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

Patent document <CIT>, according to its abstract, states: a system and method to automate the assembly of a wing panel, such as utilized by commercial aircraft. In the context of a system, a tacking cell is provided that is configured to tack one or more stringers to a skin plank. The system also includes a riveting cell configured to receive a tacked plank from the tacking cell and to rivet the one or more stringers to the skin plank. The system also includes a splicing cell configured to receive a plurality of riveted planks from the riveting cell and to attach one or more splice stringers to the plurality of riveted planks. Further, the system includes a side of body cell configured to receive a spliced panel from the splicing cell and to attach a side of body chord thereto to produce a wing panel.

Patent document <CIT>, according to its abstract, states: a system for distortional clamping of a flexible member may include a dimensional reader and a positioning fixture. The dimensional reader may have a plurality of reader pogos that may be axially movable into contacting relation with a detail to measure a detail contour. The positioning fixture may have a plurality of positioning pogos and at least one clamping finger configured to mechanically clamp a flexible member between the positioning pogos and the clamping finger. The positioning pogos may be axially movable to deflect the flexible member into a contour that may be complementary to the detail contour.

Patent document <CIT>, according to its abstract, states: a production system for manufacturing a workpiece comprises an index system including a plurality of index devices removably mounted on the workpiece at known longitudinally spaced locations therealong, and a longitudinally extending index member releasably engaged with at least two of the index devices such that a position and orientation of the index are fixed relative to the workpiece by the index devices, the index member having position-indicating features distributed therealong. The production system further comprises a machine module mounted for longitudinal movement along the index member and operable to perform an operation, the machine module being operable to detect the position-indicating features on the index member and thereby determine a position of the machine module relative to the workpiece.

Patent document <CIT>, according to its abstract, states: a flexible fixture system and method wherein a single fixture system can accommodate and hold a plurality of different workpieces. The flexible fixture system comprises a plurality of posts each including a plurality of different contoured formers, one former for each of the different workpieces to be accommodated and held by the flexible fixture system. Depending upon which workpiece is to be held by the fixture system, the required former on each post is selected automatically and moved into position for operative association with the workpiece. The contoured formers include powered clamps for holding details to be fastened to the workpiece. Each post of the flexible fixture system also includes a plurality of holding devices, such as suction cup type devices, which are moved into position to hold the workpiece and maintain its curvature.

Disclosed are a workpiece holder for handling a composite workpiece according to claim <NUM> and a method for handling a composite workpiece according to claim <NUM>. Further aspects are defined by the dependent claims <NUM>-<NUM> and <NUM>-<NUM>.

Referring generally to <FIG>, by way of examples, the present disclosure is directed to a system <NUM> for handling a composite workpiece <NUM>. The system <NUM> facilitates one or more post-cure processing operation, such as at least one machining operation, being performed on the composite workpiece <NUM>. More particularly, the system <NUM> facilitates automated indexing of the composite workpiece <NUM> within a work cell and conformance of the composite workpiece <NUM> to a predetermined or desired shape within the work cell during a post-cure processing operation. As such, the system <NUM> advantageously improves the accuracy and precision of the machining operation and facilitates determinant assembly and/or predictive assembly of a structure that includes the composite workpiece <NUM>.

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

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

For the purpose of the present disclosure, the term "as-built," such as in reference to an as-built condition or an as-built shape (e.g., generally referred to herein as an as-built shape <NUM>) of the composite workpiece <NUM>, refers to a condition of the composite workpiece <NUM> in which the composite workpiece <NUM> has a shape (e.g., geometry, profile, contour, structural features, and the like) upon a tool in which the composite workpiece <NUM> was cured (e.g., tool <NUM>). In other words, as an example, the as-built shape <NUM> of the composite workpiece <NUM> is a shape of the composite workpiece <NUM> that is substantially the same as a shape of the composite workpiece <NUM> as cured on a tool or mandrel (e.g., tool <NUM>) and prior to separation from the tool or mandrel.

For the purpose of the present disclosure, the term "real-time," such as in reference to a real-time condition or a real-time shape (e.g., generally referred to herein as a real-time shape <NUM>) of the composite workpiece <NUM>, refers to an immediate condition of the composite workpiece <NUM> in which the composite workpiece <NUM> has a shape (e.g., geometry, profile, contour, structural features, and the like) as presently positioned, such as before or during a post-cure processing operation (e.g., one or more machining operations).

For the purpose of the present disclosure, the term "as-machined," such as in reference to an as-machined condition or an as-machined shape (e.g., generally referred to herein as an as-machined shape <NUM>) of the composite workpiece <NUM>, refers to a post-processing condition of the composite workpiece <NUM> in which the composite workpiece <NUM> has a shape (e.g., geometry, profile, contour, structural features, and the like) after a post-cure processing operation (e.g., one or more machining operations) is performed on the composite workpiece <NUM>.

It can be appreciated that a tool upon which a composite workpiece is cured provides a support structure that reinforces a shape of the composite workpiece while the composite workpiece is on the tool. Once a composite workpiece or other composite structure is removed from a tool upon which it is cured, the reinforcement provided by the tool is also removed and the composite structure may tend to change its shape (e.g., droop, sag, bend, twist, deflect, etc.) from its reinforced shape (e.g., as-build shape), as supported by the tool, to an unreinforced shape, as unsupported by the tool, which is different than its reinforced shape. When the tool that provides the reinforcement is removed, the composite workpiece may change shape, for example, due to residual stresses in the composite structure or due to external forces applied to the composite structure during post-cure processing, such as, but not limited to, gravity causing drooping and/or sagging or loads applied to the composite structure by machine tools during processing. The principles and implementations of the system <NUM> disclosed herein enable a composite workpiece to be maintained in or to be conformed to the as-built shape (e.g., a shape that is substantially the same as the shape of the composite workpiece reinforced by the tool) once the composite workpiece is removed from the tool. As such, a machining operation can be performed on the composite workpiece with the composite workpiece in the as-built shape, thereby, reducing or eliminating inaccurate or inconsistent machining due to the machining operation being performed on a composite workpiece while the composite workpiece has a shape that is different than the as-built shape.

Additionally, the principles and implementations of the system <NUM> disclosed herein enable a digital model to be generated, which is representative of the composite workpiece having the as-built shape. The digital model of the composite workpiece (e.g., in the as-built shape) may be used to automatically index, for example, under computer control, the composite workpiece before a post-cure processing operation is performed on the composite workpiece. As such, a machining operation performed on the composite workpiece, in the as-built shape and appropriately indexed, improves processing speeds and increases the accuracy of the machining operation being performed on the composite workpiece. For example, the as-built shape will closely correspond to the contour and/or shape of the composite workpiece (e.g., a panel) when the composite workpiece is assembled into final structure (e.g., a wing with ribs and spars).

Further, the digital model of the composite workpiece may also be used to conform the composite workpiece to the as-built shape during a processing operation performed on the composite workpiece. As such, machining operations performed on the composite workpiece, conformed to the as-built shape, reduces or eliminates inaccurate or inconsistent machining due to the machining operation being performed on the composite workpiece while the composite workpiece has a shape that is different than the as-built shape and/or the as-machined shape.

Moreover, the principles and implementations of the system <NUM> disclosed herein enable the digital model to be updated after a machining operation is performed, such that the digital model is representative of an as-machined shape of the composite workpiece <NUM>. The digital model of the composite workpiece (e.g., in the as-machined shape) may be used to index the composite workpiece before a subsequent post-cure processing operation is performed on the composite workpiece. The digital model of the composite workpiece may also be used to conform the composite workpiece to the as-machined shape during a subsequent post-cure processing operation performed on the composite workpiece. As such, the principles of the system <NUM> disclosed herein also enable determinant assembly or predictive assembly of the composite workpiece based on the digital model of the composite workpiece, which is updated throughout post-cure processing of the composite workpiece.

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

Referring to <FIG>, <FIG> and <FIG>, in one or more examples, at least a portion of the system <NUM> is associated with at least one of the work cells <NUM>. In one or more examples, the system <NUM> forms a sub-system of the manufacturing environment <NUM>. The system <NUM> facilitates transporting the composite workpiece <NUM> through the work cells <NUM>, indexing the composite workpiece <NUM> relative to the work cells <NUM>, conforming the composite workpiece <NUM> to the as-built shape <NUM>, or to the as-machined shape, in the work cells <NUM>, and performance of at least one post-cure processing operation on the composite workpiece <NUM> in the work cells <NUM>.

As best illustrated in <FIG>, in one or more examples, at least a portion of the system <NUM> is associated with the second work cell <NUM>. The system <NUM> facilitates indexing of the composite workpiece <NUM> relative to the second work cell <NUM>, conforming the composite workpiece <NUM> to the as-built shape <NUM>, and performing at least one post-cure processing operation (e.g., drilling) on the composite workpiece <NUM> in the second work cell <NUM> with the composite workpiece <NUM> appropriately indexed and conformed to the as-built shape <NUM>.

As best illustrated in <FIG>, in one or more examples, at least a portion of the system <NUM> is associated with the first work cell <NUM>. After the composite workpiece <NUM> is cured (e.g., using a curing apparatus, such as an oven or autoclave), the composite workpiece <NUM> is transported to the first work cell <NUM> on a tool <NUM>. In one or more examples, the tool <NUM> is a cure tool upon which the composite workpiece <NUM> was cured.

