Shim Fabrication Using External Measurement of Gap Model Points
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Solution Overview
Problem
The manual process of manufacturing shims is time-consuming and costly, especially when tight tolerance requirements are involved, as it typically requires iterative adjustments to achieve the desired shape between components.
Innovation Solution
A method involving a mechanical tool that inserts into a shim space, modifies its configuration to establish model points, and is then measured externally to generate machining instructions for fabricating a shim, using a distinct measurement station and processing circuitry to create a shim based on these instructions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a manual process is used to manufacture shims with iterative adjustments, then the shim can be manually shaped to fit the gap, but the process becomes time-consuming and costly
Solution Approach 1:
The patent applies preliminary action by pre-configuring the mechanical tool with adjustable components (such as adjustable legs or probes) that can be set to specific configurations before entering the shim space. This allows the tool to establish model points that define the desired shim geometry in advance, eliminating the need for iterative manual shaping during the actual manufacturing process.
Solution Approach 2:
The patent replaces the manual mechanical shaping process with an automated system. A mechanical tool equipped with sensors or measurement capabilities is inserted into the shim space to automatically capture geometric data, and this data is used to generate machining instructions for automated fabrication, substituting the manual iterative adjustment process with an automated measurement-and-manufacturing workflow.
2Extent of automation
If a mechanical tool is inserted into the shim space to establish model points, then automated manufacturing is enabled, but the tool must be removed for external measurement
Solution Approach 1:
The patent applies the taking out principle by separating the measurement function from the tooling function. The mechanical tool is used solely to establish model points within the shim space, and then the tool is removed. The measurement is performed externally by a separate measurement system that reads the positions of the model points, rather than attempting to perform measurement while the tool remains in place. This simplifies both the tool design and the measurement system.
Solution Approach 2:
The patent uses model points as an intermediary between the mechanical tool and the measurement system. The mechanical tool establishes these model points (such as reference spheres or marked locations) at specific positions that define the shim geometry. These model points then serve as intermediaries that the external measurement system can easily detect and measure, bridging the gap between mechanical tooling and electronic measurement without requiring complex integrated systems.
3Manufacturing precision
If tight tolerance requirements are imposed on the gap between shim and components, then the shim fit quality improves, but the manual iterative process becomes even more expensive and time-consuming
Solution Approach 1:
The patent replaces the manual visual inspection and iterative adjustment process with an automated measurement system that can precisely measure the positions of model points to sub-millimeter or even micrometer accuracy. This automated system generates exact machining instructions that ensure tight gap tolerances are achieved in a single pass, eliminating the need for repeated manual adjustments and significantly reducing labor costs while maintaining or improving tolerance quality.
Solution Approach 2:
The patent creates a digital copy or virtual model of the shim space geometry by measuring the positions of model points established by the mechanical tool. This digital representation is then used to generate precise machining instructions that replicate the desired geometry, ensuring tight tolerances are achieved through automated fabrication rather than manual trial-and-error, thereby reducing costs while maintaining high precision.
Data Source
AI summary
A method of manufacturing a shim and related systems and equipment. A mechanical tool inserted into a shim space defined between two or more components with the mechanical tool in a first configuration. The mechanical tool is free of measurement electronics. The mechanical tool, while in the shim space, is modified such that the mechanical tool assumes a second configuration to establish a plurality of model points corresponding to a boundary surface of the shim space. The mechanical tool is removed from the shim space while maintaining the mechanical tool in the second configuration. Using a measurement station distinct from the tool, the positions of the model points are electronically measured while the mechanical tool is both disposed outside of the shim space and in the second configuration. Machining instructions are generated based on the measured positions. A shim is fabricated based on the generated machining instructions.