUM>, <NUM>-<NUM> in order to index the downstream work station <NUM>, <NUM>-<NUM> to the composite part <NUM>, <NUM>-<NUM> before performing work such as NDI, drilling, installing fasteners, installing frames, cutting out windows or doors, installing window or door surrounds, etc. In further embodiments, multiple downstream work stations <NUM>, <NUM>-<NUM> are placed along a track <NUM> for carrying the demolded composite part <NUM>, <NUM>-<NUM>, and multiple types of indexing features <NUM>, B126 (e.g., having different shapes, sizes, and/or spacing) are installed at the composite part <NUM>, <NUM>-<NUM>. In such embodiments, different ones of the downstream work stations <NUM>, <NUM>-<NUM> may utilize different types of indexing features <NUM>, B126 at the composite part <NUM>, <NUM>-<NUM>.

In an embodiment, indexing features <NUM>, B126 are created prior to hardening the composite part <NUM>. In such an embodiment, the composite part <NUM> is laid-up as a preform <NUM>, <NUM>-<NUM> onto the layup surface <NUM> of the mandrel <NUM>. In order to apply indexing features before hardening, index contour features <NUM> on mandrel <NUM> are recesses, indents, dimple, bumps or ridges that are filled with resin and reinforcing fibers or otherwise shapes resin and reinforcing fibers, respectively, thus imparting an indexing feature <NUM>-<NUM>, B126-<NUM> into manufacturing excess <NUM>, <NUM>, <NUM>-<NUM> prior to hardening which is made permanent by the hardening process.

Again referring to <FIG>, <FIG>, a version that does not include indexing features <NUM>, B126 is also envisioned. This version has the bearing edge <NUM> and/or edge <NUM>-<NUM>. Another version has a indexing features <NUM>, B126 along one manufacturing excess <NUM>-<NUM>, <NUM>-<NUM> between final trim <NUM>, <NUM>-<NUM> and bearing edge <NUM> or edge <NUM>-<NUM>, respectively.

Illustrative details of the operation of fabrication environment <NUM>, <NUM>-<NUM> will be discussed with regard to <FIG>. Assume, for this embodiment, that mandrel <NUM>, <NUM>-<NUM> has received a laminate, and that heat and pressure has been applied to harden the laminate on the mandrel <NUM>, <NUM>-<NUM> in order to form the composite part <NUM>, <NUM>-<NUM>.

<FIG> is a flowchart illustrating a method for applying indexing features <NUM>, <NUM>-<NUM> through <NUM>-<NUM> and B126, B126-<NUM> through B126-<NUM> to composite parts <NUM>, <NUM>-<NUM> in an illustrative embodiment. The steps of method <NUM> are described with reference to fabrication environment <NUM>, <NUM>-<NUM> of <FIG>, but those skilled in the art will appreciate that method <NUM> may be performed in other systems. The steps of the flowcharts described herein are not all inclusive and may include other steps not shown. The steps described herein may also be performed in an alternative order.

Step <NUM> includes receiving a mandrel <NUM>, <NUM>-<NUM> to which a composite part <NUM>, <NUM>-<NUM> has been placed. For example, mandrel <NUM>, <NUM>-<NUM> may comprise a contoured layup mandrel onto which the composite part <NUM>, <NUM>-<NUM> has been hardened. The mandrel <NUM>, <NUM>-<NUM> may be continuously moved or pulsed in the process direction during fabrication and/or assembly of the composite part <NUM>, <NUM>-<NUM>, or may remain stationary after removal from an autoclave. Receiving the mandrel <NUM>, <NUM>-<NUM> comprises the mandrel <NUM>, <NUM>-<NUM> being placed at a location where it may be indexed by the mandrel work station <NUM>, <NUM>-<NUM>, through <NUM>-<NUM>.