As best illustrated in <FIG>, in one or more examples, the composite workpiece <NUM> is digitized while on the tool <NUM> to capture the as-built shape <NUM> of the composite workpiece <NUM>. In one or more examples, an as-built model <NUM> (e.g., as shown in <FIG>) is generated that represents the composite workpiece <NUM> in the as-built shape <NUM>.

In one or more examples, an initial post-cure processing operation (e.g., a machining, drilling, or trimming operation) may be performed on the composite workpiece <NUM> while the composite workpiece <NUM> is on the tool <NUM> (e.g., in the first work cell <NUM>). In these examples, the composite workpiece <NUM> is digitized after the initial post-cure processing operation. As such, the as-built model <NUM> may also represent initially machined features of the composite workpiece <NUM>.

As best illustrated in <FIG>, in one or more examples, the composite workpiece <NUM> is removed from the tool <NUM> and is transported from the first work cell <NUM> to the second work cell <NUM> for performance of a post-cure processing operation.

As best illustrated in <FIG>, in one or more examples, the composite workpiece <NUM> is then successively transported from one of the work cells <NUM> (e.g., the second work cell <NUM>) to another one of the work cells <NUM> (e.g., the third work cell <NUM>) for performance of subsequent post-cure processing operations. This process may be repeated any number of times to move the composite workpiece <NUM> through the work cells <NUM> and to perform any number of post-cure processing operations.

Referring now to <FIG>, in one or more examples, the system <NUM> includes or is associated with at least one of the work cells <NUM> (e.g., the second work cell <NUM>). The system <NUM> includes a plurality of workpiece holders <NUM>. The workpiece holders <NUM> hold the composite workpiece <NUM> in the second work cell <NUM>. Each one of the workpiece holders <NUM> is selectively controlled to index the composite workpiece <NUM> in the second work cell <NUM>. For example, with the composite workpiece <NUM> held by the workpiece holders <NUM>, the workpiece holders <NUM> appropriately position the composite workpiece <NUM> in the second work cell <NUM> for performance of a post-cure processing operation. Additionally, the workpiece holders <NUM> conform the composite workpiece <NUM> to the as-built shape <NUM> of the composite workpiece <NUM>, for example, before and/or during performance of a post-cure processing operation.

Referring now to <FIG> and <FIG>, which schematically illustrate examples of a workpiece holder <NUM>. The workpiece holder <NUM> is an example of at least one of the workpiece holders <NUM> (e.g., as shown in <FIG>). In some examples, each one of the workpiece holders <NUM> is substantially the same, for example, includes substantially the same features and/or operates substantially the same, as the workpiece holder <NUM>. In other examples, one or more of the workpiece holders <NUM> is different, for example, includes different features and/or operates different, than as the example of the workpiece holder <NUM>.

In one or more examples, the workpiece holder <NUM> includes a base <NUM> and a clamp <NUM>. The clamp <NUM> is coupled to the base <NUM>. In one or more examples, the clamp <NUM> is movable relative to the base <NUM> to appropriately position the clamp <NUM> in the work cell (e.g., the second work cell <NUM>) and/or relative to the composite workpiece <NUM>. In one or more examples, the base <NUM> is located on a manufacturing floor of the manufacturing environment <NUM> (e.g., <FIG>) in one of the work cells <NUM>(e.g., the second work cell <NUM>). In one or more examples, the base <NUM> is movable relative to one of the work cells <NUM> (e.g., the second work cell <NUM>) to appropriately locate the clamp <NUM> in the work cell and/or relative to the composite workpiece.

Referring to <FIG>, in one or more examples, the base <NUM> of the workpiece holder <NUM> is linearly movable along a first translation axis <NUM> (e.g., in the directions of first directional arrow <NUM>). In one or more examples, the base <NUM> of the workpiece holder <NUM> is linearly movable along a second translation axis <NUM> (e.g., in the directions of second directional arrow <NUM>). The second translation axis <NUM> is approximately perpendicular to the first translation axis <NUM>.

With the clamp <NUM> unclamped from the composite workpiece <NUM>, movement of the base <NUM> along the first translation axis <NUM> locates the clamp <NUM> along the first translation axis <NUM>, for example, relative to the composite workpiece <NUM>.

With the clamp <NUM> clamped to the composite workpiece <NUM>, movement of the base <NUM> along the first translation axis <NUM> locates the composite workpiece <NUM> along the first translation axis <NUM>, for example, relative to an associated one of the work cells <NUM> (e.g., the second work cell <NUM>) or relative to a machine tool <NUM> (e.g., as shown in <FIG>) associated with one of the work cells <NUM> (e.g., the second work cell <NUM>).

With the clamp <NUM> unclamped from the composite workpiece <NUM>, movement of the base <NUM> along the second translation axis <NUM> locates the clamp <NUM> along the second translation axis <NUM>, for example, relative to the composite workpiece <NUM>.

Referring to <FIG>, in one or more examples, the clamp <NUM> of the workpiece holder <NUM> (e.g., as shown in <FIG> and <FIG>) or any one of the workpiece holders <NUM> (e.g., as shown in <FIG>) includes a first jaw <NUM>, a support member <NUM> that is coupled to the first jaw <NUM>, and a second jaw <NUM> that is coupled to the support member <NUM>. The second jaw <NUM> is movable along the support member <NUM> relative to the first jaw <NUM> to clamp the composite workpiece <NUM> between the first jaw <NUM> and the second jaw <NUM>. In one or more examples, the second jaw <NUM> and the first jaw <NUM> clamp the composite workpiece <NUM> in the as-built shape <NUM>.

Referring again to <FIG>, in one or more examples, the second jaw <NUM> of the clamp <NUM> is linearly movable along a third translation axis <NUM> relative to the first jaw <NUM> (e.g., in the directions of third directional arrow <NUM>). Movement of the second jaw <NUM> along the third translation axis <NUM> clamps or unclamps a portion of the composite workpiece <NUM> between the first jaw <NUM> and the second jaw <NUM>.

Referring still to <FIG>, in one or more examples, the clamp <NUM> of the workpiece holder <NUM> is rotationally movable about a first rotation axis <NUM> relative to the base <NUM> of the workpiece holder <NUM> (e.g., in the directions of fourth directional arrow <NUM>). In one or more examples, clamp <NUM> of the workpiece holder <NUM> is rotationally movable about a second rotation axis <NUM> relative to the base <NUM> of the workpiece holder <NUM> (e.g., in the directions of fifth directional arrow <NUM>). The second rotation axis <NUM> is approximately perpendicular to the first rotation axis <NUM>. The second rotation axis <NUM> is approximately parallel to or coaxial with the first translation axis <NUM>. The first rotation axis <NUM> is approximately parallel to or coaxial with the second translation axis <NUM>.

With the clamp <NUM> unclamped from the composite workpiece <NUM>, movement of the clamp <NUM> about the second rotation axis <NUM> adjusts an angular orientation of the first jaw <NUM> and the second jaw <NUM> about the second rotation axis <NUM> relative to the composite workpiece <NUM>.

With the clamp <NUM> clamped to the composite workpiece <NUM>, movement of the clamp <NUM> about the first rotation axis <NUM> adjusts an angular orientation of the composite workpiece <NUM> about the first rotation axis <NUM>.

Accordingly, movement of the second jaw <NUM> relative to the first jaw <NUM> clamps the composite workpiece <NUM> within the clamp <NUM>. Movement of the clamp <NUM> relative to the base <NUM> and movement of the base <NUM> appropriately positions the composite workpiece <NUM> in one of the work cells <NUM>. For example, movement of the clamp <NUM> relative to the base <NUM> and movement of the base <NUM> indexes the composite workpiece <NUM> in one of the work cells <NUM> for performance of a post-cure processing operation.

Referring now to <FIG>, which schematically illustrate examples of the clamp <NUM> of the workpiece holder <NUM>, and to <FIG>, which schematically illustrate examples of a portion of the clamp <NUM>. In one or more examples, the workpiece holder <NUM> (e.g., at least one of the workpiece holders <NUM>) includes a plurality of numerical control contacts <NUM>. Throughout the present disclosure, the term "numerical control" may be referred to as "NC. " The numerical control contacts <NUM> are located along the first jaw <NUM>. The workpiece holder <NUM> also includes a plurality of force control contacts <NUM>. The force control contacts <NUM> are located along the second jaw <NUM>.

Each one of the numerical control contacts <NUM> is selectively movable relative to the first jaw <NUM> to a numerical control location <NUM> (e.g., as shown in <FIG>). The numerical control location <NUM> for each one of the numerical control contacts <NUM> is based on the as-built shape <NUM> of the composite workpiece <NUM>.

Each one of the force control contacts <NUM> is selectively movable relative to the second jaw <NUM> to apply a shaping force <NUM> (e.g., as shown in <FIG>) to the composite workpiece <NUM>. The shaping force <NUM>, applied by each one of the force control contacts <NUM>, forces the composite workpiece <NUM> against the numerical control contacts <NUM> to conform the composite workpiece <NUM> to the as-built shape <NUM> of the composite workpiece <NUM>.

