Shimless Wing Assembly Synchronization Using Predicted Dimensions
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional manufacturing processes for aircraft wings require the use of shims to fill gaps between structural components, leading to increased costs, delays, and inefficiencies due to the need for additional assembly steps and precise placement of shims.
Innovation Solution
Predicting manufacturing dimensions for parts based on historical data and independent factors, allowing for partial or full manufacturing of second parts before scanning the first part, and modifying parts to accommodate deviations within predetermined tolerances, thereby eliminating the need for shims.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If shims are used to fill gaps between structural components, then assembly fit is improved, but manufacturing time and cost increase
Solution Approach 1:
The patent applies preliminary action by predicting the as-built dimensions of the first part before it is actually manufactured, and using these predictions to guide the manufacturing of the second part. This allows the second part to be manufactured in advance based on predicted dimensions, eliminating the need to wait for the first part to be built and scanned, thereby reducing manufacturing time while maintaining assembly fit through subsequent modification if needed.
2Manufacturing precision
If shims are used to fill gaps between structural components, then assembly fit is improved, but logistical complexity increases
Solution Approach 1:
The patent applies the taking out principle by removing the shim component entirely from the assembly process. Instead of manufacturing and managing shims as separate components that need to be placed and secured, the invention modifies the second part directly to fit the first part, thereby eliminating the logistical complexity of shim management while maintaining assembly fit.
3Manufacturing precision
If the second part is manufactured after scanning the first part, then manufacturing precision is improved, but productivity decreases
Solution Approach 1:
The patent applies preliminary action by manufacturing the second part before the first part is scanned, based on predicted as-built dimensions. This reverses the conventional sequence where the second part would wait for actual measurement data, thereby improving productivity while maintaining the ability to achieve dimensional accuracy through post-manufacturing modification if deviations are detected.
Solution Approach 2:
The patent applies feedback by scanning the first part after manufacturing to determine actual as-built dimensions, comparing these to the predicted dimensions used for manufacturing the second part, and then modifying the second part if non-compliant deviances are detected. This closed-loop feedback ensures dimensional accuracy is achieved while allowing parallel manufacturing processes to improve productivity.
4Manufacturing precision
If manufacturing tolerances are enforced to eliminate gaps, then assembly fit is improved, but manufacturing cost increases
Solution Approach 1:
The patent applies parameter changes by allowing the second part to be manufactured based on predicted dimensions with predetermined allowances, rather than enforcing strict tolerances during manufacturing. The actual as-built dimensions are then used to modify the second part if needed, thereby achieving assembly fit without the high costs associated with tight manufacturing tolerances.
Data Source
Figure 1
Figure 2
Figure 3
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.