Shimless Assembly Synchronization Using Predicted Part Dimensions
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Solution Overview
Problem
Conventional manufacturing processes for structural components, such as aircraft wings, often require the use of shims to fill gaps caused by manufacturing tolerances, leading to increased costs, inefficiencies, and complex assembly procedures.
Innovation Solution
Predicting manufacturing dimensions using historical datasets and scanning parts to determine actual dimensions, allowing for partial or full manufacturing of secondary components before the primary part is fully scanned, and modifying parts to fit within predetermined tolerances without the need for shims.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If shims are used to fill gaps between structural components, then manufacturing tolerances are accommodated, but manufacturing time increases and assembly complexity increases
Solution Approach 1:
The patent applies preliminary action by manufacturing the second structural component based on predicted dimensions before the first component is fully scanned and measured. This allows the second component to be prepared in advance with anticipated interface dimensions, eliminating the need for waiting periods and shim fabrication while maintaining proper fit-up.
2Manufacturing precision
If shims are manufactured and assembled, then gaps are filled, but assembly complexity and cost increase
Solution Approach 1:
The patent extracts and eliminates the shim from the assembly process entirely. By predicting dimensions and manufacturing the second component to fit the predicted interface, the need for shims as separate filler components is removed, simplifying the assembly process and reducing the number of parts required.
3Manufacturing precision
If the second part is manufactured after scanning the first part, then dimensional accuracy is ensured, but manufacturing time increases
Solution Approach 1:
The patent applies preliminary action by manufacturing the second structural component based on predicted dimensions before the first component is fully scanned and measured. This allows the second component to be prepared in advance with anticipated interface dimensions, eliminating the need for waiting periods and shim fabrication while maintaining proper fit-up.
Solution Approach 2:
The patent applies partial action by manufacturing the second component to fit within a range of predetermined allowances rather than waiting for exact final dimensions. This partial manufacturing approach based on predicted dimensions within tolerance ranges enables parallel processing and improves productivity while ensuring the component will fit when assembled.
4Manufacturing precision
If extreme tolerances are enforced, then fit quality improves, but manufacturing cost increases
Solution Approach 1:
The patent applies parameter changes by shifting from enforcing extreme tolerances on individual components to predicting dimensions within a range of predetermined allowances. The second component is manufactured to fit this predicted range, achieving acceptable fit quality while avoiding the prohibitive costs of extreme tolerance enforcement through statistical and predictive approaches.
Data Source
AI summary
Methods aim to reduce and/or eliminate the need for shims in manufacturing assemblies, such as in manufacturing of aircraft wings. Exemplary methods include predicting a set of predicted manufacturing dimensions within a range of predetermined allowances for a first part, manufacturing the first part, scanning the first part to determine a set of actual manufacturing dimensions for the first part, and at least beginning manufacturing a second part before the scanning the first part is completed. The second part may be manufactured based on the set of predicted manufacturing dimensions for the first part. Once the scan of the first part is completed, the set of predicted manufacturing dimensions may be compared to a set of actual manufacturing dimensions to check for any non-compliant deviances between the predicted and actual manufacturing dimensions. Repairs and local re-scans may be performed in the areas of the non-compliant deviances, which may streamline manufacturing.