As illustrated in <FIG> and <FIG>, in one or more examples, the composite workpiece <NUM> is positioned between the first jaw <NUM> and the second jaw <NUM> of the clamp <NUM>. In one or more examples, a portion of a first surface <NUM> of the composite workpiece <NUM> is supported on, is support by, or is in contact with one or more of the numerical control contacts <NUM> before the composite workpiece <NUM> is clamped between the first jaw <NUM> and the second jaw <NUM> (e.g., as shown in <FIG>).

The second jaw <NUM> is moved toward the first jaw <NUM> (e.g., in the direction of third directional arrow <NUM> shown in <FIG> and <FIG>) to move the force control contacts <NUM> toward a second surface <NUM> of the composite workpiece <NUM>. In one or more examples, the second jaw <NUM> is moved toward the first jaw <NUM> until at least one of the force control contacts <NUM> is in contact with the second surface <NUM> of the composite workpiece <NUM> (e.g., as shown in <FIG> and <FIG>). In one or more examples, the second jaw <NUM> is moved toward the first jaw <NUM> to clamp a portion of the composite workpiece <NUM> between the first jaw <NUM> and the second jaw <NUM> and, more particularly, between at least one of the numerical control contacts <NUM> and at least one of the force control contacts <NUM>.

In one or more examples, each one of the numerical control contacts <NUM> is linearly movable (e.g., extends and retracts) relative to the first jaw <NUM> (e.g., in the directions of sixth directional arrow <NUM> shown in <FIG>). Each one of the numerical control contacts <NUM> moves (e.g., extends or retracts) to the numerical control location <NUM> associated with it (e.g., as shown in <FIG>).

In one or more examples, each one of the numerical control contacts <NUM> is moved to the numerical control location <NUM> before the composite workpiece <NUM> is placed between the first jaw <NUM> and the second jaw <NUM>. In one or more examples, each one of the numerical control contacts <NUM> is moved to the numerical control location <NUM> after the composite workpiece <NUM> is placed between the first jaw <NUM> and the second jaw <NUM>.

As illustrated in <FIG>, with the numerical control contacts <NUM> moved to the numerical control location <NUM>, one or more of the numerical control contacts <NUM> may not be in contact with the first surface <NUM> of the composite workpiece <NUM> upon placement of the composite workpiece <NUM> between the first jaw <NUM> and the second jaw <NUM>. As illustrated in <FIG> and <FIG>, with the numerical control contacts <NUM> moved to the numerical control location <NUM>, one or more of the numerical control contacts <NUM> may not be in contact with the first surface <NUM> of the composite workpiece <NUM> upon initial movement of the second jaw <NUM> to initially clamp the composite workpiece <NUM>.

In one or more examples, the numerical control location <NUM> of each one of the numerical control contacts <NUM> corresponds to a coordinate location on the first surface <NUM> of the composite workpiece <NUM> having the as-built shape <NUM>. In one or more examples, the coordinate location on the first surface <NUM> of the composite workpiece <NUM> is represented by or is extracted from the as-built model <NUM> (e.g., as shown in <FIG>) of the composite workpiece <NUM>. The as-built model <NUM> is representative of the composite workpiece <NUM> having the as-built shape <NUM>. As such, with each one of the numerical control contacts <NUM> at the numerical control location <NUM>, the numerical control contacts <NUM> match a shape or contour of the first surface <NUM> of the composite workpiece <NUM> having the as-built shape <NUM>.

As illustrated in <FIG>, <FIG> and <FIG>, with the composite workpiece <NUM> initially clamped between the first jaw <NUM> and the second jaw <NUM> and, more particularly, between at least one of the numerical control contacts <NUM> and at least one of the force control contacts <NUM>, each one of the force control contacts <NUM> moves into contact with the second surface <NUM> of the composite workpiece <NUM> and applies the shaping force <NUM> (e.g., as shown in <FIG> and <FIG>) to a portion of the composite workpiece <NUM>. The shaping force <NUM>, applied by the force control contacts <NUM>, urges the portion of the composite workpiece <NUM> toward and against the numerical control contacts <NUM> such that the numerical control contacts <NUM> are in contact with the first surface <NUM> of the composite workpiece <NUM>. As such, the force control contacts <NUM> conform the composite workpiece <NUM> to the as-built shape <NUM>, which is defined by each one of the numerical control contacts <NUM> at the numerical control location <NUM>.

In one or more examples, each one of the force control contacts <NUM> is linearly movable (e.g., extends and retracts) relative to the second jaw <NUM> (e.g., in the directions of seventh directional arrow <NUM> shown in <FIG> and <FIG>). Each one of the force control contacts <NUM> moves (e.g., extends) to apply the shaping force <NUM> to the composite workpiece <NUM>. In one or more examples, each one of the force control contacts <NUM> moves (e.g., extends) until a threshold force is achieved. In one or more examples, the shaping force <NUM> is less than or equal to the threshold force. As such, the threshold force limits the shaping force <NUM> or represents a maximum magnitude of the shaping force <NUM> required to urge the composite workpiece <NUM> against the numerical control contacts <NUM> and, thus, limits movement (e.g., extension) of the force control contacts <NUM>.

As illustrated in <FIG> and <FIG>, with the numerical control contacts <NUM> moved to the numerical control location <NUM> and the force control contacts <NUM> moved until reaching the threshold force, each one of the numerical control contacts <NUM> is in contact with the first surface <NUM> of the composite workpiece <NUM> and each one of the force control contacts <NUM> is in contact with the second surface <NUM> of the composite workpiece <NUM>, the composite workpiece <NUM> is clamped between the numerical control contacts <NUM> and the force control contacts <NUM>, and the composite workpiece <NUM> is conformed to the as-built shape <NUM>.

Referring now to <FIG>, in one or more examples, each one of the numerical control contacts <NUM> includes a numerical control actuator <NUM> and a first vacuum gripper <NUM> that is coupled to the numerical control actuator <NUM>.

In one or more examples, the workpiece holder <NUM> also includes a first actuator control unit <NUM>. The first actuator control unit <NUM> controls extension and retraction of the numerical control actuator <NUM> to locate an end of the first vacuum gripper <NUM> at the numerical control location <NUM>.

In one or more examples, the first actuator control unit <NUM> is dedicated to and provides instructions to one of the numerical control contacts <NUM>. For example, each one of the numerical control contacts <NUM> includes the first actuator control unit <NUM>.

In one or more examples, the first actuator control unit <NUM> is shared by and provides instructions to more than one of the numerical control contacts <NUM>. For example, a set (e.g., portion) of the numerical control contacts <NUM> includes the first actuator control unit <NUM>.

Referring still to <FIG>, in one or more examples, each one of the force control contacts <NUM> includes a force control actuator <NUM> and a second vacuum gripper <NUM> that is coupled to the force control actuator <NUM>.

In one or more examples, the workpiece holder <NUM> includes a force sensor <NUM>. The force sensor <NUM> detects a load, or reaction force, applied to the force control actuator <NUM> by the composite workpiece <NUM> as the force control contacts <NUM> apply the shaping force <NUM> to the composite workpiece <NUM>.

In one or more examples, the workpiece holder <NUM> includes a second actuator control unit <NUM>. The second actuator control unit <NUM> controls extension and retraction of the force control actuator <NUM> to apply the shaping force <NUM> to the composite workpiece <NUM>.

The force sensor <NUM> is coupled to or is in communication with the second actuator control unit <NUM>. The load, or reaction force, applied to the force control actuator <NUM> by the composite workpiece <NUM> is compared to the threshold force. Upon the load, or reaction force, applied to the force control actuator <NUM> by the composite workpiece <NUM> and detected by the force sensor <NUM> being equal to the threshold value, the second actuator control unit <NUM> instructs the force control actuator <NUM> to stop moving.

In one or more examples, the second actuator control unit <NUM> is dedicated to and provides instructions to one of the force control contacts <NUM>. For example, each one of the force control contacts <NUM> includes the second actuator control unit <NUM>.

In one or more examples, the second actuator control unit <NUM> is shared by and provides instructions to more than one of the force control contacts <NUM>. For example, a set (e.g., portion) of the force control contacts <NUM> includes the second actuator control unit <NUM>.

In one or more examples, the force sensor <NUM> is dedicated to and detects the load applied to one of the force control contacts <NUM>. For example, each one of the force control contacts <NUM> includes the force sensor <NUM>.

In one or more examples, the force sensor <NUM> is shared by and detects loads applied to more than one of the force control contacts <NUM>. For example, a set (e.g., portion) of the force control contacts <NUM> includes the force sensor <NUM>.

Referring again to <FIG>, in one or more examples, the workpiece holder <NUM> includes a drive mechanism <NUM>. In one or more examples, the drive mechanism <NUM> selectively moves the second jaw <NUM> along the support member <NUM> relative to the first jaw <NUM>. In one or more examples, the drive mechanism <NUM> selectively moves the clamp <NUM> relative to the base <NUM>. The drive mechanism <NUM> includes any suitable type and/or number of motor and drive systems, such as a mechanical drive, a hydraulic drive, an electric drive, a pneumatic drive, or a combination thereof.

