Automated Gap Detection for 3D Assembly Models
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Solution Overview
Problem
Unintended gaps between structural components in assemblies, such as aircraft, are difficult to detect through visual inspection, leading to costly custom shims, potential cracking, and unsafe flight conditions, highlighting the need for an automated gap detection system.
Innovation Solution
A system comprising a visualization application for 3D modeling, a proximity analysis application to identify non-acceptable gaps, and a data analysis application to automatically select shims or adjust part positions to correct gaps, using a processor and memory to generate corrected 3D models for production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If visual inspection is used to detect gaps, then some gaps can be found, but the detection is time consuming and many gaps remain undetected
Solution Approach 1:
The patent replaces manual visual inspection with an automated computer-based system that uses algorithms to analyze 3D models and detect gaps. This substitution of mechanical/manual processes with automated computational methods enables comprehensive detection of all gaps without time constraints, directly resolving the contradiction between detection completeness and inspection time.
Solution Approach 2:
The patent creates digital 3D model copies of the actual assembly components and performs gap detection on these virtual representations. This copying approach allows automated analysis of the entire assembly without physically inspecting each component, achieving complete gap detection while eliminating time consumption associated with manual inspection.
2Measurement precision
If visual inspection is used to detect gaps, then some gaps can be found, but the detection accuracy is insufficient for small gaps
Solution Approach 1:
The patent replaces human visual inspection with automated computational algorithms that can precisely measure and detect small gaps in 3D models. This substitution eliminates human limitations in detecting small features, achieving high detection accuracy for even the smallest gaps without increasing measurement difficulty.
Solution Approach 2:
The patent transitions from 2D visual inspection to 3D digital model analysis, enabling detection of gaps in three-dimensional space. This dimensional enhancement allows the system to accurately detect and measure small gaps that are difficult or impossible to identify through traditional visual inspection methods.
3Reliability
If custom shims are manufactured to correct gaps, then gap acceptance can be achieved, but manufacturing costs increase significantly
Solution Approach 1:
The patent performs gap detection and analysis on 3D models before manufacturing begins, identifying potential gap issues in the design phase. By detecting and addressing gaps preliminarily through digital modeling and simulation, the system prevents the need for expensive custom shims and fillers during actual manufacturing, thereby maintaining gap acceptance while reducing material costs.
Solution Approach 2:
The patent uses digital 3D model copies to simulate and analyze gap conditions, allowing virtual testing and correction of assembly issues before physical manufacturing. This copying approach enables identification of gap problems in the virtual model, preventing the need to manufacture expensive corrective components like custom shims.
4Productivity
If gap detection is performed late in the process, then manufacturing can proceed, but safety problems may arise
Solution Approach 1:
The patent performs gap detection and analysis as a preliminary step before manufacturing and assembly processes begin. By identifying and addressing potential gap issues in the design phase through 3D model analysis, the system ensures manufacturing can proceed without delays while simultaneously guaranteeing safety by preventing defective assemblies from being produced.
Data Source
AI summary
A system for analysis of gaps between modeled parts of an assembly to be produced is provided. The system generates a three-dimensional (3D) visualization environment of 3D models of a plurality of parts in the assembly and performs an analysis of those of the 3D models within a given proximity to each other to determine gaps therebetween, including any non-acceptable gaps with gap distances that exceed an acceptable gap threshold. The system generates, for a non-acceptable gap, an instruction and automatically implements the instruction to correct the non-acceptable gap and confirms that the non-acceptable gap as corrected does not have a gap distance that exceeds the acceptable gap threshold. The system generates an output of a 3D model of the assembly populated with the 3D models and with the non-acceptable gap as corrected for use in connection with production of the assembly.