Predictive Shim Profile Generation for Aircraft Assembly
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Solution Overview
Problem
The existing methods for shimming gaps in aircraft structures are time-consuming and costly due to the need for manual inspection and measurement, especially for large or flexible parts with varying geometries, which increases manufacturing cycle time and costs.
Innovation Solution
A method and apparatus for predictive shimming that involves obtaining baseline surface models, scanning parts in deviated configurations to generate scan-based models, deforming these models to account for physical responses and imperfections, and comparing them to generate a shim profile, allowing for pre-fabrication of shims and reducing the need for extensive manual inspection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual inspection is used to gather measurement data for shim fabrication, then measurement accuracy can be achieved, but manufacturing cycle time and cost increase significantly
Solution Approach 1:
The patent replaces manual mechanical inspection with an automated optical scanning system using lasers or cameras to capture surface geometry data. This substitution eliminates manual measurement operations while maintaining high measurement accuracy through digital surface modeling and automated gap analysis algorithms.
Solution Approach 2:
The patent creates digital surface models (copies) of the actual part surfaces through scanning. These digital copies allow for automated gap analysis and shim design without requiring physical contact or manual measurement of the actual parts, significantly reducing measurement time while preserving accuracy.
2Measurement precision
If manual inspection is used to gather measurement data, then measurement data can be obtained, but the process becomes cumbersome due to the size of the component being inspected
Solution Approach 1:
The patent replaces manual inspection operations with automated scanning systems that can efficiently capture data from large aircraft components. The automated systems eliminate the physical burden of manual measurement on large structures while maintaining comprehensive data collection across entire surfaces.
Solution Approach 2:
The patent transitions from traditional point-by-point manual measurement to comprehensive surface scanning that captures entire surfaces in three dimensions. This dimensional approach allows automated processing of large components without the operational complexity of manual inspection across extensive surfaces.
3Reliability
If custom shims are fabricated to fill gaps between structural components, then structural performance is maintained, but manufacturing cost increases
Solution Approach 1:
The patent performs gap analysis and generates shim design data during the manufacturing process itself, before final assembly. By identifying and addressing gaps proactively during manufacturing rather than during assembly or maintenance, the need for expensive custom shim fabrication is reduced while maintaining structural performance requirements.
Data Source
AI summary
A method for determining a shim profile for assembling a first mating surface of a first part with a second mating surface of a second part includes: obtaining a baseline surface model of the first mating surface; scanning the first mating surface when the first part is in a deviated configuration to generate a scan-based surface model of the first mating surface; deforming the scan-based surface model of the first mating surface relative to the baseline surface model of the first mating surface to generate a first deformed surface model of the first mating surface; deforming the first deformed surface model of the first mating surface relative to a surface model of the second mating surface to generate a second deformed surface model of the first mating surface; and comparing the second deformed surface model of the first mating surface to the surface model of the second mating surface.