Joint Assembly Surface Adjustment for Predictive Gap Filling
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Solution Overview
Problem
Current methods for determining and addressing gaps between part surfaces during assembly are labor-intensive and iterative, requiring multiple temporary assemblies and significant manual labor, especially when using composite materials like carbon-fiber-reinforced polymers.
Innovation Solution
A system and method that utilizes nondestructive inspection data to calculate as-built thickness values and generate digital models for determining the need and size of shims or sacrificial material, allowing for automated addition and machining to fill gaps, reducing the need for iterative processes and manual labor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional iterative assembly and inspection methods are used to determine gap requirements, then the assembly process can achieve proper fit, but the process requires multiple temporary assemblies and significant manual labor
Solution Approach 1:
The system performs nondestructive inspection and calculates as-built thickness values before the actual assembly process. This preliminary determination of gap requirements eliminates the need for multiple iterative temporary assemblies, as the shim or sacrificial material requirements are known in advance.
Solution Approach 2:
The patent replaces manual measurement and iterative mechanical assembly processes with an automated nondestructive inspection system that uses ultrasonic or other sensing methods to measure thickness and calculate gaps, substituting human labor with automated detection and computation.
2Manufacturing precision
If multiple layers of sacrificial material are added to fill gaps, then gap filling is achieved, but the process requires subsequent machining operations
Solution Approach 1:
The system calculates the exact thickness of sacrificial material needed based on as-built thickness measurements and predetermined shim allowances. By determining the precise material requirement before application, the system minimizes the amount of material that needs to be removed in subsequent machining operations.
Solution Approach 2:
The patent dynamically adjusts the thickness parameter of sacrificial material based on actual measured deviations from nominal dimensions. The system changes the material parameter (thickness) to match the specific gap requirement, optimizing the balance between filling capability and machining removal.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach streamlines the assembly process by automating the determination and application of shims or sacrificial material, significantly reducing labor costs and cycle time, improving efficiency, and enhancing the precision of the assembly process.
Implementation Method 1
Nondestructive inspection methods include the use of ultrasonics, eddy current, x-ray, magnetic resonance, optical imaging, and microwave
Data Source
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AI summary
A method and system provide for reducing gaps between two mating parts. Either or both parts may be nondestructively inspected at a plurality of locations on a surface to gather a data set relating to the part thickness. The data set may be used to calculate a set of as-built thickness values for the part and a set of deviations from a design model. A mating area may be determined for mating surfaces of the parts. One or more layers of sacrificial material in the mating area may be prepared for any deviations greater than a design allowance. The system may include a ply cutting device and an additive manufacturing device coupled to a computer to receive the sacrificial material layer data and shim data and to cut the one or more layers of sacrificial material and to construct the shim. A shim may be constructed for any deviations equal to or greater than a minimum shim thickness. The one or more layers of sacrificial material may be applied to the part, cured, and machined to a desired thickness. The shim may be applied between the part surfaces. The parts may be fitted and assembled together.