A method for compensating assembly gaps in composite material structures and composite material structures

Abstract

This invention discloses a method for compensating assembly gaps in composite material structures and the composite material structure itself, belonging to the field of aerospace manufacturing technology. The assembly gap compensation method includes the following steps: S100: Applying a preset external force to the composite material structure; under the applied force, measuring a first gap between a first component and a third component, and measuring a second gap between the first component and a second component; S200: Based on the second gap, adding a control block between the first component and the second component, and then removing the external force; S300: Based on the first gap, adding a shim unit between the first component and the third component, wherein the shim unit is a liquid shim, or a shim unit is a combination of a solid shim and a liquid shim. The assembly gap compensation method and composite material structure of this invention improve the shim addition qualification rate, reduce the rework rate, and thus reduce production costs.

Description

Technical Field

[0001] This invention relates to the field of aerospace manufacturing technology, and in particular to a method for compensating assembly gaps in composite material structures and a composite material structure. Background Technology

[0002] Composite materials possess advantages such as light weight, high strength, corrosion resistance, high temperature resistance, and designability, and are widely used in cutting-edge technology fields such as aerospace and defense. However, due to the complexity and difficulty in manufacturing composite parts, the manufacturing precision is difficult to control, and the dimensional accuracy of the parts is often poor. This makes it easy for composite parts to misalign at the mating surfaces during assembly, resulting in assembly gaps. According to engineering design requirements, forced assembly of composite parts in aircraft structures is not permitted to avoid generating large internal stresses within the composite parts, which could lead to internal damage.

[0003] In existing technologies, when gap compensation is performed on composite material parts using liquid gaskets alone or in combination with solid gaskets, the gap compensation method mainly includes the following steps: drilling initial mounting holes between the first and second components; measuring the gap between the first and second components; adding shims to compensate for the assembly gap between the first and second components; and applying tension to the second component using C-clamps / core clamps / spring clamps to squeeze out excess liquid gaskets between the first and second components. However, the above methods cannot effectively guarantee the construction quality of liquid gaskets in areas where the second component is thick or the shim compensation area is large. This often leads to poor surface quality of the liquid gaskets after shimming and excessive gasket thickness, resulting in a high rework rate. Summary of the Invention

[0004] The purpose of this invention is to provide a method for compensating assembly gaps in composite material structures and a composite material structure, thereby improving the shim qualification rate, reducing the rework rate, and thus reducing production costs.

[0005] To achieve this objective, the present invention adopts the following technical solution:

[0006] On the one hand, a method for compensating assembly gaps in a composite material structure is provided. The composite material structure includes a first structural component and a second structural component. The first structural component includes a first member and a second member, and the second structural component includes a third member. The assembly gap compensation method includes the following steps:

[0007] S100: Apply a preset external force to the composite material structure, and under the applied force, measure the first gap between the first component and the third component, and measure the second gap between the first component and the second component;

[0008] S200: According to the second gap, place the control block between the first component and the second component, and remove the external force;

[0009] S300: According to the first gap, a gasket unit is added between the first component and the third component, wherein the gasket unit is a liquid gasket, or the gasket unit is a combination of a solid gasket and a liquid gasket.

[0010] In some possible implementations, during step S100,

[0011] Multiple gap measurement points are measured between the first component and the second component, and these multiple gap measurement points form the second gap.

[0012] Multiple gap measurement points are measured between the first component and the third component, and the multiple gap measurement points form the first gap.

[0013] In some possible implementations, multiple gap measurement points are adaptively spaced between the first component and the second component, depending on their shape and size.

[0014] Based on the shape and size of the first component and the third component, multiple gap measurement points are adaptively spaced between the first component and the third component.

[0015] In some possible implementations, the control block is adaptively configured according to the second gap.

[0016] In some possible implementations, prior to step S100, the following steps are also included:

[0017] S101: Position the first component on the second component, and process a portion of the mounting structure on the first component and the third component for mounting the first component and the third component;

[0018] Following step S300, the method further includes:

[0019] S400: A further mounting structure is machined on the first component and the third component for mounting the first component and the third component.

[0020] In some possible implementations, the mounting structure is a mounting hole through which fasteners pass to the mounting holes of the first component and the third component to connect the first component and the third component.

[0021] In some possible implementations, the second structural component further includes a fourth component, and prior to step S100, it further includes:

[0022] S101: The third component is fixedly connected to the fourth component.

[0023] In some possible implementations, between step S300 and step S400, the following is also included:

[0024] S301: Check the quality of the gasket unit. If it is qualified, proceed to S400.

[0025] In some possible implementations, after step S400, the method further includes:

[0026] S500: Remove the control block.

[0027] On the other hand, a composite material structure is provided, which is manufactured using the above-mentioned composite material structure assembly gap compensation method.

