Virtual Assembly Verification for Structural Components
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Solution Overview
Problem
The traditional engineering, procurement, and construction process for structures often results in assembly issues due to component deviations, leading to costly reworks and delays, as the assembly process assumes perfect fitment without adequate infrastructure for manufacturing tools at the construction site, and incorrect support structure orientations can further complicate the process.
Innovation Solution
A method and system for virtual assembly of structure components before shipping, involving remote measurement of components, creation of virtual representations, and analysis of adjustment solutions such as reworking, exchanging, or redesigning components to ensure assembly tolerances are met, using CAD data and digital terrain models, with optimization algorithms to consider time and cost impacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional assembly process is used assuming perfect fitment, then assembly speed is improved, but assembly precision deteriorates leading to costly reworks
Solution Approach 1:
The patent performs virtual assembly and component measurement before actual shipping and physical assembly. By measuring components at production sites and creating virtual representations for pre-assembly verification, the system identifies and corrects fitment issues before components reach the construction site, preventing costly reworks while maintaining efficient on-site assembly
Solution Approach 2:
The patent introduces a virtual assembly environment as an intermediary between design and physical assembly. This virtual model allows verification of component fitment and assembly feasibility without physical trial assembly, acting as a mediator that validates the assembly process before actual construction begins
2Manufacturing precision
If virtual assembly verification is performed before shipping, then assembly precision is improved, but process complexity increases
Solution Approach 1:
The patent creates virtual copies (digital representations) of physical components through measurement at production sites. These virtual models are used in virtual assembly verification, allowing precision checking without requiring complex physical prototypes or trial assemblies. The copying approach simplifies the verification process while maintaining high precision
Solution Approach 2:
The patent replaces physical trial assembly and mechanical verification with virtual assembly simulation and computational analysis. By substituting physical trial-and-error processes with digital verification, the system achieves high assembly precision while reducing the complexity of physical trial assembly infrastructure
3Measurement precision
If components are measured at production sites, then measurement precision is improved, but logistics complexity increases
Solution Approach 1:
The patent performs component measurement at production sites before shipping, creating virtual representations that accompany the physical components throughout logistics. This preliminary measurement ensures high measurement precision and enables pre-assembly verification, while the digital data stream simplifies logistics tracking and component identification at the construction site
Data Source
AI summary
The present invention relates to a method for virtual assembly of a structure, the structure being supposed to be assembled from a multitude of components on a construction site, the method comprising measuring, at a multitude of locations remote from the construction site, the components of the structure subsequent to their production and prior to their transport to the construction site, wherein the measuring comprises measuring at least the shape and size of connecting elements of each of the components, creating virtual representations of the components, virtually assembling the representations of the components, determining, based on assembly tolerances, whether the structure can be assembled with the measured components, and deciding, by means of an optimization algorithm, whether one or more components are to be reproduced, one or more components are to be reworked, and/or the structure is to be redesigned.