Patent Application
20240385588
The present disclosure relates generally to predictive shimming and assembly manufacturing and, more particularly, to systems and methods for predictive shimming. fabricating double-contoured shims, and assembly manufacturing that uses the double-contoured shims to fill gaps in joints between part surfaces.
During the assembly of parts, it may be necessary to affix the parts to one another such that any gap between two parts is occupied by a filler material, commonly referred to as a “shim.” Gaps are typically formed by misalignment of parts during assembly or by variation in manufacture of the parts being assembled. A shim is designed to approximately fill the gap between the mating surfaces of the parts. Shims are used throughout the aerospace industry to compensate for part variation due to the complex aerodynamic shapes of various assembled parts. For example, when a gap exceeds a specified tolerance, a shim can be inserted into the gap in order to assure a within-tolerance fit between the parts.
Manual shimming requires the parts to be installed and measured, shims to be fabricated and installed, and gaps to be checked. Measuring gaps is a time-consuming process and fabricating the shims after part installation requires additional production flow. In recent years, a process called predictive shimming has been developed to reduce the manufacturing time and cost associated with shimming activities. Predictive shimming typically involves measuring surfaces of the parts prior to assembly, performing a virtual assembly of the parts, estimating the resulting gap between the parts, and then fabricating a shim prior to assembly.
However, in conventional shimming techniques, the measured or estimated deviations between mating surfaces of the parts are summed and pushed to one side for fabrication of the shim. As such, a fabricated shim only addresses surface contour of one of the mating surfaces and surface contour of the opposing mating surface is considered addressed after applying clamp-up forces and final connection of the assembled parts. Accordingly, those skilled in the art continue with research and development efforts in the field of predictive shimming and assembly manufacturing.
Disclosed are examples of a system for fabricating a double-contoured shim, a method for fabricating a double-contoured shim, a double-contoured shim, a method for shimming, a computer program product, a data processing system, and a computer-readable storage media. The following is a non-exhaustive list of examples, which may or may not be claimed, of the subject matter according to the present disclosure.
In an example, the disclosed system includes a computer and a manufacturing system. The computer generates a shim model to fill a gap between a first mating-surface of a first component and a second mating-surface of a second component. The computer generates a virtual plane that divides the shim model into a first shim model and a second shim model. The manufacturing system fabricates a first shim that is based on the first shim model and that includes a first contoured shim-surface that is complementary to a first mating-surface area of the first mating-surface and a first planar shim-surface that is opposite the first contoured shim-surface. The manufacturing system fabricates a second shim that is based on the second shim model and that includes a second contoured shim-surface that is complementary to a second mating-surface area of the second mating-surface and a second planar shim-surface that is opposite the second contoured shim-surface.
In an example, the method for fabricating includes steps of: (1) generating a shim model to fill a gap between a first mating-surface of a first component and a second mating-surface of a second component; (2) generating a virtual plane that divides the shim model into a first shim model and a second shim model; (3) fabricating a first shim, based on the first shim model, that includes a first contoured shim-surface that is complementary to a first mating-surface area of the first mating-surface and a first planar shim-surface that is opposite the first contoured shim-surface; and (4) fabricating a second shim, based on the second shim model, that includes a second contoured shim-surface that is complementary to a second mating-surface area of the second mating-surface and a second planar shim-surface that is opposite the second contoured shim-surface.
In an example, the disclosed double-contoured shim includes a first shim and a second shim. The first shim includes a first contoured shim-surface and a first planar shim-surface that is opposite the first contoured shim-surface. The second shim includes a second contoured shim-surface and a second planar shim-surface that is opposite the second contoured shim-surface. The first shim and the second shim are coupled together along the first planar shim-surface and the second planar shim-surface.
In one or more examples, the method for shimming includes steps of: (1) manufacturing a double-contoured shim; (2) installing the double-contoured shim in a gap between a first mating-surface of a first component and a second mating-surface of a second component; and (3) assembling the first component, the second component, and the double-contoured shim to form a finally assembled structure.