In step <NUM>, the mandrel work station <NUM>, <NUM>-<NUM>, through <NUM>-<NUM> indexes <NUM>, <NUM>-<NUM> to the mandrel <NUM>, <NUM>-<NUM>. This may be performed by placing indexing key <NUM> into one or more of the mandrel indexing features <NUM>, B114 at the mandrel <NUM>, <NUM>-<NUM>, in order to precisely enforce a positional relationship/offset between the mandrel <NUM>, <NUM> and the mandrel work station <NUM>, <NUM>-<NUM>, through <NUM>-<NUM>. Because the position of the mandrel work station <NUM>, <NUM>-<NUM>, <NUM>-<NUM> relative to the mandrel <NUM>, <NUM>-<NUM> is precisely known when coupled with the mandrel indexing feature <NUM>, B114, the mandrel work station <NUM>, <NUM>-<NUM>, <NUM>-<NUM> may be operated to install the indexing features <NUM>, B126 as desired. In one embodiment, the mandrel <NUM>, <NUM>-<NUM> includes recesses or holes that facilitate cutting through the composite part <NUM>. These recesses may be filled in with potting compound. In such embodiments, the potting compound permits a smooth tooling surface for layup and curing, while also allowing tooling to cut through the inner mold line of the composite part <NUM> and the outer mold line/tooling surface of the mandrel <NUM>. In further embodiments, scanners or imaging systems (e.g., cameras, lasers, ultrasonic sensors, etc.) are utilized to index to the mandrel <NUM>. Further, index contour features <NUM> on mandrel <NUM> are recesses, indents, dimple, bumps or ridges that are filled with resin and reinforcing fibers or otherwise shapes resin and reinforcing fibers, respectively, thus imparting a indexing feature <NUM>-<NUM>, B126-<NUM> into manufacturing excess <NUM>-<NUM>, <NUM>-<NUM>, <NUM> prior to hardening which is made permanent by the hardening process.

In step <NUM>, the mandrel work station <NUM>, <NUM>-<NUM>, <NUM>-<NUM> is operated to install part indexing feature <NUM>, B126 into a manufacturing excess <NUM>-<NUM>, <NUM> of the composite part <NUM>. The indexing feature <NUM>, B126 is offset from the mandrel indexing feature <NUM> at the mandrel <NUM>. Installing the indexing feature <NUM>, B126 may comprise cutting, drilling, or otherwise removing and/or adding material from or onto the composite part <NUM>, <NUM>-<NUM>. In further embodiments installing the indexing feature <NUM>, B126 comprises milling or machining a portion of the composite part <NUM>, <NUM>-<NUM> that was formed during layup. That is, installing the indexing feature <NUM> comprises machining a layup feature in the composite part <NUM>. For example, this comprises adding cup locating features <NUM>-<NUM>, B126-<NUM> for a cup and cone arrangement, drill start locations <NUM>-<NUM>, B126-<NUM>, drill through locations <NUM>-<NUM>, B126-<NUM>, slots <NUM>-<NUM>, B126-<NUM>, installed pins <NUM>-<NUM>, B126-<NUM>, RFID tags <NUM>-<NUM>, B126-<NUM> and bar codes <NUM>-<NUM>, B126-7In embodiments where the indexing feature <NUM>, B126 is a pin that is placed into the composite part <NUM>, installing the indexing feature <NUM> may comprise the pin installer <NUM> (<FIG>) driving the pin <NUM>-<NUM>, B126-<NUM> through a hole in the composite part <NUM>, <NUM>-<NUM>. In one embodiment, the mandrel <NUM> is removed from an autoclave, the separated flash edge <NUM>-<NUM>, <NUM>-<NUM> is created from the composite part <NUM>, <NUM>-<NUM> to reveal the bearing edge <NUM> and edge <NUM>-<NUM>. The cutter <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM> and <NUM>-<NUM> with a blade <NUM>, such as blade, drill, mill, to create separated manufacturing excess <NUM>-<NUM> and/or separated flash edge <NUM>-<NUM> from manufacturing edge <NUM>-<NUM>, <NUM>-<NUM> leaving edge <NUM>, <NUM>-<NUM> on one or more ends of mandrel <NUM>, <NUM>-<NUM>, respectively.

Step <NUM> may be repeated multiple times (e.g., once per mandrel indexing feature <NUM>, B114. Each time the mandrel work station <NUM>, <NUM>-<NUM>, <NUM>-<NUM> is progressed relative to mandrel <NUM>, <NUM>-<NUM> from mandrel indexing feature <NUM>, B114 to place multiple indexing features <NUM>, B126 to be installed a manufacturing excess <NUM>-<NUM>, <NUM>, <NUM>-<NUM> of the composite part <NUM>, <NUM>-<NUM>, respectively. The mandrel work station <NUM>, <NUM>-<NUM>, <NUM>-<NUM> is progressed in either the process direction <NUM>, <NUM>-<NUM> when progressing from mandrel indexing feature <NUM>, <NUM>-<NUM> through <NUM>-<NUM> and B114, B114-<NUM> through B114-<NUM> to the next mandrel indexing feature <NUM>, <NUM>-<NUM> through <NUM>-<NUM> and B114, B114-<NUM> through B114-<NUM> and installing each successive indexing feature <NUM>, B126 linked to the mandrel indexing feature <NUM>. The indexing features <NUM> are used by work stations <NUM>, <NUM>-<NUM> as the composite part <NUM>, <NUM>-<NUM> advances in the process direction <NUM>, <NUM>-<NUM>, respectively.

