Predictive Surface Adjustment for Gap-Free Joint Assembly
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Solution Overview
Problem
The existing methods for assembling parts require labor-intensive iterative processes to determine and fill gaps between part surfaces, involving nondestructive inspection and temporary assemblies, which impact production flow and require significant manual labor.
Innovation Solution
A system and method that uses data from nondestructive inspection combined with digital models to predict gaps and determine the need for sacrificial material, allowing for the addition and machining of material to reduce gaps, eliminating the need for iterative processes by automating the determination and fabrication of shims and sacrificial material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional iterative assembly processes are used to determine and fill gaps between parts, then assembly fit accuracy can be achieved, but production cycle time increases and labor requirements increase
Solution Approach 1:
The patent applies preliminary action by performing nondestructive inspection and calculating as-built thickness values before the actual assembly process. The system determines shim and sacrificial material requirements in advance using inspection data and digital models, eliminating the need for iterative trial assemblies. This preliminary determination of gap conditions and material requirements allows the assembly to proceed directly with the correct materials, reducing cycle time while maintaining precision.
Solution Approach 2:
The patent uses digital models as copies of the physical parts to perform virtual assembly simulations and gap analyses. By overlaying as-built thickness data on digital models, the system can predict gap conditions without physically assembling parts multiple times. This digital copying approach allows for accurate prediction of assembly fit before actual assembly, reducing both time and physical iterations.
2Manufacturing precision
If traditional iterative assembly processes are used to determine and fill gaps between parts, then assembly fit accuracy can be achieved, but manual labor requirements increase
Solution Approach 1:
The system applies self-service by automatically processing nondestructive inspection data to determine as-built thickness values and predict gap conditions. The computer system autonomously calculates shim and sacrificial material requirements without requiring manual measurement or iterative adjustment by workers. This automation reduces manual labor while maintaining the precision that would otherwise require skilled technicians to achieve through repeated trial assemblies.
Solution Approach 2:
The patent replaces manual mechanical processes with automated computational methods. Instead of workers physically assembling parts, measuring gaps, and iteratively adjusting shims, the system uses computer-based algorithms to process inspection data and predict assembly conditions. This substitution of mechanical/manual operations with computational analysis significantly reduces labor requirements while maintaining or improving accuracy.
3Productivity
If nondestructive inspection data is collected and processed to predict gaps and determine sacrificial material needs, then iterative processes are eliminated and productivity improves, but system complexity increases
Solution Approach 1:
The patent applies universality by creating a multi-functional system that performs nondestructive inspection, processes inspection data, calculates as-built thickness values, predicts gap conditions, and determines material requirements all within a single integrated workflow. The computer system serves multiple functions: storing digital models, processing inspection data, performing calculations, and generating assembly instructions. This consolidation of multiple functions into one system improves productivity without proportionally increasing complexity.
Solution Approach 2:
The patent uses digital models as intermediaries between the physical inspection data and the assembly decision-making process. The as-built thickness values calculated from nondestructive inspection are overlaid on digital models to predict gap conditions. This intermediary digital representation simplifies the connection between inspection and assembly planning, allowing the system to process complex data relationships without requiring equally complex physical trial assemblies.
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 reduces labor costs and cycle time, enhances efficiency, and improves the accuracy of assembly operations by automating the collection and analysis of data for shim and sacrificial material requirements, enabling precise assembly without manual measurement and drilling.
Implementation Method 1
Nondestructive inspection methods include the use of ultrasonics, eddy current, x-ray, magnetic resonance, optical imaging, and microwave
Data Source
AI summary
A method and system provide for reducing gaps between two mating parts. Either or both parts may be nondestructively inspected at a plurality of locations on a surface to gather a data set relating to the part thickness. The data set may be used to calculate a set of as-built thickness values for the part and a set of deviations from a design model. A mating area may be determined for mating surfaces of the parts. One or more layers of sacrificial material in the mating area may be prepared for any deviations greater than a design allowance. The system may include a ply cutting device and an additive manufacturing device coupled to a computer to receive the sacrificial material layer data and shim data and to cut the one or more layers of sacrificial material and to construct the shim. A shim may be constructed for any deviations equal to or greater than a minimum shim thickness. The one or more layers of sacrificial material may be applied to the part, cured, and machined to a desired thickness. The shim may be applied between the part surfaces. The parts may be fitted and assembled together.