[0028] The beneficial effects of this invention are:

[0029] This invention provides a method for compensating assembly gaps in composite material structures and a composite material structure itself. A preset external force is applied to the composite material structure, equivalent to applying a pre-tightening force to the first component before measurement. By adding a shim control block and then removing the external force, continuous and stable pressure is maintained on the first component. Both the shim unit and the control block are set according to actual measurement results. The applied clamping force is continuous and stable, effectively improving the surface quality of the liquid shim in the shim unit. Furthermore, the position of the first component before and after compensation by the shim unit is effectively controlled, thereby effectively controlling the thickness of the shim unit between the first and third components. This avoids excessively thick shim units affecting the pass rate, thus reducing rework and lowering production costs. Attached Figure Description

[0030] Figure 1 This is a flowchart of a composite material structure assembly gap compensation method provided in a specific embodiment of the present invention;

[0031] Figure 2 This is a pre-assembled cross-sectional view of a composite material structure provided in a specific embodiment of the present invention;

[0032] Figure 3 This is a schematic diagram of the pre-assembly gap measurement of composite material structures provided in a specific embodiment of the present invention;

[0033] Figure 4 This is a schematic diagram of the first structural component provided in a specific embodiment of the present invention;

[0034] Figure 5 This is a schematic diagram of the second structural component provided in a specific embodiment of the present invention;

[0035] Figure 6This is a schematic diagram of the control block provided in a specific embodiment of the present invention.

[0036] In the picture:

[0037] 1. First structural component; 11. First component; 12. Second component; 121. Outer shape plate; 122. Drill template;

[0038] 2. Second structural component; 21. Third component; 22. Fourth component;

[0039] 3. Control block;

[0040] A. First gap; B. Second gap. Detailed Implementation

[0041] To make the technical problems solved by the present invention, the technical solutions adopted, and the technical effects achieved clearer, the technical solutions of the embodiments of the present invention will be further described in detail below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0042] In the description of this invention, unless otherwise explicitly specified and limited, the terms "connected," "linked," and "fixed" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0043] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0044] This embodiment provides a method for compensating assembly gaps in composite material structures, such as... Figures 1-6As shown, the composite material structure includes a first structural component 1 and a second structural component 2. The first structural component 1 includes a first member 11 and a second member 12, and the second structural component 2 includes a third member 21. The assembly gap compensation method includes:

[0045] S100: Apply a preset external force to the composite material structure. Under the applied force, measure the first gap A between the first component 11 and the third component 21, and measure the second gap B between the first component 11 and the second component 12.

[0046] S200: According to the second gap B, the control block 3 is placed between the first component 11 and the second component 12, and the external force is removed;

[0047] S300: According to the first gap A, a gasket unit is added between the first member 11 and the third member 21, wherein the gasket unit is a liquid gasket, or the gasket unit is a combination of a solid gasket and a liquid gasket.

[0048] Applying a preset external force to the composite material structure is equivalent to applying a pre-tightening force to the first component 11 before measurement. By adding a shim control block 3 and then removing the external force, pressure is continuously and stably maintained on the first component 11. Both the shim unit and the control block 3 are set according to the actual measurement results. The applied clamping force is continuous and stable, which effectively improves the surface quality of the liquid shim of the shim unit. It also effectively controls the position of the first component 11 before and after the shim unit compensation, thereby effectively controlling the thickness of the shim unit between the first component 11 and the third component 21, avoiding the shim unit being too thick and affecting the pass rate, thereby reducing rework and lowering production costs.

[0049] In one embodiment, such as Figure 3 As shown, in step S100,

[0050] Multiple gap measurement points are measured between the first component 11 and the second component 12, and these multiple gap measurement points form a second gap B.

[0051] Multiple gap measurement points are measured between the first component 11 and the third component 21, and these multiple gap measurement points form the first gap A.

[0052] By measuring multiple gap measurement points, the measurement accuracy of the second gap B and the first gap A is improved, thereby improving the installation accuracy of the control block 3 and the second gap B, enhancing the reliability of the clamping force applied by the control block 3, and further improving the surface quality of the liquid gasket in the gasket unit. In one embodiment, based on the shape and size of the first component 11 and the second component 12, multiple gap measurement points are adaptively spaced between the first component 11 and the second component 12 to further improve the measurement accuracy of the first gap A. Similarly, based on the shape and size of the first component 11 and the third component 21, multiple gap measurement points are adaptively spaced between the first component 11 and the third component 21 to further improve the measurement accuracy of the second gap B. Optionally, when the shapes of the first component 11, the second component 12, and the third component 21 are uniform, the multiple gap measurement points are evenly distributed, for example, with an interval of 200 mm between adjacent gap measurement points.

[0053] like Figure 6 As shown, control block 3 can be a rectangular block or other shapes.

