Flexible Component Shaping With Closed-Loop Fit Alignment
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Solution Overview
Problem
Current processes for assembling large, flexible aerospace components are time-consuming and labor-intensive, and there is a need for efficient control of shape and fit between components to minimize deformation and ensure precise alignment.
Innovation Solution
A manufacturing system utilizing a holding structure, actuators, and a closed feedback loop to iteratively adjust the shape of components to a target shape using a controller that determines deviations and applies displacements until a tolerance is met, incorporating metrology systems for precise measurement and control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional manual processes are used for assembling large flexible components, then labor flexibility is maintained, but manufacturing time increases and labor costs increase
Solution Approach 1:
The system enables self-service through automated actuators that automatically adjust component shapes based on real-time metrology measurements and controller directives, eliminating the need for manual labor while maintaining precise control over the assembly process
Solution Approach 2:
Manual mechanical adjustment processes are replaced with an automated control system comprising actuators, metrology systems, and controllers that use feedback loops to automatically shape and position components, substituting human labor with automated mechanical and computational systems
2Manufacturing precision
If traditional assembly processes are used for large flexible components, then process simplicity is maintained, but shape control precision deteriorates
Solution Approach 1:
The system employs closed-loop feedback control where metrology systems continuously measure component shapes, the controller compares measurements against target specifications, and actuators automatically adjust shapes based on the feedback, ensuring precise shape control throughout the assembly process
Solution Approach 2:
The control system integrates multiple functions into a unified platform: metrology systems perform both measurement and quality verification, actuators provide both shaping and positioning capabilities, and the controller coordinates all operations, reducing overall system complexity despite enhanced precision requirements
3Manufacturing precision
If iterative shape adjustment is implemented, then shape accuracy improves, but process time increases
Solution Approach 1:
The iterative adjustment process operates continuously without interruption: metrology systems continuously monitor component shapes, the controller continuously processes measurements and generates adjustment directives, and actuators continuously apply corrections, maintaining uninterrupted productive action throughout the shaping process
Solution Approach 2:
The system performs preliminary shaping actions using actuators before final assembly operations, pre-positioning components to within acceptable tolerances in advance, which reduces the need for time-consuming adjustments during the actual assembly process
Data Source
AI summary
A manufacturing system and method for determining and optimizing shaping locations and shaping inputs and shaping a component using the shaping locations and shaping inputs includes steps of: determining shaping locations on the component for application of shaping inputs that change an as-built shape of the component toward a target shape of the component and determining the shaping inputs to be applied to the component at the shaping locations to change the as-built shape of the component toward the target shape of the component; applying the shaping inputs to the component at the shaping locations on the component; and changing the as-built shape of the component to within a predetermined tolerance of the target shape.