Predictive Assembly Gap Analysis with Deformation Filtering
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional predictive assembly methods fail to accurately predict the dimensions of gaps between mated surfaces when one or more components experience deformation during assembly, leading to excessive gaps that require disassembly and remanufacturing.
Innovation Solution
A system and method that utilize data filtering to remove pre-assembly deformation from 3D measurement data, allowing for accurate prediction of gap dimensions by accounting for waviness and recommending proactive actions based on gap thresholds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional predictive assembly methods are used to predict gap dimensions, then the prediction process is simple, but the prediction accuracy deteriorates when components experience deformation during assembly
Solution Approach 1:
The system performs preliminary filtering of deformation from 3D measurement data before assembly occurs. By removing deformation characteristics from the measured data in advance, the system predicts what the gap dimensions will be after assembly, rather than measuring the deformed state directly. This preliminary action enables accurate prediction without requiring complex real-time deformation compensation during assembly.
Solution Approach 2:
The patent replaces direct physical measurement of gap dimensions after assembly with a computational approach. Instead of mechanically measuring the assembled components, the system uses 3D scanning combined with deformation filtering algorithms to virtually predict the gap dimensions. This substitution of mechanical measurement with computational prediction maintains simplicity while improving accuracy.
2Manufacturing precision
If components are assembled without predictive analysis, then the assembly process is fast, but excessive gaps require disassembly and remanufacturing
Solution Approach 1:
The system performs gap prediction before assembly takes place, allowing manufacturers to identify potential gap issues in advance. This preliminary analysis enables proactive decision-making about whether to proceed with assembly, rework components, or adjust manufacturing parameters, thereby preventing excessive gaps that would require costly disassembly and remanufacturing.
Solution Approach 2:
The predictive assembly system enables the manufacturing process to self-correct by providing advance information about potential gap issues. Manufacturers can use the predictions to adjust component manufacturing or selection before assembly, allowing the system to self-regulate quality without requiring post-assembly inspection and rework cycles.
3Measurement precision
If 3D measurement data is used directly for prediction, then the measurement process is simple, but deformation causes inaccurate gap dimension prediction
Solution Approach 1:
The system extracts deformation characteristics from the 3D measurement data through filtering operations. By separating the deformation component from the actual geometric features, the system isolates only the relevant information needed for accurate gap prediction. This extraction process removes the harmful deformation influence while preserving the essential dimensional data.
Solution Approach 2:
The patent introduces deformation filtering algorithms as an intermediary processing step between 3D scanning and gap prediction. This intermediary layer transforms the raw, deformation-affected measurement data into corrected data that accurately represents the component geometry after assembly, enabling precise gap dimension prediction without directly confronting the deformation measurement problem.
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
A system for predictive assembly includes a model generator, a model analyzer, and an assembly planner. The model generator generates a first model of a first component and a second model of a second component before the first component and the second component are coupled together. The model analyzer analyzes the first model and the second model to determine a dimension of a gap between a first mating surface of the first component and a second mating surface of the second component after the first component and the second component are coupled together. The assembly planner recommends an action based on a comparison of the gap to a gap threshold.