Aircraft Wing-to-Body Join Using 3D Surface Scanning and Virtual Fit
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Solution Overview
Problem
The aircraft assembly process is hindered by the time-consuming and labor-intensive custom design and installation of shims to fill gaps between large components, which can lead to inaccuracies due to manual measurement techniques and deviations from engineering designs, especially in large assemblies like wing-to-body joins.
Innovation Solution
The use of photogrammetry sensors to measure and generate 3D surface profiles of wing root and wing stub interfaces, calculating a virtual fit to determine shim dimensions, and aligning the components using position sensors to achieve a precise real fit, thereby reducing the need for manual adjustments and improving accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual feeler gauges are used to measure gaps between components, then measurement can be performed with simple equipment, but the process is time consuming and tedious with accuracy dependent on operator skill
Solution Approach 1:
The patent replaces manual mechanical feeler gauge measurement with an automated optical scanning system using laser line projectors and cameras to capture 3D surface profiles of component interfaces. This substitution eliminates manual intervention, provides consistent high-precision measurements independent of operator skill, and dramatically reduces measurement time through automated data capture and processing.
2Productivity
If predictive shimming with virtual fitting is used, then assembly speed can be improved, but accuracy deteriorates due to deviations from engineering design and inaccurate surface measurements
Solution Approach 1:
The patent performs preliminary 3D surface scanning and virtual fitting operations before actual assembly to determine precise shim specifications. By measuring actual component surfaces in-situ and calculating required shim dimensions in advance, the system enables rapid assembly execution while maintaining high precision through data-driven shim fabrication rather than relying on theoretical engineering designs alone.
Solution Approach 2:
The system uses feedback from actual 3D surface measurements of component interfaces to adjust and refine the virtual fitting model. The measured surface profiles feed into the gap analysis algorithm, which iteratively optimizes shim designs to achieve the desired fit. This closed-loop feedback ensures that the final assembly accuracy reflects actual component variations rather than idealized design assumptions.
3Manufacturing precision
If custom shims are designed and fabricated for each gap, then structural integrity and fit accuracy are improved, but the process becomes labor intensive and time consuming
Solution Approach 1:
The patent creates accurate digital 3D copies of the actual component interface surfaces through laser scanning. These digital surface models serve as virtual replicas that can be manipulated, analyzed, and used to generate shim designs without physical trial-and-error. The digital copying process captures all surface irregularities and enables precise virtual gap analysis, eliminating the need for repeated physical measurements and iterative shim adjustments.
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 method enables quicker and more accurate assembly of aircraft components by reducing the reliance on manual measurements and ensuring precise alignment, leading to improved structural integrity and reduced production time.
Implementation Method 1
measuring a 3D surface contour of at least one wing root interface surface of the wing root; measuring a 3D surface contour of at least one wing stub interface surface of the wing stub by scanning a series of wing stub inspection regions of the at least one wing stub interface surface with the photogrammetry sensor
Data Source
AI summary
Disclosed aircraft wing-to-body join methods include measuring a 3D surface contour of each wing root interface surface of a wing root to form a complete wing root 3D surface profile; measuring a 3D surface contour of each wing stub interface surface of a wing stub to form a complete wing stub 3D surface profile; calculating a virtual fit between the aircraft wing and the aircraft body assembly that defines one or more gaps between the wing root interface surface and the wing stub interface surface; and aligning the aircraft wing to the aircraft body assembly to achieve a real fit consistent with the virtual fit.