Automated Wing Junction Milling for Shim Elimination
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Solution Overview
Problem
Current methods for assembling aircraft wings require manual measurement and shim insertion, leading to inefficiencies and inaccuracies due to the need for new tooling for each shipset junction and increased production time, as well as the use of shims that can cause shear stress.
Innovation Solution
An automated system that uses software to automatically measure and generate a milling program to machine shape parts with overmaterial, minimizing shim thickness to under 0.3 mm, eliminating the need for shims by aligning and fitting semi-wing parts with a best positioning algorithm and 5-axis milling machine.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual measurement and shim insertion methods are used, then assembly can be performed with conventional tooling, but production time increases and measurement precision decreases
Solution Approach 1:
The patent replaces manual mechanical measurement methods with automated optical scanning systems and computer-based measurement algorithms. The system uses scanners to automatically capture geometric data of wing components and employs computational algorithms to calculate optimal positioning and required shim thicknesses, eliminating manual measurement errors and significantly reducing measurement time while improving precision.
Solution Approach 2:
The system performs preliminary automated measurement and calculation of gap dimensions before actual assembly. By pre-calculating the exact shim thickness required based on scanned geometric data and algorithmic analysis, the system eliminates time-consuming trial-and-error adjustments during assembly, allowing for direct precise assembly with pre-determined shim specifications.
2Manufacturing precision
If new tooling is manufactured for each shipset junction to minimize gaps, then gap precision improves, but device complexity and manufacturing cost increase
Solution Approach 1:
Instead of manufacturing different physical tooling for each junction, the system changes the parameters of the existing tooling through software-based positioning algorithms. The universal tooling can be dynamically adjusted to accommodate different gap conditions by computing optimal positioning parameters and shim specifications for each specific wing junction, eliminating the need for custom tooling while maintaining high precision.
Solution Approach 2:
The system creates a digital copy or virtual model of the wing junction geometry through automated scanning. This digital replica is then used for measurement, analysis, and calculation of optimal assembly parameters. By working with the digital copy rather than requiring physical custom tooling for each configuration, the system achieves high precision gap minimization with standardized physical tooling.
3Manufacturing precision
If shims are inserted to fill gaps between junction parts, then structural gaps are eliminated, but shear stress is introduced into the structure
Solution Approach 1:
The system extracts or removes the need for thick shims by implementing precise automated measurement and positioning. By accurately determining the actual gap dimensions and calculating optimal positioning parameters, the system minimizes gaps to such extent that shim insertion becomes unnecessary or requires only minimal thin shims, thereby eliminating the source of shear stress while still achieving gap elimination.
Solution Approach 2:
Instead of using full-thickness shims that completely fill gaps but introduce stress, the system applies partial action by using minimal or no shims. The automated positioning system achieves such precise gap control that only minimal material compensation is needed, if any, thereby eliminating the harmful shear stress effect while still addressing the gap issue.
Data Source
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AI summary
A method comprising the steps of: manufacturing with a milling machine a junction part for an airplane wing with overmaterial (204); each part is measured with a laser based interferometer or other scanning technique and the "as built" measurements are compared with a model to generate a new trajectory milling program to fill or prevent gaps between parts using a points cloud and B-Spline algorithm to generate a new surface to be milled (206, 208); once the program is generated (new trajectories) and post processed, it is sent to a milling machine to perform overmaterial milling on already milled parts with overmaterial (210). This technique can be used to eliminate gaps between junction parts and the corresponding need for shims.