In step <NUM>, operate the mandrel work stations <NUM>-<NUM> through <NUM>-<NUM> to trim the composite part <NUM>, <NUM>-<NUM> to remove manufacturing excess while composite part <NUM>, <NUM>-<NUM> is still on the mandrel <NUM>, <NUM>-<NUM> using info conveyed by the mandrel <NUM>, <NUM>-<NUM>.

In step <NUM>, the composite part <NUM> is demolded from the mandrel <NUM>. This may comprise lifting, flexing, or otherwise separating the composite part <NUM>, <NUM>-<NUM> from the mandrel <NUM>, <NUM>-<NUM>. The composite part <NUM>, <NUM>-<NUM> then proceeds to an assembly line <NUM>, <NUM>-<NUM> for further fabrication and assembly, while the mandrel <NUM>, <NUM>-<NUM> returns for cleaning, reconditioning and receiving another preform <NUM>, <NUM>-1for a composite part <NUM>, <NUM>-<NUM>. In one embodiment, the mandrel <NUM> is also reworked (e.g., refilled with potting material, repaired, etc.) and transported to a layup start location. In one embodiment, the composite part <NUM>, <NUM>-<NUM> is placed on track <NUM>, <NUM>-<NUM> for transport to a downstream work station <NUM>, <NUM>-<NUM>. The track <NUM>, <NUM>-<NUM> may include rails or stanchions at desired position in order to enforce a desired curvature/contour (e.g., shape and loft) onto the composite part <NUM>, <NUM>-<NUM>. The track <NUM> may include rails or stanchions at a position to carry bearing edge <NUM> in order to enforce a desired curvature/contour (e.g., shape and loft) onto the composite part <NUM>, in particular half barrel section <NUM>.

The method then continues, for example, the composite part <NUM>, <NUM>-<NUM> is indexed to work station <NUM>, <NUM>-<NUM> or shuttle, in particular with wing panel <NUM>-<NUM>, in an assembly line <NUM>, <NUM>-<NUM> via the indexing features <NUM>, B126, and work may be performed on the composite part <NUM>, <NUM>-<NUM> by one or more of the work stations <NUM>, <NUM>-<NUM> at the same time while the composite part <NUM>, <NUM>-<NUM> is indexed to the one or more work stations <NUM>, <NUM>-<NUM>. Again, work may be performed by one or more work stations <NUM>, <NUM>-<NUM> singularly or in multiples at the same time
In step <NUM>, the composite part <NUM>, <NUM>-<NUM> is advanced in the process direction <NUM>, <NUM>-<NUM>, for example by operating a drive system at the track <NUM>, <NUM>-<NUM>, or by pulling the composite part <NUM>, <NUM>-<NUM> along the track <NUM>, <NUM>-<NUM>. This may be performed in a micro pulsed, pulsed or continuous fashion, after demolding from mandrel <NUM>, <NUM>-<NUM>.

In step <NUM>, the composite part <NUM>, <NUM>-<NUM> is indexed to the downstream work station <NUM>, <NUM>-<NUM> (or any work station, or multiple work stations at the same time, including an upstream or adjacent work station) via the indexing features <NUM>, B126 installed onto the composite part <NUM>, <NUM>-<NUM>. For example, the downstream work station <NUM>, <NUM>-<NUM> may couple with (e.g., buck into) the indexing features <NUM>, B126 to determine the positions of the indexing features <NUM>, B126. The downstream work station <NUM>, <NUM>-<NUM> may then adjust its position based on the positions of the indexing features <NUM>, B126, in order to account for any deviations from an expected position/orientation. According to the method of indexing described herein, each downstream work station <NUM>, <NUM>-<NUM> is dependent on the requirements of location accuracy used for the alignment and placement of a component being installed.

