Shim Fabrication from Gap Modeling for Tight Tolerances
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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 and system that involves inserting a mechanical tool into a shim space to establish model points, which are then electronically measured outside the space, generating machining instructions, and fabricating the shim using these instructions, without the need for measurement electronics within the tool.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual iterative adjustment process is used to manufacture shims, then the shim can be customized to fit the gap, but the manufacturing time and cost increase significantly
Solution Approach 1:
The invention performs preliminary measurement and planning actions before actual shim fabrication. A measurement system scans the gap space between components to create a digital model, and manufacturing instructions are generated in advance. This preliminary digital preparation eliminates the need for iterative manual adjustments during fabrication, as the shim is manufactured directly to precise specifications based on the pre-acquired gap geometry.
Solution Approach 2:
The invention replaces the manual mechanical iterative adjustment process with an automated measurement and manufacturing system. Instead of workers repeatedly measuring and adjusting shims by hand, a measurement system with sensors and a computing device automatically captures gap geometry and generates manufacturing instructions, which are then used to fabricate the shim with precise fit without manual intervention.
2Manufacturing precision
If manual visual observation and iterative modification is used, then the worker can identify high spots, but the process becomes expensive and time-consuming
Solution Approach 1:
The invention replaces manual visual observation with an automated measurement system that uses sensors to detect the geometry of the gap space. The measurement system objectively captures the precise positions of surfaces and identifies high spots through electronic measurement rather than human visual inspection, eliminating subjectivity and reducing the complexity of manual judgment while maintaining or improving measurement accuracy.
Solution Approach 2:
The invention creates a digital copy or model of the physical gap space by scanning its geometry with measurement sensors. This digital representation includes accurate information about surfaces and high spots, which can be analyzed and used to generate manufacturing instructions without requiring repeated physical inspection and manual modification cycles.
3Manufacturing precision
If iterative manual process is used for tight tolerance requirements, then the desired precision can be achieved, but the cost and time increase significantly
Solution Approach 1:
The invention replaces iterative manual measurement and adjustment with an automated measurement system that rapidly captures gap geometry and a manufacturing system that precisely fabricates the shim according to generated instructions. This substitution of manual processes with automated systems maintains tight tolerance control while dramatically improving manufacturing efficiency and reducing the time required to produce shims meeting specified tolerances.
Solution Approach 2:
The invention performs all measurement, analysis, and manufacturing instruction generation before actual shim fabrication. The measurement system scans the gap space and creates a digital model in advance, allowing the manufacturing system to produce the shim with precise fit in a single operation without subsequent adjustments, thereby maximizing productivity while maintaining tight tolerances.
Data Source
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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.