Referring now to <FIG>, <FIG>, <FIG> and <FIG>, in one or more examples, with the composite workpiece <NUM> held by the clamp <NUM> of the workpiece holder <NUM> (e.g., each one of the workpiece holders <NUM>), the drive mechanism <NUM> rotates the clamp <NUM> about the first rotation axis <NUM> (e.g., as shown in <FIG>) relative to the base <NUM> to adjust an angular orientation of the composite workpiece <NUM>. In one or more examples, with the composite workpiece <NUM> held by the clamp <NUM> of the workpiece holder <NUM> (e.g., each one of the workpiece holders <NUM>), the drive mechanism <NUM> linearly moves the base <NUM> along at least one of the first translation axis <NUM> and the second translation axis <NUM> (e.g., as shown in <FIG>) relative to one of the work cells <NUM> to adjust a location of the composite workpiece <NUM>.

In one or more examples, the composite workpiece <NUM> is initially positioned or loaded in the clamp <NUM>, between the first jaw <NUM> and the second jaw <NUM>, in first orientation, such as an approximately horizontal orientation (e.g., as shown in <FIG>). With the composite workpiece <NUM> in the first orientation (e.g., approximately horizontal orientation), the clamp <NUM> clamps the composite workpiece <NUM> between the first jaw <NUM> and the second jaw <NUM> and, more particularly, between the numerical control contacts <NUM> and the force control contacts <NUM>. The numerical control contacts <NUM> and the force control contacts <NUM> conform the composite workpiece <NUM> to the as-built shape <NUM>.

In one or more examples, the clamp <NUM> rotationally moves relative to the base <NUM> to move the composite workpiece <NUM> from the first orientation (e.g., approximately horizontal orientation) to a second orientation, such as an approximately vertical orientation (e.g., as shown in <FIG>). In one or more examples, a post-cure processing operation (e.g., drilling operation) is performed on the composite workpiece <NUM> in the second orientation (e.g., the approximately vertical orientation as shown in <FIG>). Additionally, movement of the clamp <NUM> relative to the base <NUM> and/or movement of the base <NUM> relative to one of the work cells <NUM> (e.g., the second work cell <NUM>) indexes the composite workpiece <NUM> for performance of the post-cure processing operation.

Referring now to <FIG> and <FIG>, which schematically illustrates an example of the first work cell <NUM>. In one or more examples, a portion of the system <NUM> is associated with the first work cell <NUM>. In one or more examples, the system <NUM> includes a first metrology system <NUM>, which may also be referred to as an as-built metrology system. In one or more examples, the first metrology system <NUM> is movable into the first work cell <NUM>. In one or more examples, at least a portion of the first metrology system <NUM> is positioned in the first work cell <NUM>.

The first metrology system <NUM> digitizes the composite workpiece <NUM> while the composite workpiece <NUM> is on the tool <NUM> and has the as-built shape <NUM>. In one or more examples, the first metrology system <NUM> generates as-built measurement data <NUM> (e.g., as shown in <FIG>) for the composite workpiece <NUM>. The as-built measurement data <NUM> represents at least a portion of the composite workpiece <NUM> while the composite workpiece <NUM> is on the tool <NUM> and has the as-built shape <NUM>.

In an example, the first metrology system <NUM> digitizes at least the second surface <NUM> of the composite workpiece <NUM> such that the as-built measurement data <NUM> represents the shape, contour, and features (e.g., edges, holes, etc.) of the second surface <NUM> of the composite workpiece <NUM>.

In one or more examples, the as-built measurement data <NUM> is used to generate the as-built model <NUM> (e.g., as shown in <FIG>) of the composite workpiece <NUM> having the as-built shape <NUM>.

Referring now to <FIG>, in one or more examples, at least a portion of the system <NUM> is associated with the second work cell <NUM>. In one or more examples, the system <NUM> includes a second metrology system <NUM>, which may also be referred to as a real-time second metrology system. In one or more examples, the second metrology system <NUM> is movable into the second work cell <NUM>. In one or more examples, at least a portion of the second metrology system <NUM> is positioned in the second work cell <NUM>.

The second metrology system <NUM> digitizes the composite workpiece <NUM> while the composite workpiece <NUM> is held in the second work cell <NUM> by the workpiece holders <NUM> and has the real-time shape <NUM>. In one or more examples, the second metrology system <NUM> generates real-time measurement data <NUM> (e.g., as shown in <FIG>) for the composite workpiece <NUM>. The real-time measurement data <NUM> represents at least a portion of the composite workpiece <NUM> while the composite workpiece <NUM> is positioned in the second work cell <NUM> by the workpiece holders <NUM> and has the real-time shape <NUM>, for example, as held by the workpiece holders <NUM>.

In an example, the second metrology system <NUM> digitizes at least the second surface <NUM> of the composite workpiece <NUM> such that the real-time measurement data <NUM> represents the shape, contour, and features (e.g., edges, holes, etc.) of the second surface <NUM> of the composite workpiece <NUM>. In another example, the second metrology system <NUM> digitizes the first surface <NUM> and the second surface <NUM> of the composite workpiece <NUM> such that the real-time measurement data <NUM> represents the shape, contour, and features (e.g., edges, holes, etc.) of the first surface <NUM> and the second surface <NUM> of the composite workpiece <NUM>.

In one or more examples, the real-time measurement data <NUM> is used to generate a real-time model <NUM> (e.g., as shown in <FIG>) that is representative of the composite workpiece <NUM> having the real-time shape <NUM>.

In one or more examples, the first metrology system <NUM> and/or the second metrology system <NUM> includes at least one scanner <NUM> that scans and digitizes at least a portion of the composite workpiece <NUM>. In one or more examples, the scanner <NUM> is any one of various types of three-dimensional (3D) scanners. In one or more examples, the scanner <NUM> includes, or is, a photogrammetric scanner, such as a photogrammetric camera. In other examples, the scanner <NUM> includes, or is, one of a laser triangulation scanner, a structured light scanner, other laser-based scanners or metrology systems, and the like.

Referring again to <FIG>, in one or more examples, the scanner <NUM> of the first metrology system <NUM> and the second metrology system <NUM> captures the geometry (e.g., size and shape), contour (e.g., curvature), physical features (e.g., holes, edges, etc.), and other details of the composite workpiece <NUM>. Scan data (e.g., measurement data) generated the scanner <NUM> is used by a computer to generate a model of the composite workpiece <NUM>. The model of the composite workpiece <NUM> is a digital three-dimensional representation of the composite workpiece <NUM>.

In one or more examples, the system <NUM> includes a computing device <NUM>. The computing device <NUM> is adapted to manipulate the scanned measurement data representing the composite workpiece <NUM> (e.g., the as-built measurement data <NUM>, the real-time measurement data <NUM>, etc.) and/or to generate models representing the composite workpiece <NUM> (e.g., the as-built model <NUM>, the real-time model <NUM>, etc.) based on the scanned measurement data generated by the scanner <NUM>.

In one or more examples, the computing device <NUM> is operable to generate the as-built model <NUM> from the as-built measurement data <NUM> generated by the first metrology system <NUM>. The as-built model <NUM> is representative of the composite workpiece <NUM> having the as-built shape <NUM>, for example, as formed and/or cured on the tool <NUM>.

In one or more examples, the computing device <NUM> is operable to generate the real-time model <NUM> from the real-time measurement data <NUM> generated by the second metrology system <NUM>. The real-time model <NUM> is representative of the composite workpiece <NUM> having the real-time shape <NUM>, for example, as held by the workpiece holders <NUM>.

In one or more examples, the workpiece holders <NUM> are selectively controlled (e.g., by instructions provided by the computing device <NUM>) to index the composite workpiece <NUM> within one of the work cells <NUM> (e.g., the second work cell <NUM>). For example, the computing device <NUM> is programmed with an indexed position <NUM> (e.g., as shown in <FIG> and <FIG>) of the composite workpiece <NUM> based on a predetermined virtual indexed position <NUM> (e.g., as shown in <FIG>) of the as-built model <NUM> in the second work cell <NUM>. The computing device <NUM> is operable to instruct the workpiece holders <NUM> to move the composite workpiece <NUM> to the indexed position <NUM> (e.g., as shown in <FIG> and <FIG>).

In one or more examples, the computing device <NUM> is operable to compare the real-time model <NUM> to the as-built model <NUM>. Comparison of the real-time model <NUM> to the as-built model <NUM> determines whether the composite workpiece <NUM> is appropriately indexed in the second work cell <NUM>. In situations where the comparison of the real-time model <NUM> to the as-built model <NUM> indicates that the composite workpiece <NUM> is not appropriately indexed, the computing device <NUM> is operable to instruct the workpiece holders <NUM> to adjust the position of the composite workpiece <NUM> in the second work cell <NUM> based on the comparison, such that the composite workpiece <NUM> is appropriately indexed.

