Delta Offset Surface Modeling for Composite Aircraft Skins
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing surface modeling tools face challenges in accurately representing the outer surface of composite parts, particularly in aircraft skins, due to variations in layer stacking, which can lead to inaccuracies in fastener placement and assembly.
Innovation Solution
A method that compares geometrical information from a reference design to a second design to determine an offset surface relative to a reference surface, generating a model of the second design's surface by combining the reference and offset surfaces, utilizing engineering ply definitions and surface data to calculate delta offsets from composite laminate buildup in multiple directions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If existing surface modeling tools are used to model the outer surface of composite parts, then the modeling process is simple, but the accuracy of the surface representation is poor due to variations in layer stacking
Solution Approach 1:
The patent segments the surface modeling process into multiple components: reference surface modeling, offset surface determination through geometrical information comparison, and composite material layer analysis. This segmentation allows each component to be handled separately, improving overall surface representation accuracy while managing complexity through systematic decomposition of the modeling task.
Solution Approach 2:
The patent introduces an intermediary offset surface that bridges the reference surface and the actual outer surface. By determining geometrical offsets from the reference surface based on composite material variations, the system accurately represents the outer surface without directly modeling complex layer stacking variations, thus improving accuracy while controlling complexity.
2Manufacturing precision
If the outer surface variations are not accounted for in the model, then the modeling process is simpler, but fastener placement and assembly accuracy deteriorate
Solution Approach 1:
The patent performs preliminary determination of offset surfaces and geometrical information comparisons before finalizing the surface model. By pre-calculating the offsets based on composite material variations and reference surface data, the system ensures accurate fastener placement information is available upfront, improving manufacturing precision while managing complexity through advance preparation.
3Measurement precision
If traditional modeling approaches are used without offset surface determination, then the computational requirements are lower, but the quality of surface representation for composite parts deteriorates
Solution Approach 1:
The patent applies local quality by determining offset surfaces specifically at regions where composite material variations affect the outer surface geometry. Rather than uniformly processing the entire surface, the system focuses computational resources on areas with significant layer stacking variations, improving surface modeling quality where it matters most while reducing unnecessary computational consumption in uniform regions.
Data Source
AI summary
A method includes receiving a reference design at a computing device. The reference design includes first geometrical information associated with a first set of composite materials to form a reference surface. The method includes receiving second geometrical information at the computing device. The second geometrical information is associated with a second set of composite materials associated with a second design. The method includes determining, based on a comparison of the first geometrical information and the second geometrical information, an offset surface relative to the reference surface. The method further includes generating a model of a surface of the second design based on the reference surface and the offset surface.