Flexible Component Assembly with Closed-Loop Shape Correction
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Solution Overview
Problem
Current processes for assembling large, flexible aerospace components are time-consuming and labor-intensive, and often result in undesirable shape mismatches due to flexing and deformation under gravity or handling loads, leading to poor fit and alignment issues.
Innovation Solution
A manufacturing system utilizing a holding structure with actuators and a closed feedback loop to apply displacements to components, monitored by a metrology system, to iteratively adjust shapes until they meet a tolerance, ensuring precise alignment and assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional manual assembly processes are used for large flexible components, then labor intensity and time consumption are high, but manufacturing precision and shape control are poor
Solution Approach 1:
The patent implements a closed-loop feedback control system where metrology systems continuously measure the actual shape of large flexible components during assembly, and this measurement data is fed back to actuators that automatically adjust component positions and orientations. This feedback mechanism enables real-time shape control precision while maintaining high assembly throughput through automation, directly resolving the contradiction between manufacturing precision and productivity.
Solution Approach 2:
The patent replaces traditional manual mechanical assembly operations with an automated system combining metrology systems for measurement, actuators for precise positioning, and control systems for coordination. This substitution eliminates labor-intensive manual handling while achieving superior shape control through automated measurement and adjustment, simultaneously improving both manufacturing precision and assembly efficiency.
2Manufacturing precision
If manual handling and assembly of large flexible components are used, then process simplicity is maintained, but shape matching and alignment accuracy deteriorate
Solution Approach 1:
The patent employs metrology systems to continuously measure the actual shapes and positions of large flexible components during assembly, providing real-time feedback data. This measurement information is used to detect shape deviations and guide actuators for precise adjustments, enabling accurate shape matching between mating components. The automated feedback control system achieves superior alignment accuracy while the added system complexity is justified by the significant improvement in manufacturing precision.
3Manufacturing precision
If traditional assembly methods are used without active shape control, then device complexity is low, but fit quality and alignment between components deteriorate
Solution Approach 1:
The patent implements a closed-loop feedback control system where metrology systems measure the actual shapes of components, and this measurement data is fed back to actuators that automatically adjust component positions and orientations. This feedback mechanism enables real-time shape control precision while maintaining high assembly throughput through automation, directly resolving the contradiction between manufacturing precision and productivity.
Solution Approach 2:
The patent replaces traditional manual mechanical assembly operations with an automated system combining metrology systems for measurement, actuators for precise positioning, and control systems for coordination. This substitution eliminates labor-intensive manual handling while achieving superior shape control through automated measurement and adjustment, simultaneously improving both manufacturing precision and assembly efficiency.
Data Source
AI summary
A manufacturing system includes a holding structure and actuators that are coupled to the holding structure. The actuators support the component and apply displacements to select locations of the component to change a current shape of the component toward a target shape of the component. The system includes a metrology system that takes measurements of the current shape of the component. The system includes a controller that utilizes a closed feedback loop to determine a deviation between the current shape and the target shape based on the measurements and to provide commands that iteratively change the displacements in response to changes in the current shape until the current shape is within a tolerance of the target shape.