In one or more examples, at least one of the workpiece holders <NUM> is selectively controlled (e.g., by instructions provided by the computing device <NUM>) to conform the real-time shape <NUM> of the composite workpiece <NUM> to the as-built shape <NUM> of the composite workpiece <NUM>. For example, the computing device <NUM> is programmed with numerical control location <NUM> for each one of the numerical control contacts <NUM> based on the as-built model <NUM>. The computing device <NUM> instructs each one of the numerical control contacts <NUM> to extend or retract to the numerical control location <NUM> (e.g., as shown in <FIG>) and instructs each one of the force control contacts <NUM> to extend and apply the shaping force <NUM> to the composite workpiece <NUM>.

In one or more examples, the computing device <NUM> is operable to compare the real-time model <NUM> to the as-built model <NUM>. Comparison of the real-time model <NUM> to the as-built model <NUM> determines whether the real-time shape <NUM> of the composite workpiece <NUM> is conformed to the as-built shape <NUM> of the composite workpiece <NUM>. In situations where the comparison indicates that the real-time shape <NUM> of the composite workpiece <NUM> is not conformed (e.g., does not substantially match) the as-built shape <NUM> of the composite workpiece <NUM>, the computing device <NUM> is operable to modify the numerical control location <NUM> of at least one of the numerical control contacts <NUM> of at least one of the workpiece holders <NUM> based on the comparison, such that the real-time shape <NUM> of the composite workpiece <NUM> is conformed (e.g., not substantially matches) the as-built shape <NUM> of the composite workpiece <NUM>.

The computing device <NUM> may include a single computer or several interconnected computers. For example, the computing device <NUM> may include any collection of computing devices that individually or jointly execute a set (or multiple sets) of instructions to implement any one or more of the operations discussed herein. The computing device <NUM> includes a processor <NUM> (e.g., at least one processing unit) that is coupled to memory <NUM>. The memory <NUM> includes program code <NUM> that is executable by the processor <NUM> to perform one or more operations.

Generally, as used herein, the phrase "the computing device <NUM> is adapted to" refers to the computing device <NUM> being configured or otherwise operable to perform a function, such as the program code <NUM> being executed by the processor <NUM> to perform a desired operation or function. The program code <NUM> is any coded instructions that is (e.g., computer readable and/or machine readable. The memory <NUM> is any a non-transitory computer readable and/or machine readable medium, such as a hard disk drive, flash memory, read-only memory, a compact disk, a digital versatile disk, a cache, random-access memory, and/or any other storage device or storage disk in which information is stored for any duration (e.g., for extended time periods, permanently, for brief instances, for temporarily buffering, and/or for caching of the information).

In one or more examples, the computing device <NUM> is adapted to perform various transforms (e.g., rigid body transforms and/or coordinate frame transforms) and/or other data manipulation operations (e.g., global best fit operations) to virtually compare the real-time model <NUM> to the as-built model <NUM>. For example, the computing device <NUM> determines at least one of a translation and a rotation required to transform the real-time model <NUM> to the as-built model <NUM>. In one or more examples, the translation and/or rotation determined by the transform is used by the computing device <NUM> to appropriately reposition the workpiece holders <NUM>, such that the composite workpiece <NUM> is appropriately indexed. In one or more examples, the translation and/or rotation determined by the transform is used by the computing device <NUM> to determine a modification for the numerical control location <NUM> of one or more of the numerical control contacts <NUM>, such that the real-time shape <NUM> of the composite workpiece <NUM> is conformed to the as-built shape <NUM> of the composite workpiece <NUM>.

Referring now to <FIG>, in one or more examples, the system <NUM> includes a machine tool <NUM>. The machine tool <NUM> is positioned (e.g., located and/or oriented) in one of the work cells <NUM> (e.g., the second work cell <NUM>). The machine tool <NUM> performs at least one machining operation on the composite workpiece <NUM> while the composite workpiece <NUM> is indexed and held in the as-built shape <NUM> by the workpiece holders <NUM>.

Referring to <FIG>, <FIG>, <FIG> and <FIG>, in one or more examples, the system <NUM> includes a damping apparatus <NUM>. In one or more examples, the damping apparatus <NUM> is positioned (e.g., located and/or oriented) between a directly adjacent pair of the workpiece holders <NUM>. The damping apparatus <NUM> is coupled to the composite workpiece <NUM>. In one or more examples, the damping apparatus <NUM> is coupled to the first surface <NUM> of the composite workpiece <NUM> while the composite workpiece <NUM> is held (e.g., clamped and conformed) by the workpiece holders <NUM> (e.g., as shown in <FIG>, <FIG> and <FIG>). The damping apparatus <NUM> reduces vibration in the composite workpiece <NUM> during the machining operation performed by the machine tool <NUM> (e.g., as shown in <FIG>). Coupling the damping apparatus <NUM> to the composite workpiece <NUM> increases a mass of the composite workpiece <NUM> at a localized area of the composite workpiece <NUM>, thereby reducing the vibrations induced in the composite workpiece <NUM> by the machine tool <NUM>.

Referring again to <FIG>, in one or more examples, the second metrology system <NUM> digitizes the composite workpiece <NUM> during and/or after performing the post-cure processing operation and while the composite workpiece <NUM> is held by the workpiece holders <NUM>. In one or more examples, the second metrology system <NUM> generates as-machined measurement data <NUM> (e.g., as shown in <FIG>) after the machining operation, for example, performed by the machine tool <NUM>. Accordingly, the second metrology system <NUM> may also be referred to as an as-machined metrology system. The as-machined measurement data <NUM> represents at least a portion of the composite workpiece <NUM> while the composite workpiece <NUM> is held by the workpiece holders <NUM> and has the as-machined shape <NUM> after the machining operation.

In an example, the second metrology system <NUM> digitizes at least the second surface <NUM> of the composite workpiece <NUM> such that the as-machined measurement data <NUM> represents the shape, contour, previous features (e.g., prior formed edges, holes, etc.) and newly added features (e.g., newly formed edges, holes, etc.) of the second surface <NUM> of the composite workpiece <NUM>. In another example, the second metrology system <NUM> digitizes the first surface <NUM> and the second surface <NUM> of the composite workpiece <NUM> such that the real-time measurement data <NUM> represents the shape, contour, previous features (e.g., prior formed edges, holes, etc.), and newly added features (e.g., newly formed edges, holes, etc.) of the first surface <NUM> and the second surface <NUM> of the composite workpiece <NUM>.

In one or more examples, the as-machined measurement data <NUM> is used to generate an as-machined model <NUM> (e.g., as shown in <FIG>) that is representative of the composite workpiece <NUM> having the as-machined shape <NUM>. Accordingly, the as-machined model <NUM> represents an update to the as-built model <NUM>, which includes features formed during the machining operation.

In one or more examples, the computing device <NUM> is operable to generate the as-machined model <NUM> from the as-machined measurement data <NUM> generated by the second metrology system <NUM>. The as-machined model <NUM> is representative of the composite workpiece <NUM> having the as-machined shape <NUM>, for example, having the as-built shape <NUM> and newly added features as held by the workpiece holders <NUM>.

Referring now to <FIG> and <FIG>, in one or more examples, at least a portion of the system <NUM> is associated with the third work cell <NUM>. In one or more examples, the third work cell <NUM> receives the composite workpiece <NUM> from the second work cell <NUM> after the machining operation is performed in the second work cell <NUM> (e.g., as shown in <FIG>).

In one or more examples, the system <NUM> includes a plurality of second workpiece holders <NUM>. In one or more examples, the workpiece holder <NUM> (e.g., as described herein above and shown in <FIG>) is an example of at least one of the second workpiece holders <NUM>. In some examples, each one of the second workpiece holders <NUM> is substantially the same, for example, includes substantially the same features and/or operates substantially the same, as the workpiece holder <NUM>. In other examples, one or more of the second workpiece holders <NUM> is different, for example, includes different features and/or operates different, than as the example of the workpiece holder <NUM>.

The second workpiece holders <NUM> clamp the composite workpiece <NUM> and hold the composite workpiece <NUM> in the third work cell <NUM> for performance of a subsequent post-cure processing operation. For example, with the composite workpiece <NUM> held by the second workpiece holders <NUM>, the second workpiece holders <NUM> appropriately position the composite workpiece <NUM> in the third work cell <NUM> for performance of the subsequent post-cure processing operation (e.g., machining, drilling, trimming, etc.).

In one or more examples, the second workpiece holders <NUM> are selectively controlled to index the composite workpiece <NUM> in the third work cell <NUM>, based on a comparison of the real-time model <NUM>, generated in the third work cell <NUM>, to the as-machined model <NUM>, generated in the second work cell <NUM>. Alternatively, the second workpiece holders <NUM> are selectively controlled to index the composite workpiece <NUM> in the third work cell <NUM>, based on a comparison of the real-time model <NUM>, generated in the third work cell <NUM>, to the as-built model <NUM>, generated in the first work cell <NUM>.

In one or more examples, the second workpiece holders <NUM> are selectively controlled to conform the composite workpiece <NUM> to the as-machined shape <NUM>, based on a comparison of the real-time model <NUM>, generated in the third work cell <NUM>, to the as-machined model <NUM>, generated in the second work cell <NUM>. Alternatively, the second workpiece holders <NUM> are selectively controlled to conform the composite workpiece <NUM> to the as-built shape <NUM>, based on a comparison of the real-time model <NUM>, generated in the third work cell <NUM>, to the as-built model <NUM>, generated in the first work cell <NUM>.

