Structure Assembly Using Profile Prediction for Contour Accuracy
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Solution Overview
Problem
In the assembly of structures like aircraft and spacecraft, components with key characteristics requiring specific contour degrees often deviate from these requirements due to production errors and deformation, leading to the need for large-scale repairs.
Innovation Solution
A method involving the measurement of profiles on key surfaces of components before assembly, adjustment of subcomponents through load application and position adjustment, and prediction of the changed profile of critical surfaces to determine optimal coupling positions, ensuring compliance with contour degree requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If subcomponents are assembled to form a component with key characteristics, then productivity is improved by modular assembly, but manufacturing precision deteriorates due to cumulative production errors and deformation
Solution Approach 1:
The patent measures profiles of surfaces on subcomponents before assembly and predicts the changed profile of the second surface after assembly. This preliminary measurement and prediction action allows the contour degree to be verified before final assembly, preventing deviations caused by cumulative errors while maintaining modular assembly productivity.
Solution Approach 2:
The patent implements a feedback mechanism where the measured profiles of subcomponents and the predicted changed profile of the assembled component are used to determine the optimal coupling position. This feedback loop ensures that manufacturing precision is maintained by adjusting assembly positions based on actual measurements rather than relying solely on nominal dimensions.
2Manufacturing precision
If load application and position adjustment are performed during assembly, then manufacturing precision is improved by correcting profile deviations, but device complexity increases due to additional adjustment mechanisms
Solution Approach 1:
The patent performs load application and position adjustment as preliminary actions during the assembly process, before final coupling. By determining the coupling position based on predicted profile changes, the necessary adjustments are made in advance, simplifying the overall assembly process rather than requiring complex real-time adjustment mechanisms.
Solution Approach 2:
The system uses measurement and prediction data to automatically determine coupling positions without requiring complex manual adjustment mechanisms. The assembly process serves itself by using measured data to guide positioning, reducing the need for additional complex adjustment devices.
3Manufacturing precision
If coupling position is determined based on predicted profile changes, then manufacturing precision is improved by ensuring contour requirements are met, but measurement precision requirements increase due to need for accurate pre-assembly measurements
Solution Approach 1:
The patent measures profiles of surfaces on subcomponents before assembly, performing the measurement action in advance. This preliminary measurement allows for prediction of assembly outcomes and determination of optimal coupling positions, ensuring manufacturing precision while using standard measurement capabilities rather than requiring extremely high measurement precision during final assembly.
Data Source
AI summary
A method of producing a structure including a first component, having a first surface, and a second component, having second and third surfaces includes: measuring profiles of the second and third surfaces; measuring profiles of fourth and fifth surfaces of subcomponents; assembling the first component by coupling the subcomponents with adjustment; recording data representing the adjustment; estimating a changed profile of the second surface in case of coupling the third surface to the first surface; determining a coupling position of the third surface to the first surface; and coupling the third surface to the first surface at the determined coupling position. The predetermined contour degree is required for the second surface. The first surface is formed by the fourth surfaces. The fifth surfaces influence a profile of the first surface. The changed profile is estimated based on the profiles of the second to fifth surfaces and the recorded data.