Method <NUM> provides a technical benefit over prior techniques and systems, because it enables indexing features to be applied to a composite part <NUM>, <NUM>-<NUM> while it is still coupled with and taking advantage of precisely fabricated composite part <NUM>, <NUM>-<NUM> and the precisely located and shaped mandrel <NUM>, <NUM>-<NUM>. This means that indexing features <NUM>, B126 are added to the composite part <NUM>, <NUM>-<NUM> without the need to reindex the composite part <NUM>, <NUM>-<NUM>, because the precise nature of the mandrel <NUM>, <NUM>-<NUM> is known and leveraged onto the composite part <NUM>, <NUM>-<NUM> prior to demolding from the mandrel <NUM>, <NUM>-<NUM>. Hence, after demolding, the composite part <NUM> does not need to be probed, scanned, or otherwise inspected as part of an indexing protocol to each work station <NUM>, <NUM>-<NUM> in order to characterize its structure and/or 3Dconfiguration before the indexing features are installed. That is, the install location of each of those indexing features is precisely known by referencing to an indexing feature that has already been installed at the mandrel. The indexing feature also conveys precise 3D configuration characterization about the composite structure within the purview <NUM>, <NUM>-<NUM> of each work station <NUM>, <NUM>-<NUM>, respectively. This saves time by not subjecting the composite part <NUM>, <NUM>-<NUM> to the need of scanning to determine the 3D configuration characterization of the structure within the purview of <NUM>, <NUM>-<NUM> or each work station <NUM>, <NUM>-<NUM> as needed in the prior art. The complexity and repetitive time consuming nature of the prior art type of indexing system is magnified by the need to scanably index to each work station <NUM>, <NUM>-<NUM> for the composite part <NUM>, <NUM>-<NUM> within purview <NUM>, <NUM>-<NUM> after each micro pulse <NUM>. Furthermore, since mandrels <NUM>, <NUM>-<NUM> are utilized to fashion multiple composite parts <NUM>, <NUM>-<NUM>, respectively, there is little additional labor and time involved in applying mandrel indexing features <NUM>, B114 to the mandrels <NUM>, <NUM>-<NUM> that guide the installation of indexing features <NUM>, B126 for composite parts <NUM>, <NUM>-<NUM>. The mandrels <NUM>, <NUM>-<NUM> are fabricated as an initial process prior to composite fabrication. Furthermore, because manufacturing excess <NUM>-<NUM>, <NUM>, <NUM>-<NUM> is retained at the composite part <NUM>, <NUM>-<NUM>, it communicates its fabrication instructions to each subsequent work station <NUM>, <NUM>-<NUM> as well as 3D configuration characterization of the structure, such as inner mold line contour and/or outer mold line contour, within the purview of <NUM>, <NUM>-<NUM> or each work station <NUM>, <NUM>-<NUM>.

<FIG> is a flowchart illustrating a method <NUM> for processing composite parts <NUM>, <NUM>-<NUM> in an illustrative embodiment. Step <NUM> includes receiving a mandrel <NUM>, <NUM>-<NUM> to which composite part <NUM>, <NUM>-<NUM> has been placed, and may be performed in a similar manner to step <NUM> above. Step <NUM> comprises processing the composite part <NUM>, <NUM>-<NUM> through the hardening process and into the assembly line <NUM>, <NUM>-<NUM> after demolding the composite part <NUM>, <NUM>-<NUM> from the mandrel <NUM>, <NUM>-<NUM> based on mandrel indexing features <NUM>, B114 located on the mandrel <NUM>, <NUM>-<NUM>. This may comprise installing indexing features <NUM>, B126 into the composite part <NUM>, <NUM>-<NUM>, trimming the composite part <NUM>, <NUM>-<NUM>, or performing any suitable actions while the composite part remains molded to the mandrel.

