Predictive Shimming for Part Alignment and Key Feature Orientation
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Solution Overview
Problem
Existing predictive shimming processes fail to optimize the final orientation of parts during assembly, neglecting key features and focusing solely on gap minimization between mating surfaces.
Innovation Solution
A method that utilizes measurement data from mating surfaces and key features to virtually align parts, ensuring optimal orientation and geometry of shims to meet engineering requirements, using a metrology-directed, DA hole placement method with 3-D CAD tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual shimming is performed by installing and measuring parts, then gaps can be identified, but the process is time-consuming and requires additional production flow
Solution Approach 1:
The system performs all measurements, virtual assembly, and shim calculations before actual part installation. By predicting the exact shim requirements in advance based on pre-assembly measurements of mating surfaces and key features, the process eliminates time-consuming post-assembly measurements and iterative shim adjustments, enabling parallel fabrication of shims while parts are being prepared
Solution Approach 2:
The patent creates virtual copies of the actual parts through 3D scanning and measurement data. These digital twins are used in virtual assembly simulations to predict gap conditions and determine optimal shim configurations, eliminating the need for physical trial-and-error measurement and adjustment during actual assembly operations
2Productivity
If predictive shimming fabricates fillers prior to assembly, then manufacturing time is reduced, but the process does not consider key features of the parts
Solution Approach 1:
The system expands the predictive model to include key feature measurements and orientation parameters. By incorporating these additional parameters into the virtual assembly simulation, the system calculates shim configurations that simultaneously achieve gap filling and satisfy engineering requirements for key feature orientations and positions, maintaining fast fabrication timing while improving precision
Solution Approach 2:
The patent uses measurement data from actual part features as feedback to refine the virtual assembly model. By comparing measured key feature positions and orientations against engineering requirements, the system iteratively adjusts predicted shim configurations to ensure all tolerances are met before fabrication begins, validating the approach before production
Data Source
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AI summary
Methods for using predictive shimming to optimize part-to-part alignment. In accordance with one embodiment, the process uses measurement data acquired from mating surfaces and key features to virtually align two parts in a manner that optimizes the final orientation of the parts and determines the geometry of the shim needed to achieve this orientation during assembly.