Dual-Scanner Predictive Shimming for Large-Part Gap Measurement
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Solution Overview
Problem
The current gap filling process in aircraft manufacturing is inefficient due to manual inspection and measurement, leading to increased manufacturing cycle time and cost, especially when dealing with large or complex parts, as conventional inspection tools struggle with accuracy and reach, resulting in inconsistent data and prolonged setup times.
Innovation Solution
A scanning apparatus with a dual-scanner system that moves independently along multiple axes to efficiently scan large parts, providing accurate and dense data for predictive shimming by overlapping scan fields to ensure comprehensive coverage and maintain consistent scanning distances, reducing the need for multiple setups and improving data consistency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual inspection and measurement are used to gather measurement data, then the process is simple to implement, but manufacturing cycle time increases and cost increases
Solution Approach 1:
The patent replaces manual mechanical inspection and measurement with an automated scanning system that uses optical or laser-based scanners to capture measurement data. This substitution eliminates manual labor while dramatically increasing measurement speed and accuracy, directly addressing the contradiction between ease of implementation and manufacturing cycle time.
Solution Approach 2:
The patent changes the measurement parameters by using non-contact scanning methods that can capture multiple measurement points simultaneously across large surfaces. This allows the system to gather comprehensive measurement data in a fraction of the time required for manual inspection, while maintaining or improving accuracy.
2Ease of operation
If conventional inspection tools are used on large or complex parts, then the tools are simple to operate, but accuracy decreases and data consistency becomes inconsistent
Solution Approach 1:
The patent divides the scanning task into multiple segments by using multiple scanners positioned at different locations. Each scanner captures data for a specific portion of the large or complex part, ensuring high measurement precision for each segment while maintaining ease of operation through automated coordination of all scanners.
Solution Approach 2:
The patent transitions from single-point or line-based measurement to three-dimensional surface scanning, capturing comprehensive geometric data across the entire part surface. This dimensional enhancement allows accurate measurement of complex geometries that conventional tools cannot measure with consistent precision.
3Measurement precision
If multiple scanners are used to scan large parts, then scanning accuracy and coverage improve, but device complexity increases
Solution Approach 1:
The patent designs the scanning system with multiple scanners that can be positioned and configured for different scanning scenarios. The system integrates multiple scanning functions into a unified platform that can handle various part sizes and geometries, improving measurement precision while managing complexity through standardized, multi-functional components.
Solution Approach 2:
The patent introduces a central control system that acts as an intermediary between multiple scanners and the data processing unit. This mediator coordinates scanner operations, synchronizes data collection, and integrates measurements from multiple sources, thereby improving overall scanning accuracy while keeping the system manageable through centralized control.
4Area of stationary object
If multiple setups are required for scanning large parts, then complete coverage can be achieved, but time consumption increases and data consistency decreases
Solution Approach 1:
The patent segments the scanning coverage area and assigns different scanners to different segments, allowing simultaneous scanning of multiple regions. This eliminates the need for sequential setups, reducing time consumption while maintaining complete coverage and ensuring data consistency through synchronized operation of all scanners.
Solution Approach 2:
The patent enables continuous scanning operation by positioning multiple scanners to cover different areas simultaneously, eliminating idle setup time between scanning operations. The system maintains continuous useful action across the entire part surface, achieving complete coverage without interruption and ensuring consistent data collection throughout the scanning process.
Data Source
AI summary
A scanning apparatus for predictive shimming includes a scanning platform. The scanning apparatus also include a first scanner, coupled to the scanning platform, and a second scanner, coupled to the scanning platform. The scanning platform is configured to move the first scanner and the second scanner together along an X-axis and a Z-axis. The scanning platform is also configured to move the first scanner and the second scanner independent of and relative to each other along a Y-axis and a Z-axis. A first field of view of the first scanner and a second field of view of the second scanner at least partially overlap when the first scanner and the second scanner move in opposite directions along the Y-axis.