<FIG> is a side view of a variety of indexing features <NUM>, B126 installed at a composite part <NUM> in an illustrative embodiment. Any one or combination of these indexing features <NUM>, B126 may be implemented at a given composite part (e.g., a half barrel fuselage section). Indexing features <NUM>, B126 may be placed in a manufacturing excess <NUM>, and these indexing features <NUM>, B126 are installed during the post cure process, prior to demolding. Eventually, when the manufacturing excess <NUM> is no longer needed for indexing, the manufacturing excess <NUM> is trimmed off (e.g., before the half barrel fuselage section is fastened to another half barrel section to form a full barrel section wherein the lower half barrel section is joined to the upper half barrel section). <FIG> are views of various indexing features <NUM>, B126. <FIG> is a cross sectional view of composite part <NUM> and cup <NUM>, which is a type of locating feature <NUM>, but could also apply to composite part <NUM>-<NUM> with indexing feature B126. The cup <NUM> is a receiver for a cone <NUM> coupled to work station <NUM> and/or work station <NUM>-<NUM> during an index mating of composite part <NUM>, <NUM>-<NUM> to work station <NUM>, <NUM>-<NUM>, respectively. The cup <NUM> has a version, as illustrated, forming a passage through composite part <NUM>, <NUM>-<NUM>. Another version has the cup <NUM> not passing entirely through the composite part <NUM>, <NUM>-<NUM>. The cup <NUM> and the cone <NUM> form a tapered female to male connection, respectively, when indexing occurs.

<FIG> is a cross sectional view of a drill start <NUM>, one of the indexing features <NUM>, B126. <FIG> illustrates a cross sectional view of composite part <NUM> and drill start <NUM>, which is a type of locating feature <NUM>, but could also apply to composite part <NUM>-<NUM> with indexing feature B126. Drill start <NUM> is a receiver for a mating coupler <NUM>, such as a stubby pin <NUM>. The drill start <NUM> is a non-through hole into the composite part <NUM>, <NUM>-<NUM>. The drill start <NUM> and the mating coupler <NUM> form a female to male connection, respectively, when indexing occurs during an index mating of composite part <NUM>, <NUM>-<NUM> to work station <NUM>, <NUM>-<NUM>.

<FIG> is a cross sectional view of a drill through <NUM>, one of the indexing features <NUM>, B126. <FIG> illustrates a cross sectional view of composite part <NUM> and drill through <NUM>, which is a type of locating feature <NUM>, but could also apply to composite part <NUM>-<NUM> with indexing feature B126. The drill through <NUM> is a receiver for a pin <NUM> coupled to work station <NUM>, <NUM>-<NUM> during index mating of composite part <NUM>, <NUM>-<NUM> to work station <NUM>, <NUM>-<NUM>. The drill through <NUM> has a version forming a passage through composite part <NUM>, <NUM>-<NUM>. The drill through <NUM> and the pin <NUM> form a female to male connection, respectively, when indexing occurs. Pin <NUM> fills at least a portion of drill through <NUM> during indexing mating.

<FIG> is a cross sectional view of slots <NUM>-<NUM>, B126-<NUM>, one of the indexing features <NUM>, B126. The slot <NUM>, corresponds to <NUM>-<NUM>, B126-<NUM>, is a receiver for a slot engager <NUM> coupled to work station <NUM>, <NUM>-<NUM> during an index mating of composite part <NUM>, <NUM>-<NUM> to work station <NUM>, <NUM>-<NUM>. The slots <NUM> has a version, as illustrated, forming a non-pass through portion of composite part <NUM>, <NUM>-<NUM>. Another version, not illustrated, has a slot passing through composite part <NUM>, <NUM>-<NUM>. The slot <NUM> and the slot engager <NUM> form a female to male connection, respectively, when indexing occurs. Slot engager <NUM> passes into composite part <NUM>, <NUM>-<NUM> during indexing mating, in one version.

<FIG> is a cross sectional view of a drill through <NUM> with pin <NUM> install therein and is one of the indexing features <NUM>, B126. <FIG> illustrates a cross sectional view of composite part <NUM> and pin <NUM>, but could also apply to composite part <NUM>-<NUM> with indexing feature B126. The pin <NUM> is a receiver for a pin connector <NUM> coupled to work station <NUM>, <NUM>-<NUM> during index mating of composite part <NUM>, <NUM>-<NUM> to work station <NUM>, <NUM>-<NUM>. The pin <NUM> and the pin connector <NUM> form a male to female connection, respectively, when indexing occurs. Pin <NUM> fills at least a portion of drill through <NUM> during indexing mating.