[0054] In one embodiment, the control block 3 is adaptively configured according to the second gap B, so that the shape and size of the control block 3 are adapted to the second gap B, and the control block 3 fits snugly against the first component 11, thereby improving the reliability of the clamping force applied by the control block 3 to the first component 11. In another embodiment, control blocks 3 of various sizes can also be pre-set, and selected according to the measurement results, which is simple and convenient.

[0055] In one embodiment, prior to step S100, the method further includes:

[0056] S101: Position the first component 11 on the second component 12, and process a portion of the mounting structure on the first component 11 and the third component 21 for mounting the first component 11 and the third component 21;

[0057] Following step S300, the method further includes:

[0058] S400: Another part of the mounting structure is machined on the first component 11 and the third component 21 for mounting the first component 11 and the third component 21.

[0059] The installation structure processed in step S101 enables the pre-installation of the first component 11 and the third component 21, ensuring a relatively accurate positional relationship between them for subsequent operations. After forming the gasket unit through steps S100, S200, and S300, another part of the installation structure is processed in step S400. This structure better meets actual installation requirements, has high processing precision, and facilitates subsequent installation.

[0060] In one embodiment, the mounting structure is a mounting hole, and the fastener passes through the mounting hole of the first component 11 and the mounting hole of the third component 21 to connect the first component 11 and the third component 21. By processing the mounting hole in steps, the processing accuracy of the processed mounting hole is further guaranteed. The mounting holes on the first component 11 and the second component 12 are aligned to facilitate subsequent assembly.

[0061] In one embodiment, the second structural component 2 further includes a fourth component 22, and prior to step S100, it further includes:

[0062] S101: The third component 21 is fixedly connected to the fourth component 22.

[0063] After the third component 21 and the fourth component 22 are assembled to form the second structural component 2, the second structural component 2 is then pre-assembled with the first structural component 1 to avoid affecting the subsequent assembly of the third component 21 and the fourth component 22.

[0064] In one embodiment, between step S300 and step S400, the following further step is included:

[0065] S301: Check the quality of the gasket unit. If it is qualified, proceed to S400 to ensure the quality of the gasket unit. If it is not qualified, rework is required, such as returning to step S300, or even steps S100 and S200, until it is qualified. The specific settings are based on actual needs and are not limited.

[0066] In one embodiment, after step S400, the method further includes:

[0067] S500: Remove control block 3 to allow the composite material structure to be transferred separately to the next stage of work.

[0068] In one embodiment, the assembly of a horizontal stabilizer of a certain model is used as an example for illustrative purposes. The extended box section of the horizontal stabilizer mainly includes extended section wall panels, beams, ribs, etc., all of which are composite material parts. During assembly, the extended section beams and ribs are first assembled into an extended section skeleton; then the extended section skeleton is assembled with the extended section wall panels. The large assembly gap between the extended section wall panels and the extended section skeleton is compensated on-site using a combination of solid gaskets and liquid gaskets. Specifically, the extended section wall panel is the first component 11, the extended section wall panel moving frame is the second component 12, the extended section skeleton is the third component 21, and the extended section main frame is the fourth component 22, as an example for illustrative purposes. The extended section wall panel moving frame is provided with an outline clamping plate 121 and a drilling template 122. In other embodiments, the first component 11, the second component 12, the third component 21, and the fourth component 22 are adaptively configured according to the specific structure and are not limited.

[0069] Through the above steps, the following problems were solved: First, by applying pressure to the entire extended section wall panel using the shim control block 3, the applied clamping force is continuous and stable, effectively improving the surface quality of the liquid gasket after shim compensation, increasing the shim pass rate, and reducing rework. Second, the extended section shim control block 3 can effectively control the position of the extended section wall panel before and after shim compensation, thereby effectively controlling the thickness of the shim applied between the extended section wall panel and the frame, avoiding excessively thick shims, improving the shim pass rate, and reducing rework.

[0070] The specific steps include the following:

[0071] Preparation work includes positioning and assembling the extended section frame on the extended section main frame, positioning the extended section wall panel on the extended section wall panel movable frame, and drilling the initial installation holes for the connection between the extended section wall panel and the extended section frame as needed.

[0072] To measure the gap, an external force of a preset magnitude is applied according to the engineering documents. This force is equivalent to the clamping force applied to the extended section wall panel during gap measurement. Under this force, the gap between the extended section wall panel and the extended section frame (the first gap A) is measured and recorded. Simultaneously, the gap between the extended section wall panel and the extended section wall panel moving frame (the second gap B) is measured and recorded. Specifically, the gaps between the extended section wall panel and the outer profile clamping plate 121 and the drilling template 122 are measured to improve measurement accuracy. Specifically, a theoretical gap of 5mm is reserved between the outer profile clamping plate 121 and the drilling template 122 and the extended section wall panel, which can be set according to requirements and is not limited.

