Adaptive Component Machining for Gap-Free Assembly Fit
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Solution Overview
Problem
Existing component machining methods often result in gaps between assembled components due to manufacturing variances, requiring the use of shims which increase the number of working steps and compromise assembly accuracy.
Innovation Solution
A component machining apparatus that includes a measurement result acquiring unit and a machining data generator, which measures the three-dimensional shape of manufactured components and generates machining data for subsequent components to account for errors, ensuring precise fitting without gaps by adjusting the machining process in real-time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If shims are inserted to fill gaps between assembled components, then assembly completeness is improved, but the number of working steps increases
Solution Approach 1:
The invention performs preliminary measurement of the first component's three-dimensional shape before assembly, and uses this measurement data to pre-calculate and prepare the machining parameters for the second component. This preliminary action eliminates the need for post-assembly shim insertion, reducing working steps while ensuring complete assembly fit.
Solution Approach 2:
The invention establishes a feedback loop where the measurement result of the first component's actual shape is fed back into the machining data generation process. The machining data for the second component is adjusted based on this feedback, ensuring that the second component is machined to complement the first component's actual geometry, thereby eliminating gaps without requiring additional shim insertion steps.
2Reliability
If shims are used to fill gaps, then assembly completeness is improved, but assembly accuracy deteriorates
Solution Approach 1:
The invention uses feedback from precise three-dimensional measurement of the first component's actual shape to adjust the machining data of the second component. This feedback mechanism ensures that the second component is machined with high precision to match the first component's actual geometry, achieving accurate assembly fit without the need for shims that would compromise precision.
Solution Approach 2:
The invention changes the machining parameters of the second component based on the measurement data of the first component. By adjusting parameters such as position, orientation, and dimensional tolerances in the machining data, the system achieves high assembly accuracy that eliminates gaps, making shim insertion unnecessary and maintaining high precision throughout.
3Ease of manufacture
If traditional machining methods are used without measurement feedback, then manufacturing simplicity is maintained, but manufacturing precision deteriorates
Solution Approach 1:
The invention introduces measurement feedback into the machining process by measuring the actual three-dimensional shape of the first component and using this data to adjust the machining parameters of the second component. This feedback loop maintains manufacturing simplicity by automating the adjustment process through computer-based machining data generation, while significantly improving dimensional tolerance and assembly precision.
Data Source
AI summary
A component machining apparatus includes a measurement result acquiring unit and a machining data generator. The measurement result acquiring unit is configured to acquire a measurement result obtained by a measurer configured to measure a three-dimensional shape of a manufactured component among components of a structure. The manufactured component is manufactured earlier than a component of interest. The machining data generator is configured to generate machining data of the component of interest based on the measurement result of the manufactured component that has been acquired by the measurement result acquiring unit.