Virtual Shim Design Using Merged Photogrammetry and Laser Tracking
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Solution Overview
Problem
The existing methods for designing and manufacturing shims in aircraft assembly are time-consuming and labor-intensive, requiring manual measurement and fabrication at the final assembly destination, which slows down the assembly process, especially when assemblies are manufactured in different geographic locations.
Innovation Solution
A method using merged photogrammetry and laser tracking techniques to generate virtual shim dimensions, allowing for automatic design and fabrication of shims without physically joining part assemblies, enabling adjustments to performance characteristics like wing incidence, sweep, and dihedral, and facilitating just-in-time assembly at the final location.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual measurement and fabrication of shims is performed at the final assembly destination, then the shims can be customized to fit specific voids, but the assembly process becomes time-consuming and labor-intensive
Solution Approach 1:
The patent applies preliminary action by performing virtual fit analysis and calculating shim dimensions before the actual assembly process. The system uses 3D scanning and virtual assembly simulation to determine all required shim dimensions in advance, allowing shims to be fabricated beforehand rather than during final assembly, thus resolving the contradiction between precision customization and assembly speed
Solution Approach 2:
The patent uses virtual copying by creating digital 3D models and virtual representations of the assembly and its voids. Instead of manually measuring physical gaps, the system scans and creates virtual copies to perform fit analysis and generate shim designs, eliminating time-consuming manual measurement while maintaining precise fit customization
2Measurement precision
If shims are designed and manufactured only after assemblies are fitted together, then accurate void dimensions can be determined, but the overall manufacturing timeline is extended
Solution Approach 1:
The system performs preliminary virtual fit analysis using 3D scanned data of the assemblies before they are physically joined. This allows accurate void dimension determination to occur in advance, enabling shim fabrication to also occur beforehand, thus eliminating the time delay while maintaining measurement accuracy through digital modeling
Solution Approach 2:
The patent replaces the mechanical process of physically assembling parts to measure voids with a digital/virtual system. 3D scanning and virtual assembly simulation substitute for physical trial-and-fit processes, allowing accurate void dimension calculation without the time penalty of sequential physical operations
3Reliability
If unique shims are designed for each aircraft, then structural integrity is improved, but the design and fabrication process becomes labor-intensive
Solution Approach 1:
The patent uses automated 3D scanning and virtual modeling to create precise digital copies of each assembly's voids. This automated digital process replaces manual measurement and design, maintaining unique customization for structural integrity while eliminating the labor-intensive aspects of manual shim design and fabrication
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 reduces the time and labor required for shim design and fabrication, enabling efficient assembly of complex aircraft parts by allowing shim dimensions to be determined and fabricated in advance, improving assembly efficiency and structural integrity.
Implementation Method 1
measuring the location of features on the part assemblies may be performed using both laser tracker and photogrammetry processes
Implementation Method 2
measuring the location of features on the part assemblies may be performed using both laser tracker and photogrammetry processes
Data Source
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AI summary
The locations of key features on first and second part assemblies are surveyed using a merged photogrammetry and laser tracking technique that generate a virtual fit. The virtual fit is generated by comparing sets of data representing the surveyed positions of features on the first and second part assemblies. The manufacturing processes of the first and/or second part assemblies may be modified to reflect the effect of part assembly fit on performance characteristics of the aircraft.