Composite Panel Fixture Calibration Using Dual 3D Surface Scans
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods for calibrating tooling and post-cure fixtures in composite panel manufacturing are inefficient, leading to deviations in panel shape and surface integrity, which can result in costly compensation processes and reduced production accuracy.
Innovation Solution
A method involving a first and second 3D surface scan of the panel's inner surface, with the panel secured to a tooling fixture and then a header structure to determine deformation functions and compensate for deviations, allowing for predictive shimming and reduced tooling constraints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional calibration methods are used for tooling and post-cure fixtures, then the manufacturing process is simpler, but panel shape deviation and surface integrity deteriorate
Solution Approach 1:
The patent performs 3D surface scans of the panel's inner surface in advance - first while secured to the tooling fixture, then after removal and securing to a header structure. This preliminary scanning and deformation function determination allows for predictive compensation before actual panel manufacturing, enabling precise calibration without requiring complex real-time measurement systems during production.
Solution Approach 2:
The patent creates a digital 3D copy of the panel's inner surface geometry through scanning. By comparing the scanned surface data with the nominal design geometry, the system generates a deformation function that replicates the tooling fixture's effect on the panel. This digital copying approach replaces complex physical calibration artifacts with computable geometric data.
2Manufacturing precision
If strict tooling constraints are maintained during post-cure fixturing, then panel shape accuracy is improved, but production costs and complexity increase
Solution Approach 1:
The patent determines a deformation function that characterizes how the panel's inner surface geometry changes between being secured to the tooling fixture versus being held at nominal configuration by a header structure. By using this deformation function for predictive shimming, the system compensates for tooling deviations computationally, allowing the post-cure fixture to use less constrained, simpler hold-down structures rather than requiring precision-machined constraint surfaces.
Solution Approach 2:
The patent replaces complex mechanical precision constraint systems with a computational approach. Instead of requiring the post-cure fixture to mechanically enforce exact nominal geometry through precision machined surfaces and tight tolerances, the system uses 3D scanning data and deformation functions to predict and compensate for deviations, substituting mechanical precision requirements with computational correction.
3Measurement precision
If multiple scanning and compensation steps are performed, then calibration accuracy is improved, but manufacturing time increases
Solution Approach 1:
The patent performs the time-consuming 3D scanning and deformation function determination as a preliminary step during tooling fixture calibration or after tooling modifications. By completing this detailed measurement and analysis work before production, the system establishes accurate compensation data that can be rapidly applied during manufacturing without repeating the full scanning process for each panel, thus minimizing ongoing production time penalties.
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
Systems and methods provide for the determination and correction of tooling deviation by comparing two different three-dimensional surface scans of a composite panel after curing. Such methods and systems may allow for less accurate post-cure fixturing (e.g., holding the panel in a less constrained state, as compared to prior art techniques), while still maintaining a sufficient amount of precision for predictive shimming and shimless techniques. Methods include performing a first three-dimensional surface scan, performing a second three-dimensional surface scan, and comparing the two to determine a deformation function corresponding to tooling deviation. In some systems, a header structure is used to hold the composite panel in a nominal configuration for the second three-dimensional surface scan. In some systems, scanning devices perform mirrored scanning on either side of the composite panel, using a common reference frame.