Digital Twin Attachment Dimensioning for Uneven Base Contours
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Solution Overview
Problem
The challenge lies in attaching prefabricated add-on parts to existing base components with varying surface contours, which often results in uneven gaps and load distribution, leading to fatigue and instability in connecting devices, especially in structures like balconies, due to large tolerances in base components and narrow tolerances in add-on parts.
Innovation Solution
A method involving the measurement of the base component's surface contour to create a digital twin, allowing for precise dimensioning and manufacturing of add-on parts that match the base component's surface, ensuring a uniform gap and even load transfer without the need for adjustment mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If prefabricated attachments with tight tolerances are attached to base components with large tolerances, then manufacturing precision of the attachment is improved, but uneven gaps and load distribution occur leading to fatigue and instability
Solution Approach 1:
The surface contour of the base component is measured and recorded before attachment, and a digital twin is created in advance. Based on this digital model, the attachment is individually dimensioned and manufactured with customized contact zones that pre-compensate for the base component's surface irregularities, eliminating uneven gaps and load distribution issues before assembly occurs.
Solution Approach 2:
Instead of requiring the entire attachment to have uniformly tight tolerances, only the contact zone of the attachment is individually dimensioned to match the specific surface contour of the base component. This localized customization ensures precise fit at the critical interface while maintaining cost-effectiveness.
2Reliability
If adjustable connecting devices are used to compensate for surface irregularities, then connection stability is improved, but device complexity and labor requirements increase
Solution Approach 1:
Adjustment mechanisms are built into the connecting devices during manufacturing based on the pre-measured surface contour data. This preliminary configuration allows the devices to automatically compensate for surface irregularities without requiring manual adjustment on-site, reducing both device complexity and labor requirements during assembly.
3Manufacturing precision
If individual measurement and customization of each attachment is performed, then manufacturing precision of the attachment is improved, but productivity and assembly speed decrease
Solution Approach 1:
A digital twin (digital copy) of the base component's surface contour is created from measurement data. This digital model is then used to automatically generate the customized dimensions for the attachment's contact zone, enabling precise manufacturing through computer-aided design and manufacturing processes rather than manual measurement and adjustment on-site.
Solution Approach 2:
Manual measurement, calculation, and adjustment processes are replaced with automated optical or laser scanning systems that capture surface geometry, computer algorithms that process the data and generate dimensioning information, and computer-aided manufacturing systems that produce the customized attachment. This substitution of mechanical processes with digital and automated systems maintains precision while improving productivity.
Data Source
Figure 1
AI summary
Method, in particular a computer-aided method, for dimensioning an attachment (1) for mounting on a base component (2), comprising the following steps: - measuring the surface contour of the base component (2) at least in a contact area (3) to which the attachment (1) is to be attached; - creating a digital twin of the base component (2) based on the measured surface contour; - dimensioning the attachment (1), in particular a contact zone (13) of the attachment (1) with which the attachment (1) is to be mounted on the base component (2), corresponding to the surface contour of the base component (2) based on the digital twin.