It can be appreciated that this process may be repeated as the composite workpiece <NUM> moves through the other work cells <NUM> of the manufacturing environment <NUM>. For example, workpiece holders associated with each one of the work cells <NUM> hold the composite workpiece <NUM> during performance of a subsequent post-cure processing operation, index the composite workpiece <NUM> before performing the subsequent post-cure processing operation, and conform the composite workpiece <NUM> to the as-built shape <NUM>, or to the as-machined shape <NUM> of an immediately prior one of the work cells <NUM>, before performing the subsequent post-cure processing operation. Additionally, the as-machined model <NUM> may be generated or updated after each subsequent post-cure processing operation, such that, upon completion of all post-cure processing operations, the as-machined model <NUM> represents the composite workpiece <NUM> having the as-built shape <NUM> and all the machined features. As such, the composite workpiece <NUM> fabricated in this manner may be used for determinant assembly or predictive assembly of another structure, such as the wing <NUM> of the aircraft <NUM> (e.g., as shown in <FIG>).

Referring now to <FIG>, <FIG>, <FIG> and <FIG>, in one or more examples, the system <NUM> includes an overhead workpiece handler <NUM>. The overhead workpiece handler <NUM> is coupled to the composite workpiece <NUM>. The overhead workpiece handler <NUM> supports the composite workpiece <NUM> while transporting the composite workpiece <NUM> between the work cells <NUM>.

In one or more examples, with the composite workpiece <NUM> released from the clamp <NUM> of each one of the workpiece holders <NUM>, the overhead workpiece handler <NUM> transports the composite workpiece <NUM> between the work cells <NUM> of the manufacturing environment <NUM>. For example, the overhead workpiece handler <NUM> transports the composite workpiece <NUM> from the second work cell <NUM>, following the post-cure processing operation, to the third work cell <NUM> for performance of a subsequent processing operation, and so on. In one or more examples, the overhead workpiece handler <NUM> carries the composite workpiece in the approximately vertical orientation.

In one or more examples, the overhead workpiece handler <NUM> also supports the composite workpiece <NUM> during the post-cure processing operation and while the composite workpiece <NUM> is held by the workpiece holders <NUM> (or the second workpiece holders <NUM>, third workpiece holders, etc.). For example, the overhead workpiece handler <NUM> supports the composite workpiece <NUM> during periods where at least a portion of the composite workpiece <NUM> is unclamped from at least one of the workpiece holders <NUM>, for example, during relocating or reorienting at least one of the workpiece holders <NUM> relative to the composite workpiece <NUM> or during adjustment of at least one of the numerical control contacts <NUM> of at least one of the workpiece holders <NUM> to conform the composite workpiece <NUM> to the as-built shape <NUM>.

In one or more examples, with the composite workpiece <NUM> coupled to the overhead workpiece handler <NUM> and released from the clamp <NUM> of the workpiece holder <NUM> (e.g., at least one of the workpiece holders <NUM>), the drive mechanism <NUM> of the workpiece holder <NUM> rotates the clamp <NUM> about the second rotation axis <NUM> relative to the base <NUM> of the workpiece holder <NUM> to angularly orient the first jaw <NUM> and the second jaw <NUM> of the clamp <NUM> relative to the composite workpiece <NUM>.

In one or more examples, with the composite workpiece <NUM> coupled to the overhead workpiece handler <NUM> and held by the clamp <NUM> of the workpiece holder <NUM> (e.g., at least one of the workpiece holders <NUM>), the drive mechanism <NUM> of the workpiece holder <NUM> linearly moves the clamp <NUM> along the first translation axis <NUM> to horizontally position the composite workpiece <NUM> in one of the work cells <NUM>.

In one or more examples, with the composite workpiece <NUM> coupled to the overhead workpiece handler <NUM> and released from the clamp <NUM> of the workpiece holder <NUM> (e.g., at least one of the workpiece holders <NUM>), the workpiece holder <NUM> linearly moves along the second translation axis <NUM> to position the first jaw <NUM> and the second jaw <NUM> of the clamp <NUM> relative to the composite workpiece <NUM>.

In one or more examples, the overhead workpiece handler <NUM> includes a support beam <NUM> and a plurality of hangers <NUM>. The hangers <NUM> are connected to the support beam <NUM> and to the composite workpiece <NUM> such that the composite workpiece <NUM> is suspended from the support beam <NUM>, such as in the approximately vertical orientation.

In one or more examples, the hangers <NUM> are connected to the composite workpiece <NUM> at, or using, holes <NUM> machined in the composite workpiece, such that the composite workpiece <NUM> is suspended from the hangers <NUM> by the holes <NUM>. In one or more examples, the holes <NUM> are machined through the composite workpiece <NUM> while the composite workpiece <NUM> is on the tool <NUM> (e.g., in the first work cell <NUM>) and has the as-built shape <NUM>. In one or more examples, the holes <NUM> are represented in the as-built model <NUM> and in the real-time model <NUM> and are used as alignment features during comparison (e.g., transform) of the real-time model <NUM> to the as-built model <NUM> for indexing the composite workpiece <NUM> and/or for conforming the composite workpiece <NUM> to the as-built shape <NUM>.

Referring now to <FIG> and <FIG>, in one or more examples, the system <NUM> includes a material handler <NUM>. The material handler <NUM> demolds (e.g., separates and removes) the composite workpiece <NUM> from the tool <NUM>. In one or more examples, the material handler <NUM> transports the composite workpiece <NUM> directly to the workpiece holders <NUM> (e.g., as shown in <FIG>). For example, the material handler <NUM> demolds the composite workpiece <NUM> from the tool <NUM> in the first work cell <NUM> and transports the composite workpiece <NUM> to the workpiece holders <NUM> associated with the second work cell <NUM>. In one or more examples, the composite workpiece <NUM> is coupled to the overhead workpiece handler <NUM> while the composite workpiece <NUM> is held by the workpiece holders <NUM>, for example, in the second work cell <NUM>.

In one or more examples, the material handler <NUM> transports the composite workpiece <NUM> in the approximately horizontal orientation. The clamp <NUM> of the workpiece holder <NUM> (e.g., each one of the workpiece holders <NUM>) receives the composite workpiece <NUM> from the material handler <NUM> with the composite workpiece <NUM> in the approximately horizontal orientation.

In one or more examples, the overhead workpiece handler <NUM> receives the composite workpiece <NUM> from the material handler <NUM> and transports the composite workpiece <NUM> from the first work cell <NUM> to the second work cell <NUM>.

The present disclosure is also directed to a method for handling the composite workpiece <NUM> using the system <NUM>. The present disclosure is further directed to the composite workpiece <NUM> manufactured using the system <NUM>. The present disclosure is additionally directed to the system <NUM> for handling the composite workpiece <NUM> that includes the workpiece holder <NUM> (e.g., at least one of the workpiece holders <NUM>). The present disclosure is also directed to the workpiece holder <NUM>, such as the plurality of workpiece holders <NUM>, for handling the composite workpiece <NUM>, for example, in at least one of the work cells <NUM> of the manufacturing environment <NUM>.

Referring generally to <FIG> and particularly to <FIG>, by way of examples, the present disclosure is also directed to a method <NUM> for handling the composite workpiece <NUM>. The method <NUM> for handling the composite workpiece <NUM> is implements during, or forms a portion of, a method for post-cure processing of the composite workpiece <NUM>. In one or more examples, the method <NUM> is implemented using the system <NUM>.

Generally, the method <NUM> includes, or begins with, a step of forming a composite layup on a tool surface of the tool <NUM>. Alternatively, the method <NUM> includes a step of forming the composite layup on a dedicate layup tool and a step of transferring the composite layup to the tool <NUM> for curing. The method <NUM> also includes a step of curing the composite layup (e.g., an uncured or "green" composite) on the tool <NUM> to form the composite workpiece <NUM> (e.g., a cured composite).

In one or more examples, the method <NUM> includes a step of performing at least one (e.g., an initial) post-cure processing operation on the composite workpiece <NUM> while the composite workpiece <NUM> is on the tool <NUM> and has the as-built shape <NUM>. For example, the holes <NUM> may be machined (e.g., drilled) through the composite workpiece <NUM>, while the composite workpiece <NUM> is on the tool <NUM> and has the as-built shape <NUM>.

In one or more examples, the method <NUM> includes a step of digitizing at least a portion of the composite workpiece <NUM> while the composite workpiece <NUM> is on the tool <NUM>. In one or more examples, the step of digitizing the composite workpiece <NUM> includes a step of (block <NUM>) generating the as-built measurement data <NUM> for the composite workpiece <NUM>. In one or more examples, the as-built measurement data <NUM> is generated using the first metrology system <NUM>. In one or more examples, the as-built measurement data <NUM> is generated while the composite workpiece <NUM> is on the tool <NUM> and has the as-built shape <NUM>. In one or more examples, the step of digitizing at least a portion of the composite workpiece <NUM> includes a step of generating the as-built model <NUM> using the as-built measurement data <NUM>.

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

In one or more examples, the method <NUM> includes a step of (block <NUM>) transporting the composite workpiece <NUM>. For example, the composite workpiece <NUM> is transported from one of the work cells <NUM> (e.g., the first work cell <NUM>) to another one of the work cells <NUM> (e.g., the second work cell <NUM>) of the manufacturing environment <NUM>.