[0073] A shim control block 3 is installed in the corresponding area of ​​the movable frame of the extended section wall panel, based on the measured gap value between the extended section wall panel and the outer shape clamping plate 121 and the drilling template 122. The shim control block 3 has the same thickness as the measured gap value. After the shim control block 3 is installed, the external force applied to its vicinity is removed, that is, the shim control block 3 is used to maintain a continuous and stable position. The shape and size of the control plate should be available in various specifications to adapt to different working conditions.

[0074] For shim compensation, based on the measured gap between the extended section wall panel and the extended section frame, after the installation of the first step extended section wall panel shim control block 3, liquid shims or a combination of solid shims and liquid shims are used to compensate for the assembly gap between the extended section wall panel and the extended section frame. Furthermore, during the shim application process, the shim control block 3 is always installed on the wall panel moving frame to ensure the surface quality of the liquid shims.

[0075] After the gasket unit is inspected and the shims between the extended section wall panel and the extended section frame are added for compensation, the quality of the liquid gasket is inspected and reworked as needed to meet the requirements.

[0076] After the shims are added and inspected, drill the initial holes for the remaining fasteners connecting the extended section wall panel and the extended section frame, as needed. Once all the necessary holes are drilled, remove the shim control block 3, and the extended section box assembly will proceed to the next stage. Furthermore, during the pre-assembly of the extended section wall panel, the extended section frame must remain firmly connected to the extended section main frame.

[0077] This embodiment also provides a composite material structure, which is made using the above-described composite material structure assembly gap compensation method, and has low cost.

[0078] Obviously, the above embodiments of the present invention are merely examples for clearly illustrating the present invention, and are not intended to limit the implementation of the present invention. Those skilled in the art can make other variations or modifications based on the above description. It is neither necessary nor possible to exhaustively describe all embodiments here. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the scope of protection of the claims of the present invention.

Claims

1. A method for compensating assembly gaps in composite material structures, characterized in that, The composite material structure includes a first structural component (1) and a second structural component (2). The first structural component (1) includes a first member (11) and a second member (12). The second structural component (2) includes a third member (21). The assembly gap compensation method includes the following steps: S100: Apply a preset external force to the composite material structure. Under the applied force, measure the first gap (A) between the first component (11) and the third component (21), and measure the second gap (B) between the first component (11) and the second component (12). S200: According to the second gap (B), the control block (3) is placed between the first member (11) and the second member (12), and the external force is removed; S300: According to the first gap (A), a gasket unit is added between the first member (11) and the third member (21), wherein the gasket unit is a liquid gasket, or the gasket unit is a solid gasket and a liquid gasket.

2. The method for compensating assembly gaps in composite material structures according to claim 1, characterized in that, In step S100, Multiple gap measurement points are measured between the first component (11) and the second component (12), and the multiple gap measurement points form the second gap (B); Multiple gap measurement points are measured between the first component (11) and the third component (21), and the multiple gap measurement points form the first gap (A).

3. The method for compensating assembly gaps in composite material structures according to claim 2, characterized in that, Based on the shape and size of the first component (11) and the second component (12), multiple gap measurement points are adaptively spaced between the first component (11) and the second component (12); Based on the shape and size of the first component (11) and the third component (21), a plurality of gap measuring points are adaptively spaced between the first component (11) and the third component (21).

4. The method for compensating assembly gaps in composite material structures according to claim 1, characterized in that, The control block (3) is adaptively configured according to the second gap (B).

5. The method for compensating assembly gaps in composite material structures according to claim 1, characterized in that, Before step S100, the method further includes: S101: Position the first component (11) on the second component (12), and process a portion of the mounting structure on the first component (11) and the third component (21) for mounting the first component (11) and the third component (21); Following step S300, the method further includes: S400: Another mounting structure is machined on the first component (11) and the third component (21) for mounting the first component (11) and the third component (21).

6. The method for compensating assembly gaps in composite material structures according to claim 5, characterized in that, The mounting structure is a mounting hole, and fasteners pass through the mounting holes of the first component (11) and the third component (21) to connect the first component (11) and the third component (21).

7. The method for compensating assembly gaps in composite material structures according to claim 1, characterized in that, The second structural component (2) further includes a fourth component (22), which, prior to step S100, also includes: S101: The third component (21) is fixedly connected to the fourth component (22).

8. The method for compensating assembly gaps in composite material structures according to claim 1, characterized in that, Between step S300 and step S400, the following is also included: S301: Check the quality of the gasket unit. If it is qualified, proceed to S400.

9. The method for compensating assembly gaps in composite material structures according to any one of claims 1-8, characterized in that, Following step S400, the method further includes: S500: Remove the control block (3).

10. A composite material structure, characterized in that, It is manufactured using the composite material structure assembly gap compensation method as described in any one of claims 1-9.

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