Feature-Based Part Alignment Using Multi-Part Scanning
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Solution Overview
Problem
Current methods for aligning parts in aerospace and aircraft applications face challenges such as high costs, rigidity, and inflexibility in accommodating different part configurations and design changes, especially with large and flexible parts that are difficult to handle and require tight dimensional tolerances.
Innovation Solution
The method involves using simultaneous scanning of features and constructing feature-based coordinate systems to determine relative positions of parts, allowing for precise alignment and adjustment using robotic manipulators, independent of part-based or global coordinate systems, and enabling alignment and joining of parts with features like edges, planes, and contoured features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual assembly using large scale fixtures or assembly jigs is used, then tight assembly tolerances can be controlled, but the system becomes expensive, difficult to install, and inflexible to design changes
Solution Approach 1:
The patent replaces mechanical fixtures and assembly jigs with a scanner-based measurement system and software processing. The scanner captures images of part features, and a computer processes these images to determine part positions and orientations, eliminating the need for complex mechanical positioning devices while maintaining tight assembly tolerances.
Solution Approach 2:
The patent creates digital copies of physical part features through scanning. The scanner captures images of features like edges, corners, and surfaces, which are then processed to generate virtual models and coordinate systems that represent the actual part geometries, allowing for precise alignment without physical fixtures.
2Manufacturing precision
If automated assembly systems using high accuracy machines are used, then dimensional requirements are met, but the system becomes expensive, mechanically complex, and sensitive to environmental changes
Solution Approach 1:
The patent replaces high-accuracy automated assembly machines with an optical scanning system. Instead of using mechanically complex positioning machines, the system uses a scanner to capture part geometries and software to compute alignment, significantly reducing mechanical complexity while maintaining precision.
Solution Approach 2:
The patent introduces a computer-based image processing system as an intermediary between the scanner and the alignment process. The computer processes scanned images, constructs feature-based coordinate systems, and determines part positions, acting as a mediator that translates raw scan data into precise alignment information without requiring complex mechanical machinery.
3Ease of operation
If prefabricated assembly features such as determinant assembly holes are used, then alignment can be achieved, but additional processing is required and structural requirements may not be met
Solution Approach 1:
The patent enables parts to serve themselves in the alignment process. Instead of requiring pre-formed alignment holes or features, the system scans the actual surface features of the parts (edges, corners, contours) and uses these existing features for alignment, allowing parts to provide their own alignment references without additional manufacturing steps.
Solution Approach 2:
The patent changes the parameters used for alignment from predetermined geometric features (like holes) to scanned surface features. By using feature-based coordinate systems constructed from scanned edges, corners, and contours, the system adapts to the actual part geometries rather than requiring specific pre-formed features, eliminating additional processing requirements.
4Length of stationary object
If large and flexible parts are handled, then assembly of large components is possible, but tight dimensional tolerances become difficult to maintain
Solution Approach 1:
The patent performs preliminary scanning and measurement of part features before final assembly. By capturing images of features and constructing feature-based coordinate systems in advance, the system establishes reference frames that guide the positioning of large flexible parts, enabling tight tolerance control even for large-scale components.
Solution Approach 2:
The patent applies feature-based alignment locally to specific scanned features on large parts. Instead of requiring global rigidity, the system identifies and uses local features (edges, corners, contours) as reference points, allowing flexible parts to be accurately positioned by controlling the geometry of specific local features rather than the entire part structure.
Data Source
AI summary
Provided are methods and systems for aligning multiple parts using simultaneous scanning of features of different parts and using feature-based coordinate systems for determining relative positions of these. Specifically, a feature-based coordinate system may be constructed using one or more critical dimensions between features of different parts. The scanner may be specifically positioned to capture each of these critical dimensions precisely. The feature-based coordinate system is used to compare the critical dimensions to specified ranges. The position of at least one part may be adjusted based on results of this comparison using, for example, a robotic manipulator. The process may be repeated until all critical dimensions are within their specified ranges. In some embodiments, multiple sets of features from different parts are used such that each set uses its own feature-based coordinate system. The part adjustment may be performed based on the collective output from these multiple sets.