In an example, the disclosed computer program product includes instructions that, when executed by a computer, causes the computer to carry out one or more steps of: (1) generating a shim model to fill a space between a first mating-surface of a first component and a second mating-surface of a second component; (2) generating a virtual plane that divides the space into a first portion and a second portion; (3) generating a first shim model that substantially fills the first portion of the space; and (4) generating a second shim model that substantially fills the second portion of the space.
In an example, the disclosed data processing system includes a processor and memory storing program code that, when executed by the processor, causes the processor to perform one or more steps of: (1) generating a shim model to fill a space between a first mating-surface of a first component and a second mating-surface of a second component; (2) generating a virtual plane that divides the space into a first portion and a second portion; (3) generating a first shim model that substantially fills the first portion of the space; and (4) generating a second shim model that substantially fills the second portion of the space.
In an example, the computer-readable storage media includes instructions that, when executed by a computer, causes the computer to carry out one or more steps of: (1) generating a shim model to fill a space between a first mating-surface of a first component and a second mating-surface of a second component; (2) generating a virtual plane that divides the space into a first portion and a second portion; (3) generating a first shim model that substantially fills the first portion of the space; and (4) generating a second shim model that substantially fills the second portion of the space.
Other examples of the system, the method, and the double-contoured shim disclosed herein will become apparent from the following detailed description, the accompanying drawings, and the appended claims.
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When the gap 210 is larger than an acceptable manufacturing tolerance, the gap 210 needs to be filled. As such, a shim can be fabricated and installed into the gap 210. The present disclosure recognizes that shims fabricated using conventional shimming techniques, including manual shimming and predictive shimming, include one side that is flat and one side that has contour. As such, all of the surface-to-surface gap deviations are applied with respect to one side of the shim. It is assumed that the flat side of the shim will conform to an actual part surface that it interfaces with after final assembly. This technique simplifies the machining of shims. While this shimming technique may be adequate for surfaces that are generally flat or that include a relatively low degree of surface contour, it is inadequate for a relatively high degree of surface contour on one or both of the mating part surfaces. As such, the double-contoured shim 200 (
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In one or more examples, the system 100 and the method 1000 utilize three-dimensional (3D) measurement data acquired from both the first component 202 and the second component 204. Utilizing both data sets, a three-dimensional geometry for the double-contoured shim 200 is created using a predictive shimming process. Generally, this predictive shimming process includes measuring surfaces of the first component 202 and the second component 204. More specifically, the first mating-surface 206 of the first component 202 that will mate with second component 204 and the second mating-surface 208 of the second component 204 that will mate with the first component 202 are measured. The surface measurement data sets are used in a virtual assembly process. During virtual assembly, the first component 202 and the second component 204 are virtually oriented and aligned relative to an aircraft coordinate system to estimate the varying thickness of the gap 210 between the first mating-surface 206 and the second mating-surface 208.
As described above, in one or more examples, the system 100 and the method 1000 utilize a predictive shimming process. Such predictive shimming processes are well-known and use commercially available 3D metrology equipment to measure the surfaces and/or features of the parts (e.g., the first component 202 and the second component 204). In one or more examples, the surface measurements are taken using at least one scanner 174 (e.g., a laser scanner, a structured light scanner, a point-based scanner, and other systems capable of creating or generating a point cloud) and measurement data 180 is stored as high-density point clouds. In one or more examples, the surface measurements are taken using at least one probe 176 and the measurement data 180 is stored as discrete points.
After the measurement data 180 has been acquired, the measurement data 180 is used to virtually align the first component 202 and the second component 204 in an assembled condition. In one or more examples, the measurement data 180 is aligned with an engineering model that specifies the locations of all parts in the final assembly. In one or more examples, the measurement data 180 for the first component 202 and the second component 204 is loaded into a computer program or application used to align measurement data sets to engineering models. The computer program or application (e.g., an alignment module or alignment application) is configured to align a first measurement data set (e.g., first measurement data 104) representing the first component 202 and a second measurement data set (e.g., second measurement data 106) representing the second component 204 to an engineering model of the assembled structure 236. In one or more examples, this alignment process uses a weighted fit or best fit algorithm to align the measured components to their engineering locations. In one or more examples, the alignment process aligns both sets of measurements to engineering locations to optimize the final part alignment rather than simply minimizing gaps between the two parts.