In one or more examples, the composite workpiece <NUM> is transported from one of the work cells <NUM> (e.g., the first work cell <NUM>) to another one of the work cells <NUM> (e.g., the second work cell <NUM>) using the material handler <NUM>. In one or more examples, the composite workpiece <NUM> is transported from one of the work cells <NUM> (e.g., the second work cell <NUM>) to another one of the work cells <NUM> (e.g., the third work cell <NUM>) using the overhead workpiece handler <NUM>.

In one or more examples, the method <NUM> includes a step of (block <NUM>) holding the composite workpiece <NUM>. In one or more examples, the composite workpiece <NUM> is held using the workpiece holder <NUM> (e.g., at least one of the workpiece holders <NUM>). For example, the composite workpiece <NUM> is held in one of the work cells <NUM> (e.g., the second work cell <NUM>) using the workpiece holders <NUM>.

In one or more examples, according to the method <NUM>, the step of (block <NUM>) holding the composite workpiece <NUM> includes a step of clamping the composite workpiece <NUM> using the clamp <NUM> of the workpiece holder <NUM> (e.g., each one of the workpiece holders <NUM>). For example, the composite workpiece <NUM> is clamped between the first jaw <NUM> and the second jaw <NUM> of the clamp <NUM> of the workpiece holder <NUM> (e.g., at least one of the workpiece holders <NUM>).

In one or more examples, the method <NUM> includes a step of (block <NUM>) indexing the composite workpiece <NUM>. In one or more examples, the composite workpiece <NUM> is indexed using the workpiece holder <NUM> (e.g., at least one of the workpiece holders <NUM>). For example, the composite workpiece <NUM> is indexed in (e.g., relative to) one of the work cells <NUM> (e.g., the second work cell <NUM>) by selectively controlling the workpiece holder <NUM> (e.g., at least one of the workpiece holders <NUM>).

In one or more examples, according to the method <NUM>, the step of (block <NUM>) indexing the composite workpiece <NUM> in the work cell <NUM> includes a step of positioning the composite workpiece <NUM> in the indexed position <NUM> in the work cell <NUM> based on the virtual indexed position <NUM> of the as-built model <NUM> of the composite workpiece <NUM> in the work cell <NUM>.

In one or more examples, according to the method <NUM>, the step of (block <NUM>) indexing the composite workpiece <NUM> in the work cell <NUM> also includes a step of generating the real-time model <NUM> of the composite workpiece <NUM> that is representative of a real-time position <NUM> of the composite workpiece <NUM> in the work cell <NUM>. The step of (block <NUM>) indexing the composite workpiece <NUM> in the work cell <NUM> further includes a step of comparing the real-time position <NUM> of the real-time model <NUM> to the virtual indexed position <NUM> of the as-built model <NUM>. The step of (block <NUM>) indexing the composite workpiece <NUM> in the work cell <NUM> additionally includes a step of repositioning the composite workpiece <NUM> in the indexed position <NUM> in the work cell <NUM> based on a comparison of the real-time position <NUM> and the virtual indexed position <NUM>.

In one or more examples, according to the method <NUM>, the step of (block <NUM>) indexing the composite workpiece <NUM> includes a step of moving the clamp <NUM> of the workpiece holder <NUM> (e.g., at least one of the workpiece holders <NUM>) relative to the base <NUM> of the workpiece holder <NUM> based on the indexed (e.g., nominal) position of the as-built model <NUM> of the composite workpiece <NUM>.

In one or more examples, the method <NUM> includes a step of (block <NUM>) conforming the composite workpiece <NUM> to the as-built shape <NUM> of the composite workpiece <NUM>. In one or more examples, the composite workpiece <NUM> is conformed to the as-built shape <NUM> using the workpiece holder <NUM> (e.g., at least one of the workpiece holders <NUM>). For example, the composite workpiece <NUM> is conformed to the as-built shape <NUM> by selectively controlling the workpiece holder <NUM> (e.g., at least one of the workpiece holders <NUM>).

In one or more examples, according to the method <NUM>, the step of (block <NUM>) conforming the composite workpiece <NUM> to the as-built shape <NUM> of the composite workpiece <NUM> includes a step of determining a plurality of coordinate locations on the first surface <NUM> of the composite workpiece <NUM> represented by the as-built model <NUM> of the composite workpiece <NUM>. The step of (block <NUM>) conforming the composite workpiece <NUM> to the as-built shape <NUM> of the composite workpiece <NUM> also includes a step of shaping the composite workpiece <NUM> to align the first surface <NUM> of the composite workpiece <NUM> with the plurality of coordinate locations.

Generally, the plurality of coordinate locations is representative of a shape or contour of the first surface <NUM> of the composite workpiece <NUM> with the composite workpiece <NUM> in the as-built shape <NUM>. The step of shaping the composite workpiece <NUM> to align the first surface <NUM> of the composite workpiece <NUM> with the plurality of coordinate locations shapes or positions the first surface <NUM> of the composite workpiece <NUM> in the as-built shape <NUM>.

In one or more examples, according to the method <NUM>, the step of shaping the composite workpiece <NUM> to align the first surface <NUM> of the composite workpiece <NUM> with the plurality of coordinate locations includes a step of moving each one of the plurality of numerical control contacts <NUM> relative to the first jaw <NUM> of the clamp <NUM> of each one of the plurality of workpiece holders <NUM> to a corresponding one of the plurality of numerical control locations <NUM> that correspond to the plurality of coordinate locations on the first surface <NUM>. The step of shaping the composite workpiece <NUM> to align the first surface <NUM> of the composite workpiece <NUM> with the plurality of coordinate locations also includes a step of moving each one of the plurality of force control contacts <NUM> relative to the second jaw <NUM> of the clamp <NUM> each one of the plurality of workpiece holders <NUM> to force the first surface <NUM> of the composite workpiece <NUM> against the plurality of numerical control contacts <NUM>.

For example, the step of (block <NUM>) conforming the composite workpiece <NUM> to the as-built shape <NUM> includes a step of moving each one of numerical control contacts <NUM> of the workpiece holder <NUM> (e.g., at least one of the workpiece holders <NUM>) relative to the first jaw <NUM> of the workpiece holder <NUM>. Each one of the numerical control contacts <NUM> is moved to the numerical control location <NUM> based on the as-built shape <NUM> of the composite workpiece <NUM>. In one or more examples, the numerical control location <NUM> of each one of the numerical control contacts <NUM> corresponds to a coordinate location on the first surface <NUM> of the composite workpiece <NUM>, which is represented by the as-built model <NUM> of the composite workpiece <NUM>.

For example, the step of (block <NUM>) conforming the composite workpiece <NUM> to the as-built shape <NUM> also includes a step of moving each one of the force control contacts <NUM> of the workpiece holder <NUM> (e.g., at least one of the workpiece holders <NUM>) relative to the second jaw <NUM> of the workpiece holder <NUM>. Each one of the force control contacts <NUM> applies (e.g., is moved to apply) the shaping force <NUM> to the composite workpiece <NUM>. In one or more examples, the method <NUM> also includes a step of limiting the shaping force <NUM> to be less than or equal to the threshold force.

For example, the step of (block <NUM>) conforming the composite workpiece <NUM> to the as-built shape <NUM> includes a step of urging, or forcing, the composite workpiece <NUM> against the numerical control contacts <NUM> to conform the composite workpiece <NUM> to the as-built shape <NUM> of the composite workpiece <NUM>.

In one or more examples, according to the method <NUM>, the step of (block <NUM>) conforming the composite workpiece <NUM> to the as-built shape <NUM> of the composite workpiece <NUM> includes a step of generating the real-time model <NUM> of the composite workpiece <NUM> that is representative of a real-time shape <NUM> of the composite workpiece <NUM> in the work cell <NUM> as held by the plurality of workpiece holders <NUM>. The step of (block <NUM>) conforming the composite workpiece <NUM> to the as-built shape <NUM> of the composite workpiece <NUM> also includes a step of comparing the real-time shape <NUM> of the real-time model <NUM> to the as-built shape <NUM> of the as-built model <NUM>. The step of (block <NUM>) conforming the composite workpiece <NUM> to the as-built shape <NUM> of the composite workpiece <NUM> further includes a step of modifying at least one of the numerical control locations <NUM> based on a comparison of the real-time model <NUM> to the as-built model <NUM>.

In one or more examples, the method <NUM> includes a step of digitizing at least a portion of the composite workpiece <NUM> while the composite workpiece <NUM> is held by the workpiece holders <NUM>. In one or more examples, the step of digitizing at least a portion of the composite workpiece <NUM> includes a step of (block <NUM>) generating the real-time measurement data <NUM> for the composite workpiece <NUM>. In one or more examples, the real-time measurement data <NUM> is generated using the second metrology system <NUM>. In one or more examples, the real-time measurement data <NUM> is generated while the composite workpiece <NUM> is held by the workpiece holders <NUM> and has the real-time shape <NUM>. In one or more examples, the step of digitizing at least a portion of the composite workpiece <NUM> includes a step of generating the real-time model <NUM> using the real-time measurement data <NUM>.

