Structural Shim Fabrication via Hardenable Composition for Aircraft Assembly
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Solution Overview
Problem
The current methods for determining the size and shape of shims required for filling gaps between aircraft components are labor-intensive and time-consuming, involving iterative assembly and measurement processes that disrupt production flow.
Innovation Solution
A method involving the creation of a physical or digital model of the gap by disposing a hardenable composition, hardening it to form a shim pattern, and then using this pattern to fabricate a structural shim, which can be precisely installed between aircraft skin and substructure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If iterative assembly and measurement processes are used to determine shim size and shape, then manufacturing precision can be achieved, but productivity decreases due to time-consuming repeated operations
Solution Approach 1:
The patent applies preliminary action by creating a digital model of the gap before actual shim fabrication. The method involves temporarily assembling parts, scanning the gap to create a digital representation, and using this model to fabricate the final shim - eliminating the need for repeated trial assemblies and measurements.
Solution Approach 2:
The patent uses copying by creating a digital model (copy) of the physical gap through scanning. This digital replica contains all necessary dimensional information and can be used to fabricate the shim without repeatedly disassembling and reassembling parts, thus maintaining precision while improving productivity.
2Manufacturing precision
If multiple temporary assembly operations are performed to achieve proper fit, then manufacturing precision is maintained, but loss of time increases due to repeated dismantling and reassembly
Solution Approach 1:
The patent performs preliminary scanning and digital modeling during the initial temporary assembly, capturing all gap information before disassembly. This allows the final shim to be precisely fabricated based on the digital model, eliminating the need for multiple reassembly cycles to verify fit.
Solution Approach 2:
The patent replaces repeated mechanical assembly-disassembly operations with a digital modeling and fabrication process. Instead of physically reassembling parts multiple times to check fit, the system uses digital scans to create an accurate model that guides shim fabrication, significantly reducing cycle time while maintaining precision.
3Measurement precision
If visual inspection and measurement methods are used to determine gap dimensions, then measurement precision can be achieved, but device complexity increases due to the need for multiple measurement tools and operations
Solution Approach 1:
The patent applies universality by using a single scanning device that performs multiple functions: it captures gap dimensions, creates a digital model, and provides data for shim fabrication. This replaces multiple specialized measurement tools and manual inspection procedures with one integrated system, reducing complexity while maintaining or improving measurement precision.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach eliminates the need for iterative processes, allowing for the efficient fabrication and installation of shims that accurately fill gaps, enhancing production efficiency and ensuring structural integrity.
Implementation Method 1
hardening the hardenable composition to provide a shim pattern that is dimensionally stable
Data Source
AI summary
Methods for making structural shims (220) for the mating assembly of parts, such as for installation between a skin (212) and substructure (214) of an aircraft. The methods include the steps of disposing a hardenable composition (216) into a gap between the first (212) and second parts (214), hardening the hardenable composition to provide a shim pattern (218) that is dimensionally stable, and removing the shim pattern from the gap without damage. The shim pattern can be used to provide a digital model thereof, which can in turn be used to fabricate the structural shim (220).