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In one or more examples, the first virtual mating-surface 158 and the second virtual mating-surface 160 that were fitted to the aligned measurement data 180 are imported into a computer program or application (e.g., model generator module or model generator application) that is configured to estimate the geometry, size, shape, etc. of a space 116 (
In one or more examples, the computer program or application (e.g., model generator module or model generator application) generates a first grid of points 186 on the fitted first virtual shim-surface 108 and a second grid of points 188 on the fitted second virtual shim-surface 110. In one or more examples, the computer program or application (e.g., model generator module or model generator application) estimates the dimensions between the first grid of points 186 and the second grid of points 188, when the first component 202 and the second component 204 are assembled, to estimate the geometry the space 116.
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In one or more examples, two groups of vectors are created during this operational step. As an example, a first group of vectors is a set of vectors from a first grid of points 186 to the second virtual mating-surface 160. A second group of vectors is a set of vectors from the second grid of points 188 to the first virtual mating-surface 158.
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For the purpose of the present disclosure, a first item, such as a first surface, a first virtual-surface, and the like, being complementary to or substantially matching a second item, such as a second surface, a second virtual-surface, and the like, refer to the first item and the second item having an at least approximately equivalent shape, contour, and/or geometry such that, when the first item and the second item are mated or are situated in intimate (e.g., surface) contact, they form a whole without significant spaces or gaps between the first and second items.
In one or more examples, the computer program or application (e.g., model generator module or model generator application) then generates a virtual plane 142 that is situated between the first virtual shim-surface 108 and the second virtual shim-surface 110. In one or more examples, the virtual plane 142 divides the shim model 118 into a first shim model 166 and a second shim model 168 (
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In one or more examples, the computer program or application (e.g., model generator module or model generator application) generates a third grid of points 190 (
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In one or more examples, two groups of vectors are created during this operational step. As an example, a first group of vectors is a set of vectors from the third grid of points 190 to the first grid of points 186. The vectors of the first group are normal to the virtual plane 142. A second group of vectors is a set of vectors from the third grid of points 190 to the second grid of points 188. The vectors of the second group are normal to the virtual plane 142.
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Since both sides of the double-contoured shim 200 will have surface contour after fabrication, the two vector groups are not merged together and the variations are not pushed to one side of the shim as in conventional shimming techniques. Rather, the two vector groups originate from the virtual plane 142, thereby enabling the first virtual shim-surface 108 to be designed and fabricated to have the first virtual shim-surface contour 122 and the second virtual shim-surface 110 to be designed and fabricates to have the second virtual shim-surface contour 124.
Generally, the first dimensions 146 of the first portion 162 of the space 116 will vary and are measured in a direction normal to the virtual plane 142 at a plurality of points across the virtual plane 142. More specifically, a distance between the virtual plane 142 and the first virtual shim-surface 108 of the first shim model 166 along a line normal to any point on the virtual plane 142 will be the thickness of a first shim 224, fabricated using the first shim model 166, at that point. Similarly, the second dimensions 148 of the second portion 164 of the space 116 will vary and are measured in a direction normal to the virtual plane 142 at a plurality of points across the virtual plane 142. More specifically, a distance between the virtual plane 142 and the second virtual shim-surface 110 of the second shim model 168 along a line normal to any point on the virtual plane 142 will be the thickness of a second shim 226, fabricated using the second shim model 166, at that point.
In one or more examples, the virtual plane 142 is situated at an approximately central location between the first virtual mating-surface 158 and the second virtual mating-surface 160. However, if the resulting vectors exceed a maximum allowable shim thickness, the vectors may be scaled to prevent the shims from creating a nonconforming condition.