In one or more examples, the method <NUM> includes a step of (block <NUM>) comparing the real-time model <NUM> (or the real-time measurement data <NUM>) to the as-built model <NUM> (or the as-built measurement data <NUM>). In one or more examples, step of (block <NUM>) comparing the real-time model <NUM> to the as-built model <NUM> includes a step of determining a transform that fits the real-time model <NUM> to the as-built model <NUM>.

In one or more examples, the method <NUM> includes a step of confirming that the composite workpiece <NUM> is appropriately indexed based on the comparison of the real-time model <NUM> to the as-built model <NUM>. In one or more examples, the method <NUM> includes a step of confirming that the composite workpiece <NUM> is conformed to the as-built shape <NUM> based on the comparison of the real-time model <NUM> to the as-built model <NUM>.

In one or more examples, the step of (block <NUM>) indexing the composite workpiece <NUM> includes a step of moving (e.g., repositioning) the clamp <NUM> of the workpiece holder <NUM> (e.g., at least one of the workpiece holders <NUM>) and/or the base <NUM> of the workpiece holder <NUM> based on the comparison of the real-time model <NUM> to the as-built model <NUM>.

In one or more examples, the step of (block <NUM>) conforming the composite workpiece <NUM> to the as-built shape <NUM> includes a step of modifying the numerical control location <NUM> of at least one of the numerical control contacts <NUM> of the workpiece holder <NUM> (e.g., at least one of the of workpiece holders <NUM>) based on the comparison of the real-time model <NUM> to the as-built model <NUM>.

In one or more examples, the method <NUM> includes a step of (block <NUM>) performing a machining operation on the composite workpiece <NUM> while the composite workpiece <NUM> is held in the indexed position <NUM> and in the as-built shape <NUM> by the workpiece holders <NUM>. In one or more examples, the machining operation is automatically performed using the machine tool <NUM>, for example, under direction from the computing device <NUM>.

In one or more examples, the method <NUM> includes a step of (block <NUM>) reducing vibration in the composite workpiece <NUM> while performing the machining operation. In one or more examples, vibrations in the composite workpiece <NUM> are reduced using the damping apparatus <NUM>, which is coupled to the composite workpiece <NUM>.

In one or more examples, the method <NUM> includes a step of coupling the damping apparatus <NUM> to the composite workpiece <NUM>. In one or more examples, the damping apparatus <NUM> is coupled to the composite workpiece <NUM> between a directly adjacent pair of the workpiece holders <NUM>. Generally, damping apparatus <NUM> is coupled to the composite workpiece <NUM> before performing the step of (block <NUM>) performing the machining operation on the composite workpiece <NUM>.

In one or more examples, the method <NUM> includes a step of suspending the composite workpiece <NUM>, for example, in the approximately vertical orientation. In one or more examples, the composite workpiece <NUM> is suspended from the overhead workpiece handler <NUM>.

In one or more examples, with the composite workpiece <NUM> coupled to the overhead workpiece handler <NUM>, the method <NUM> includes a step of unclamping the composite workpiece <NUM> from the clamp <NUM> of the workpiece holder <NUM> (e.g., at least one of the workpiece holders <NUM>). The method <NUM> includes a step of rotationally moving the clamp <NUM> of the workpiece holder <NUM> (e.g., at least one of the workpiece holders <NUM>) relative to the base <NUM> of the workpiece holder <NUM> to angularly orient the first jaw <NUM> and the second jaw <NUM> relative to the composite workpiece <NUM>. These steps may be used to reposition the clamp <NUM> so that the composite workpiece <NUM> is appropriately indexed (e.g., block <NUM>) or so that the composite workpiece <NUM> appropriately conformed to the as-built shape <NUM> (e.g., block <NUM>).

In one or more examples, with the composite workpiece <NUM> coupled to the overhead workpiece handler <NUM>, the method <NUM> includes a step of unclamping the composite workpiece <NUM> from the clamp <NUM> of the workpiece holder <NUM> (e.g., at least one of the workpiece holders <NUM>. The method <NUM> includes a step of linearly moving the workpiece holder <NUM> (e.g., at least one of the workpiece holders <NUM>) to position the first jaw <NUM> and the second jaw <NUM> of the clamp <NUM> relative to the composite workpiece <NUM>. These steps may be used to reposition the clamp <NUM> so that the composite workpiece <NUM> is appropriately indexed (e.g., block <NUM>) or so that the composite workpiece <NUM> appropriately conformed to the as-built shape <NUM> (e.g., block <NUM>).

In one or more examples, the method <NUM> includes a step of digitizing at least a portion of the composite workpiece <NUM> after the machining operation (e.g., block <NUM>). In one or more examples, the step of digitizing at least a portion of the composite workpiece <NUM> includes a step of (block <NUM>) generating the as-machined measurement data <NUM> for the composite workpiece <NUM>. In one or more examples, the as-machined measurement data <NUM> is generated using the second metrology system <NUM>. In one or more examples, the as-machined measurement data <NUM> is generated while the composite workpiece <NUM> is held by the workpiece holders <NUM> and has the as-machined shape <NUM> (e.g., the as-built shape <NUM> updated with newly added features). In one or more examples, the step of digitizing at least a portion of the composite workpiece <NUM> includes a step of generating the as-machined model <NUM> using the as-machined measurement data <NUM>.

In one or more examples, at least a portion of the steps described above are repeated a number of times as the composite workpiece <NUM> moves through the work cells <NUM> and a number of post-processing operations are performed on the composite workpiece <NUM>.

The present disclosure is also directed to the system <NUM> for handling the composite workpiece <NUM>, which is implemented according to the method <NUM>. The present disclosure is further directed to the composite workpiece <NUM> that is manufacturing according to the method <NUM>.

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

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

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

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

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

In can be appreciated that performing at least a portion of the post-cure processing operation on the composite workpiece <NUM> while the composite workpiece <NUM> is held, indexed, and conformed to the as-built shape <NUM> by the workpiece holders (e.g., workpiece holders <NUM>, second workpiece holders <NUM>, etc.) in one or more of the work cells <NUM>, and updating the model of the composite workpiece <NUM> (e.g., the as-machined model <NUM>) after each subsequent post-cure processing operation may improve the accuracy and speed of the processing operation and enable determinant or predictive assembly using the composite workpiece <NUM>.

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

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

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

Unless otherwise indicated, the terms "first," "second," "third," etc. are used herein merely as labels, and are not intended to impose ordinal, positional, or hierarchical requirements on the items to which these terms refer.

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

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

As used herein, relative positional (e.g., locational and/or orientational) terms, such as parallel, perpendicular, horizontal, vertical, and similar terms include approximations of such positional terms (e.g., approximately parallel, approximately perpendicular, approximately, vertical, approximately horizontal, etc.).

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

Conditional language such as, among others, "can" or "may," unless specifically stated otherwise, are understood within the context as used to generally convey that a certain example includes, while other examples do not include, certain features, elements and/or steps. Thus, such conditional language is not generally intended to imply that features, elements and/or steps are in any way required for one or more examples or that one or more examples necessarily include logic for deciding, with or without user input or prompting, whether these features, elements and/or steps are included or are to be performed in any example.

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

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

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

Claim 1:
A workpiece holder (<NUM>) for handling a composite workpiece (<NUM>), wherein the workpiece holder (<NUM>) comprises:
a base (<NUM>);
a clamp (<NUM>) coupled to the base (<NUM>), wherein the clamp (<NUM>) comprises:
a first jaw (<NUM>);
a support member (<NUM>) coupled to the first jaw (<NUM>); and
a second jaw (<NUM>) coupled to the support member (<NUM>),
wherein:
the second jaw (<NUM>) is movable along the support member (<NUM>) relative to the first jaw (<NUM>) to clamp the composite workpiece (<NUM>) between the first jaw (<NUM>) and the second jaw (<NUM>) so that the composite workpiece (<NUM>) conforms to an as-built shape (<NUM>) of the composite workpiece (<NUM>); and
with the composite workpiece (<NUM>) clamped between the first jaw (<NUM>) and the second jaw (<NUM>), the clamp (<NUM>) is movable relative to the base (<NUM>) to index the composite workpiece (<NUM>) in a work cell (<NUM>)
the workpiece holder (<NUM>) further comprising:
a plurality of numerical control contacts (<NUM>) located along the first jaw (<NUM>); and
a plurality of force control contacts (<NUM>) located along the second jaw (<NUM>),
wherein:
each one of the plurality of numerical control contacts (<NUM>) is selectively movable relative to the first jaw (<NUM>) to a numerical control location (<NUM>) based on the as-built shape (<NUM>) of the composite workpiece (<NUM>);
each one of the plurality of force control contacts (<NUM>) is selectively movable relative to the second jaw (<NUM>) to apply a shaping force (<NUM>) to the composite workpiece (<NUM>); and
the shaping force (<NUM>), applied by each one of the plurality of force control contacts (<NUM>), forces the composite workpiece (<NUM>) against the plurality of numerical control contacts (<NUM>) to conform the composite workpiece (<NUM>) to the as-built shape (<NUM>) of the composite workpiece (<NUM>).