Shim Dimensions via Virtual Deformation Analysis
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Solution Overview
Problem
Conventional shim sizing methods often result in excessively thick shims that conflict with engineering requirements and increase structure weight, while failing to provide accurately sized and dimensioned shims.
Innovation Solution
A method involving digital representations of members to be joined, aligned in a common coordinate system, with virtual deformation analysis to determine shim dimensions based on applied loading, allowing for precise fabrication of shims to minimize voids between parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional shim sizing methods are used, then shims can be easily selected and fabricated, but the shims become excessively thick and increase structure weight
Solution Approach 1:
The patent applies preliminary action by performing virtual deformation analysis and determining accurate shim dimensions through digital modeling before actual shim fabrication. This pre-calculation approach ensures shims are precisely sized to match the actual gap requirements, preventing excessive thickness and reducing structure weight while maintaining ease of manufacture through automated digital processes
Solution Approach 2:
The patent utilizes parameter changes by considering virtual deformation under applied loading conditions to determine the actual gap between members. By changing the state of the members from unloaded to loaded conditions in the digital model, the method calculates the precise shim thickness needed, avoiding excessive material and reducing weight
2Ease of manufacture
If conventional shim sizing methods are used, then fabrication process is simple, but manufacturing precision of shim dimensions is insufficient
Solution Approach 1:
The patent applies copying by creating accurate digital representations (copies) of the physical members and their deformation states. These digital models precisely capture the geometry and deformation characteristics, enabling calculation of exact shim dimensions. This digital copying approach maintains fabrication simplicity while dramatically improving manufacturing precision
Solution Approach 2:
The patent replaces manual measurement and estimation mechanical processes with computational analysis. By substituting physical trial-and-error shim fitting with virtual deformation analysis and digital modeling, the method achieves high manufacturing precision while keeping the actual shim fabrication process simple and straightforward
3Reliability
If thicker shims are used to account for surface variances, then gaps between members are better filled, but engineering requirements are conflicted and weight increases
Solution Approach 1:
The patent applies parameter changes by analyzing the deformation state of members under loading conditions to determine the actual gap requirements. By changing from static, unloaded geometry to dynamic, loaded geometry in the digital model, the method calculates precise shim thickness that exactly fills gaps without excessive material, maintaining reliability while meeting engineering requirements
Solution Approach 2:
The patent performs preliminary virtual deformation analysis and gap calculation before shim fabrication. This advance determination of precise shim dimensions ensures gaps are effectively filled without using excessively thick shims, thereby maintaining structural integrity and meeting engineering requirements while improving reliability
Data Source
AI summary
A method is provided that includes providing a first digital representation of a first member and a second digital representation of a second member. The first member and the second member are configured to be joined. The method also includes aligning the first digital representation and the second digital representation in a same coordinate system. Further, the method includes determining, in the coordinate system, a virtual deformation corresponding to at least one of the first digital representation or the second digital representation corresponding to an applied loading. Also, the method includes determining shim dimensions for a shim to be interposed between the first member and the second member based on the virtual deformation. The method further includes fabricating a shim having the shim dimensions.