In one or more examples, after the first dimensions 146 and the second dimensions 148 have been projected to the 2D shim profiles, the first virtual shim-surface 108 and the second virtual shim-surface 110 are fitted to the projected space. More specifically, once the first group of vectors are mapped to their respective 2D shim profile, their end points are used to construct the first virtual shim-surface 108 and the first virtual planar surface 192. The first virtual shim-surface 108 is fitted to the first virtual mating-surface 158 and represents a first contoured shim-surface 212 of one of the final machined surfaces of the double-contoured shim 200. Similarly, once the second group of vectors are mapped to their respective 2D shim profile, their end points are used to construct the second virtual shim-surface 110 and the second virtual planar surface 194. The second virtual shim-surface 110 is fitted to the second virtual mating-surface 160 and represents a second contoured shim-surface 214 of one of the final machined surfaces of the double-contoured shim 200.
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The first shim 224 is fabricated to include the first contoured shim-surface 212, a first planar shim-surface 232, and a first thickness 228. The second shim 226 is fabricated to include the second contoured shim-surface 214, a second planar shim-surface 234, and a second thickness 230. Once the first shim 224 and the second shim 226 have been fabricated, the first shim 224 and the second shim 226 are joined along the first planar shim-surface 232 and the second planar shim-surface 234 to form the double-contoured shim 200. The double-contoured shim 200 is installed within the gap 210 between the first component 202 and the second component 204 during final assembly of the structure 236.
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For the purpose of the present disclosure, a “component” refers to any manufactured or fabricated part, object, article, and the like that is intended to be coupled to another component during assembly and/or manufacture of a larger structure. In an aerospace example, components can include, but are not limited to, skin panels, stiffeners, stringers, ribs, frames, and the like, which are joined and/or assembled to form a fuselage barrel, a wing, a stabilizer, and the like. For the purpose of the present disclosure, a “surface” may be a continuous surface, or a discontinuous surface that includes or is made up of multiple surfaces. For the purpose of the present disclosure, a “mating-surface” refers to a surface intended to be placed adjacent to and/or in intimate contact with another surface to form a joint between surfaces.
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In one or more examples, prior to assembly, at least a portion of the first mating-surface 206 of the first component 202 and at least a portion of the second mating-surface 208 of the second component 204 are measured. Examples of the system 100 and the method 1000 described herein utilize a metrology-directed method coupled and a predictive shimming method using a suite of metrology and three-dimensional (3D) CAD tools. Predictive shimming is achieved by virtually fitting the first component 202 and the second component 204 per engineering requirements and filling any instances of the gap 210 (e.g., one or more gaps) that exist between the first mating-surface 206 and the second mating-surface 208 with a filler that accommodates surface contours of both first mating-surface 206 and the second mating-surface 208.
In one or more examples, certain operations described herein as being performed by the system 100, such as various data-processing operations used to analyze measurement data and generate design geometries for the double-contoured shim 200, are performed using a computer 128. In one or more examples, the computer 128 serves as an analysis and design environment and is programmed to perform various operations of the system 100. In one or more examples, the computer 128 executes one or more software programs or applications. In one or more examples, the computer 128 includes a data processing system 900 (
In one or more examples, the system 100 includes a surface generator 102. In one or more examples, the system 100 includes a model generator 112. As will be described in more detail here, the surface generator 102 and/or the model generator 112 are used to design the double-contoured shim 200 having appropriate dimensions and geometry. In one or more examples, the surface generator 102 and/or the model generator 112 are implemented by the computer 128, such as in the form of data-processing modules, program code applications, application software, and the like, which are stored and executed using the data processing system 900.
For the purpose of the present disclosure, general reference to the computer 128 may, in some examples, refer to the data processing system 900, components of the data processing system 900, or data-processing modules and/or program code applications (e.g., the surface generator 102, the model generator 112, and the like) that are implemented or executed by the data processing system 900.
In one or more examples, the system 100 includes a manufacturing system 134. As will be described in more detail herein, the manufacturing system 134 is configured or adapted to fabricate or otherwise manufacture the double-contoured shim 200.
In one or more examples, the system 100 includes measurement system 136. As will be described in more detail herein, the measurement system 136 is configured or adapted to take measurements and/or generate the measurement data 180 used by the system 100, such as the computer 128, to generate the design geometry for the double-contoured shim 200.