<FIG> is a cross sectional view of a Radio Frequency Identification (RFID) Chip <NUM> and is one of the indexing features <NUM>, B126. <FIG> illustrates a cross sectional view of composite part <NUM> and RFID Chip <NUM>, but could also apply to composite part <NUM>-<NUM> with indexing feature B126. The Radio Frequency Identification (RFID) Reader <NUM> is a receiver for RFID Chip <NUM> communicated information. RFID Reader <NUM> is coupled to work station <NUM>, <NUM>-<NUM> during index mating of composite part <NUM>, <NUM>-<NUM> to work station <NUM>, <NUM>-<NUM>.

<FIG> is a cross sectional view of a Bar Code <NUM> and is one of the indexing features <NUM>, B126. <FIG> illustrates a cross sectional view of composite part <NUM> and Bar Code <NUM>, but could also apply to composite part <NUM>-<NUM> with indexing feature B126. The Bar Code Reader <NUM> is a receiver for Bar Code <NUM> communicated information. Bar Code Reader <NUM> is coupled to work station <NUM>, <NUM>-<NUM> during index mating of composite part <NUM>, <NUM>-<NUM> to work station <NUM>, <NUM>-<NUM>.

<FIG> is a cross sectional view of notch <NUM>, one of the indexing features <NUM>, B126. Notch <NUM> of any suitable shape (e.g., trapezoid, square, triangle, vertical hole, etc.) machined out of the bearing edge <NUM> of the composite part <NUM>, which terminates leaving a backing <NUM> as shown in <FIG>. The notch <NUM> is a receiver for a notch engager <NUM> coupled to work station <NUM>, <NUM>-<NUM> during an index mating of composite part <NUM>, <NUM>-<NUM> to work station <NUM>, <NUM>-<NUM>. The notch <NUM> has a version, as illustrated, forming a non-pass through portion of composite part <NUM>, <NUM>-<NUM>. Another version, not illustrated, has a notch <NUM> passing through composite part <NUM>, <NUM>-<NUM>. The notch <NUM> and the notch engager <NUM> form a female to male connection, respectively, when indexing occurs. Notch engager <NUM> passes into composite part <NUM>, <NUM>-<NUM> during indexing mating, in one version.

Each of these different indexing features <NUM>, B126 may therefore be utilized to facilitate indexing or other operations at various work stations <NUM>, <NUM>-<NUM>. For example, some work stations <NUM>, <NUM>-<NUM> may use one type of feature (e.g., blind holes that facilitate placement of a structure relative to the work station <NUM>, <NUM>-<NUM>), while other work stations <NUM>, <NUM>-<NUM> may use another type of features (e.g., pins that facilitate gripping of the part). The potential to use male features (e.g., pins) and/or female features (e.g., holes) means that low-profile work stations <NUM>, <NUM>-<NUM> (e.g., NDI inspection stations) can interact with female indexing features <NUM>, B126 of a composite part <NUM>, <NUM>-<NUM> without encountering physical interference, These are all examples of some of the many geometries that could be implemented in order to achieve indexing fits in desired fashions. Still further, the shapes of indexing features <NUM>, B126 (and/or corresponding receptacles at work stations <NUM>, <NUM>-<NUM>) may be shaped to constrain the composite part <NUM>, <NUM>-<NUM> to a desired position, without over-constraining the composite part <NUM>, <NUM>-<NUM>. For example, a slot <NUM>, is an example of an indexing feature <NUM>, B126 may constrain vertical motion while enabling motion in the process direction <NUM>, <NUM>-<NUM>, while a pin, notch, slot or hole may constrain motion in both the process direction <NUM>, <NUM>-<NUM> as well as vertically.

In further embodiments, the features described herein may be installed into any suitable portions of the composite part <NUM>, <NUM>-<NUM> (e.g., a door cut-out region or window cut-out region), or indexing features <NUM>, B126 may even be applied to composite parts <NUM>, <NUM>-<NUM> during layup, by placing pins, bladders, or other tools onto a laminate for the composite part <NUM>, <NUM>-<NUM> before the laminate is hardened.

<FIG> are views of a downstream work station <NUM> that indexes <NUM>, <NUM>-<NUM> to indexing features <NUM> installed onto a composite part <NUM> in an illustrative embodiment. Indexing features <NUM> and composite part <NUM> correspond to indexing features <NUM>, B126 and composite part <NUM>, <NUM>-<NUM>, respectively. In this embodiment, receptacles <NUM> at a frame <NUM> of the work station <NUM> receive indexing features <NUM> in the form of pins <NUM> cantilevered out from composite part <NUM>. Each pin <NUM> is engaged and/or engaged by a receptacle <NUM> and indexes <NUM>, <NUM>-<NUM> and/or places the composite part <NUM> in a desired position along the process direction <NUM>, <NUM>-<NUM>.

