Compound Shim Tab Placement for Precise Gap Fitting
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Solution Overview
Problem
Traditional shimming and filling methods struggle to accurately fit gaps between complex structure components due to variations in exact geometries, leading to inefficiencies in stress reduction and force distribution in joints of structures like aircraft and automobiles.
Innovation Solution
A method and apparatus for forming a compound shim by identifying and applying multiple shim tabs with an end-effector, adjusting their placement and thickness based on surface characteristics of the components to be joined, allowing for customizable shimming sizes and shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If prebuilt shims and fillers are used to fill gaps between components, then joint stress reduction is improved, but manufacturing precision deteriorates due to difficulty in fitting exact component geometries
Solution Approach 1:
The shim is divided into multiple shim tabs that can be individually applied to different locations on the component. Each shim tab can be independently positioned and sized to match the specific geometry of the gap, allowing precise adaptation while maintaining stress reduction benefits
Solution Approach 2:
Each shim tab is customized with specific dimensions, shapes, and thicknesses tailored to the local gap characteristics at its application location. This local customization ensures optimal fit precision for each specific gap while collectively providing comprehensive stress reduction across the entire joint area
2Adaptability or versatility
If multiple shim tabs are applied to form a compound shim, then adaptability to varying geometries is improved, but device complexity increases
Solution Approach 1:
The shim tab system uses standardized tabs with consistent material properties and attachment methods that can be universally applied across different gap geometries. While each tab is customized in dimension, the fundamental application process and tab design remain consistent, reducing operational complexity despite geometric variability
Solution Approach 2:
The shim tabs are pre-configured with appropriate dimensions, shapes, and thicknesses before application. This preliminary customization allows the tabs to be ready-to-apply with minimal on-site adjustment, reducing the complexity of the application process while maintaining high adaptability to various geometries
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
Disclosed herein is a method. The method includes identifying a first location on a first part (110) to place a first shim tab (416) to form a first portion of a compound shim (100). The method also includes applying the first shim tab to the first location on the first part with an end-effector (204). The method also includes identifying a second location directly adjacent to the first location on the first part to place a second shim tab. The method also includes applying the second shim tab to the second location on the first part with the end-effector to form a second portion of the compound shim. The method also includes applying a third shim tab to the second shim tab at the second location to increase a thickness of the second portion of the compound shim.