Surface Profile Assembly for Aircraft Contour Precision
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Solution Overview
Problem
In aircraft and spacecraft assembly, components with key characteristics often deviate from contour degree requirements due to production errors and misalignment, necessitating large-scale repairs and adjustments.
Innovation Solution
A method involving surface profile measurement, subcomponent assembly with load and position adjustments, and finite element method analysis to predict and correct the contour profile of critical surfaces, ensuring accurate coupling positions to maintain contour degree requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If subcomponents are assembled with production errors and positioning shifts, then assembly flexibility is improved, but contour degree precision deteriorates
Solution Approach 1:
The method performs preliminary measurement of subcomponent surfaces and preliminary estimation of the second surface profile before final assembly. This allows positioning adjustments to be calculated in advance based on measured production errors, ensuring that the final assembly achieves the required contour degree precision while accommodating the production variations
Solution Approach 2:
The method implements a feedback loop where the measured profiles of subcomponents and the estimated changed profile of the second surface are used to determine optimal coupling positions. This feedback mechanism allows the assembly process to compensate for production errors and positioning shifts, maintaining high contour degree precision while preserving assembly flexibility
2Manufacturing precision
If large-scale repair is performed to correct contour deviations, then contour degree precision is improved, but device complexity and repair time increase
Solution Approach 1:
The method performs preliminary measurement and estimation before assembly is completed, identifying potential contour deviations early. This allows corrections to be made through simple positioning adjustments rather than requiring large-scale repairs later, reducing repair complexity and time while maintaining contour degree precision
Solution Approach 2:
The method converts the potentially harmful effect of production errors and positioning shifts into beneficial information by measuring and estimating their impact on the second surface profile. This information is then used to determine optimal coupling positions, transforming what would require complex repairs into simple positional corrections
3Manufacturing precision
If coupling position is adjusted to compensate for production errors, then contour degree precision is improved, but measurement and calculation complexity increases
Solution Approach 1:
The method segments the measurement and calculation process into distinct, manageable steps: measuring individual subcomponent surfaces, assembling subcomponents with adjustments, recording adjustment data, estimating the changed profile of the second surface, and determining coupling positions. This segmentation makes the overall complex process more manageable and systematic
Data Source
Figure 1
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Figure 5(A)~5(C)
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.