In <FIG>, which corresponds with view arrows <NUM> of <FIG>, the half-barrel shape of the composite part <NUM> is clearly visible. Furthermore, the indexing features <NUM> (i.e., pins) are more clearly visible within receptacles <NUM>.

Referring more particularly to the drawings, embodiments of the disclosure may be described in the context of aircraft manufacturing and service in method <NUM> as shown in <FIG> and an aircraft <NUM> as shown in <FIG>. During pre-production, method <NUM> may include specification and design <NUM> of the aircraft <NUM> and material procurement <NUM>. During production, component and subassembly manufacturing <NUM> and system integration <NUM> of the aircraft <NUM> takes place. Thereafter, the aircraft <NUM> may go through certification and delivery <NUM> in order to be placed in service <NUM>. While in service by a customer, the aircraft <NUM> is scheduled for routine work in maintenance and service <NUM> (which may also include modification, reconfiguration, refurbishment, and so on). Apparatus and methods embodied herein may be employed during any one or more suitable stages of the production and service described in method <NUM> (e.g., specification and design <NUM>, material procurement <NUM>, component and subassembly manufacturing <NUM>, system integration <NUM>, certification and delivery <NUM>, service <NUM>, maintenance and service <NUM>) and/or any suitable component of aircraft <NUM> (e.g., airframe <NUM>, systems <NUM>, interior <NUM>, propulsion system <NUM>, electrical system <NUM>, hydraulic system <NUM>, environmental <NUM>).

As shown in <FIG>, the aircraft <NUM> produced by method <NUM> may include an airframe <NUM> with a plurality of systems <NUM> and an interior <NUM>. Examples of systems <NUM> include one or more of a propulsion system <NUM>, an electrical system <NUM>, a hydraulic system <NUM>, and an environmental system <NUM>. Any number of other systems may be included. Although an aerospace example is shown, the principles of the invention may be applied to other industries, such as the automotive industry.

As already mentioned above, apparatus and methods embodied herein may be employed during any one or more of the stages of the production and service described in method <NUM>. For example, components or subassemblies corresponding to component and subassembly manufacturing <NUM> may be fabricated or manufactured in a manner similar to components or subassemblies produced while the aircraft <NUM> is in service. Also, one or more apparatus embodiments, method embodiments, or a combination thereof may be utilized during the subassembly manufacturing <NUM> and system integration <NUM>, for example, by substantially expediting assembly of or reducing the cost of an aircraft <NUM>. Similarly, one or more of apparatus embodiments, method embodiments, or a combination thereof may be utilized while the aircraft <NUM> is in service, for example and without limitation during the maintenance and service <NUM>. Thus, the invention may be used in any stages discussed herein, or any combination thereof, such as specification and design <NUM>, material procurement <NUM>, component and subassembly manufacturing <NUM>, system integration <NUM>, certification and delivery <NUM>, service <NUM>, maintenance and service <NUM>) and/or any suitable component of aircraft <NUM> (e.g., airframe <NUM>, systems <NUM>, interior <NUM>, propulsion system <NUM>, electrical system <NUM>, hydraulic system <NUM>, and/or environmental <NUM>.

Claim 1:
A method for preparing a composite part for assembly, the method comprising:
- placing a preform (<NUM>, <NUM>-<NUM>) with a manufacturing excess (<NUM>, <NUM>-<NUM>) upon a mandrel (<NUM>, <NUM>-<NUM>);
- hardening the preform (<NUM>, <NUM>-<NUM>) into composite part (<NUM>, <NUM>-<NUM>) with a hardened manufacturing excess (<NUM>, <NUM>-<NUM>) while still upon mandrel (<NUM>, <NUM>-<NUM>); and
- operating a mandrel work station (<NUM> through <NUM>-<NUM>) to install an indexing feature (<NUM>, B126) into the manufacturing excess (<NUM>, <NUM>-<NUM>) of the composite part (<NUM>, <NUM>-<NUM>) pre-hardening and/or post hardening prior to demolding the composite part (<NUM>, <NUM>-<NUM>) from mandrel (<NUM>, <NUM>-<NUM>).