Predictive Shim Generation Using As-Built Thickness Data

Solution Overview

Problem

The current methods for determining the size and shape of shims to fill gaps between part surfaces are labor-intensive and iterative, requiring multiple temporary assemblies and measurements, which disrupts production flow and increases labor costs.

Innovation Solution

A system and method that uses data from nondestructive inspection combined with digital models to predict shim dimension data, allowing for the automated calculation and manufacturing of shims to fill gaps between parts, eliminating the need for iterative processes and reducing labor costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If traditional iterative shimming process is used with multiple temporary assemblies and visual measurements, then shim fit can be determined, but production flow is disrupted and labor costs increase

Engineering Contradiction:

Improveshim fit precisionVSAvoidproduction flow efficiency

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The system performs nondestructive inspection and calculates as-built thickness values before assembly occurs. The shim dimension data is predicted in advance using digital models and inspection data, eliminating the need for iterative temporary assemblies and visual measurements during the assembly process.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent replaces manual visual inspection and measurement processes with automated nondestructive inspection systems and digital computing. The mechanical iterative assembly-disassembly-measure cycle is substituted with automated data collection, processing, and prediction systems that calculate shim dimensions directly from inspection data.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If traditional iterative shimming process is used with multiple temporary assemblies, then shim dimensions can be determined, but cycle time increases

Engineering Contradiction:

Improveshim dimension accuracyVSAvoidassembly cycle time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The system performs nondestructive inspection and calculates as-built thickness values before assembly occurs. The shim dimension data is predicted in advance using digital models and inspection data, eliminating the need for iterative temporary assemblies and visual measurements during the assembly process.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system enables continuous production flow by performing all inspection, calculation, and prediction operations before assembly. The automated process eliminates interruptions caused by iterative assembly-disassembly cycles, maintaining continuous productive action throughout the manufacturing process.

Inventive Principle:

Principle #20Continuity of useful action

3Manufacturing precision

If manual visual inspection and measurement is used for gap determination, then shim requirements can be identified, but labor intensity increases

Engineering Contradiction:

Improvegap measurement accuracyVSAvoidmanufacturing process simplicity

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent replaces manual visual inspection and measurement processes with automated nondestructive inspection systems and digital computing. The mechanical iterative assembly-disassembly-measure cycle is substituted with automated data collection, processing, and prediction systems that calculate shim dimensions directly from inspection data.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system allows the inspection and measurement process to serve itself automatically. The nondestructive inspection system collects its own data, the digital models process the information, and the system automatically predicts shim dimensions without requiring manual intervention for measurement and calculation.

Inventive Principle:

Principle #25Self-service

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 automates the determination and production of shims, reducing labor costs and cycle time, improving efficiency, and enabling precise assembly without manual measurement, thereby enhancing production efficiency and quality.

Implementation Method 1

Nondestructive inspection methods include the use of ultrasonics, eddy current, x-ray, magnetic resonance, optical imaging, and microwave.

Methodology Applied

Scientific EffectUltrasound: Ultrasound

Data Source

PatentUS10139808B2Predictive shimming of joints

Publication Date: 2018.11.27 THE BOEING CO

AI summary

A method and a system are provided for predicting and creating a shim for use in a joint where two parts, such as a skin and a substructure, are assembled together. Digital models for the skin and the substructure may be used as nominal maps of the outlines and profiles of the parts. The skin may be inspected, e.g., by nondestructive means, such as ultrasound, to determine as-built thickness profile for comparison to the skin's digital model of the thickness profile. Mating areas of the skin and substructure may be determined from their digital models of their outlines. Deviations in the mating areas of the as-built thickness of the skin from the digital model of the skin may be used to generate a digital model of a shim. The shim may be constructed from its digital model by additive manufacturing techniques that may involving machining or 3D printing.