Additive Correction of Assembly Surface Geometrical Discrepancies
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Solution Overview
Problem
Existing methods for assembling mechanical structures face challenges due to geometrical discrepancies between nominal and real surfaces of parts, leading to stress modifications, material degradation, and increased weight when using fillers, which complicates the assembly process and reduces mechanical strength.
Innovation Solution
A device and method that utilize acquisition, simulation, and additive fabrication means to measure and correct geometrical differences by depositing material on assembly surfaces, ensuring minimal stress introduction and maintaining mechanical strength, suitable for automated production lines and various shapes and materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If polymerizable filler mastic is deposited at the interface to fill voids, then contact between parts is improved, but the weight of the assembled structure increases and the assembly process becomes more complex
Solution Approach 1:
The invention measures the geometry of assembly surfaces before assembly and performs corrective machining operations in advance. This preliminary action ensures that parts fit together correctly during assembly without requiring filler materials, thereby avoiding the weight increase and process complexity associated with mastic deposition.
Solution Approach 2:
The invention extracts and eliminates the need for filler materials by implementing precise measurement and correction processes. By removing the requirement for polymerizable filler mastic, the solution avoids the associated drawbacks of weight increase and assembly complexity while maintaining reliable contact between parts.
2Reliability
If forces are introduced during connection production to deform parts and eliminate interface discrepancy, then contact between parts is improved, but the mechanical stress state of parts is modified and mechanical strength may be affected
Solution Approach 1:
The invention performs measurement and corrective machining operations before assembly to ensure proper fit. By addressing geometrical discrepancies in advance through material removal rather than deformation, the solution achieves reliable contact without modifying the mechanical stress state or compromising the strength of the parts.
Solution Approach 2:
The invention replaces the mechanical deformation approach with a precision measurement and material removal system. Instead of applying forces to deform parts into contact, the solution uses measurement devices and machining operations to create complementary geometries, thereby avoiding stress modifications and preserving mechanical strength.
3Manufacturing precision
If material is removed from parts to correct geometry of nominal surfaces, then interface fit is improved, but the mechanical strength of thin parts is reduced
Solution Approach 1:
The invention applies corrective operations only at the specific assembly interface areas where geometrical discrepancies exist, rather than removing material from entire parts. This localized approach minimizes the impact on overall structural strength while achieving the necessary precision for proper fit and contact at the interface.
Solution Approach 2:
The invention performs precise measurement and selective material removal in advance of assembly, allowing for optimization of the correction process. By planning and executing corrections beforehand with full knowledge of the geometrical discrepancies, the solution minimizes unnecessary material removal and preserves the mechanical strength of thin parts while achieving the required interface precision.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively corrects geometrical discrepancies without degrading mechanical strength, allowing for automated and efficient assembly with reduced supplementary manipulations, ensuring precise interface contact and improved structural integrity.
Implementation Method 1
additive fabrication means receiving from the simulation means data representative of the thicknesses of the voids resulting from the geometrical discrepancies between said assembly surfaces and configured to deposit material on the assembly surface of at least one of the parts so as at least partly to fill the void resulting from said geometrical discrepancies between said assembly surfaces
Data Source
AI summary
A device to correct geometrical differences of surfaces of parts to be assembled at the interface of the assembly. A measurer to acquire data by measuring the geometry of the assembly surfaces of two parts to be assembled to each other with their respective assembly surfaces facing. A simulator configured to simulate the assembly of the parts and to determine from the acquired data at each measured point of a sampling of the interface a thickness of the void resulting from the geometrical discrepancies between the assembly surfaces. An additive fabricator to receive from the simulator data representative of the thicknesses of the voids resulting from the geometrical discrepancies between the assembly surfaces. The additive fabricator configured to deposit material on the assembly surface of at least one of the parts to at least partly fill the void resulting from the geometrical discrepancies between the assembly surfaces.