Digital Map-Based Component Fitment Without Shims
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Solution Overview
Problem
Existing manufacturing techniques require custom-machined fillers (shims) to accommodate variations in part dimensions, leading to increased production time and expense in assembling complex structures like aircraft and vehicles.
Innovation Solution
A computer-based system generates digital maps of adjoining components, defines surfaces for precise alignment, and updates part definitions to eliminate the need for shims by machining components with sacrificial material for exact fitment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If custom-machined fillers (shims) are used to accommodate variations in part dimensions, then manufacturing flexibility is improved, but production time and expense increase
Solution Approach 1:
The patent applies preliminary action by incorporating sacrificial material during the initial component manufacturing process. The sacrificial material is pre-added to compensate for dimensional variations, allowing components to self-adjust during assembly without requiring post-manufacturing shims or fillers. This eliminates the need for custom-machined fillers while maintaining manufacturing flexibility.
Solution Approach 2:
The patent changes the dimensional parameters of components by adding sacrificial material with specific thickness values. This parameter modification allows the components to accommodate tolerance stack-ups inherently, replacing the traditional approach of using adjustable shims. The sacrificial material thickness is calculated based on expected dimensional variations, enabling direct assembly without additional fitting operations.
2Manufacturing precision
If custom-machined fillers (shims) are used to accommodate variations in part dimensions, then fitment precision is improved, but manufacturing complexity increases
Solution Approach 1:
The patent merges the function of dimensional compensation directly into the component manufacturing process itself. Instead of treating shim fabrication as a separate, complex operation, the sacrificial material is integrated into the primary manufacturing process. This consolidation eliminates the need for separate filler fabrication, inventory management, and installation procedures, thereby reducing overall manufacturing complexity while maintaining fitment precision.
Solution Approach 2:
The patent extracts the dimensional compensation function from the traditional shim-based approach and embeds it directly into the component design. By removing the need for separate filler components and their associated manufacturing processes, the solution simplifies the overall manufacturing system while achieving the same fitment precision goals.
3Ease of operation
If allowances are provided in part dimensions to accommodate tolerance stack-up, then assembly ease is improved, but material waste increases
Solution Approach 1:
The patent applies local quality by adding sacrificial material only in specific locations where dimensional variations occur, rather than uniformly increasing all dimensions. This targeted approach provides the necessary allowances for tolerance stack-up in critical areas while minimizing unnecessary material addition elsewhere. The sacrificial material is placed precisely where needed to facilitate easy assembly, reducing overall material waste compared to blanket dimensional allowances.
Data Source
AI summary
Manufacturing systems and methods are disclosed. In one example, a computer based system comprises a non-transitory computer readable memory, a processor, and logic instructions stored in the non-transitory computer readable memory. When executed by the processor, the logic instructions configure the processor to perform operations, comprising receiving a first digital map of a first component and a second digital map of a second component, defining a first surface on the first component and a second surface on the second component, wherein at least a portion of the first surface is to adjoin at least a portion of the second surface in a manufactured assembly, updating a first part definition for the first component to include the first surface and, optionally, updating a second part definition for the second component to include the second surface.