In one or more examples, the computer 128 (e.g., the model generator 112) is programmed to generate a shim model 118. The shim model 118 is representative of the double-contoured shim 200. The shim model 118 is designed or generated such that the double-contoured shim 200 fabricated based on the shim model 118 includes an appropriate size, shape, and geometry to substantially fill the gap 210 between the first mating-surface 206 of the first component 202 and the second mating-surface 208 of the second component 204. The shim model 118 is designed or generated such that the double-contoured shim 200 fabricated based on the shim model 118 includes opposing surfaces having contours that mate with or substantially match contours of the first mating-surface 206 and the second mating-surface 208.
In one or more examples, the computer 128 (e.g., the model generator 112) is programmed to generate the virtual plane 142. The virtual plane 142 divides the shim model 118 into the first shim model 166 and the second shim model 168.
In one or more examples, the manufacturing system 134 fabricates the first shim 224. The first shim 224 is based on the first shim model 168. The first shim 224 includes the first contoured shim-surface 212 and the first planar shim-surface 232. The first contoured shim-surface 212 is complementary to or substantially matches at least a first portion, such as a first mating-surface area 216 as represented by a first virtual-surface portion 170, of the first mating-surface 206. The first planar shim-surface 232 is opposite the first contoured shim-surface 212.
In one or more examples, the manufacturing system 134 fabricates the second shim 226. The second shim 226 is based on the second shim model 168. The second shim 226 includes the second contoured shim-surface 214 and the second planar shim-surface 234. The second contoured shim-surface 214 is complementary to or substantially matches at least a second portion, such as a second mating-surface area 218 as represented by a second virtual-surface portion 172, of the second mating-surface 208. The second planar shim-surface 234 is opposite the second contoured shim-surface 214.
In one or more examples, the computer 128 (e.g., the model generator 112) is programmed to generate three-dimensional geometry data 114 for the space 116 between the first virtual mating-surface 158 and the second virtual mating-surface 160.
In one or more examples, the virtual plane 142 divides the space 116 into the first portion 162 and the second portion 164. The first shim model 166 substantially fills the first portion 162 of the space 116 between the virtual plane 142 and the first virtual mating-surface 158. The second shim model 168 substantially fills the second portion 164 of the space 116 between the virtual plane 142 and the second virtual mating-surface 160.
In one or more examples, the computer 128 (e.g., the surface generator 102) is programmed to align the first measurement data 104 of the first mating-surface 206 and the second measurement data 106 of the second mating-surface 208.
In one or more examples, the computer 128 (e.g., the surface generator 102) is programmed to generate the first virtual shim-surface 108 based on the three-dimensional geometry data 114, for example, from the first measurement data 104, that is fitted to, is complementary to, or that substantially matches the first virtual-surface portion 170 of the first virtual mating-surface 158. In one or more examples, the computer 128 (e.g., the surface generator 102) is programmed to generate the second virtual shim-surface 110 based on the three-dimensional geometry data 114, for example, from the second measurement data 106, that is fitted to, is complementary to, or that substantially matches the second virtual-surface portion 172 of the second virtual mating-surface 160.
In one or more examples, the computer 128 (e.g., the model generator 112) is programmed to generate (e.g., calculate or estimate) the first dimensions 146 of the first portion 162 of the space 116 between the first virtual shim-surface 108 and the virtual plane 142. In one or more examples, the computer 128 (e.g., the model generator 112) is programmed to generate (e.g., calculate or estimate) the second dimensions 148 of the second portion 164 of the space 116 between the second virtual shim-surface 110 and the virtual plane 142.
In one or more examples, the manufacturing system 134 fabricates the first shim 224 that includes the first thickness 228. The first thickness 228 varies as a function of the first dimensions 146. In one or more examples, the manufacturing system 134 fabricates the second shim 226 that includes the second thickness 230. The second thickness 230 varies as a function of the second dimensions 148.
In one or more examples, the computer 128 (e.g., the model generator 112) is programmed to generate a planar data set 144 that corresponds to the virtual plane 142. The planar data set 144 is an example of the third grid of points 190 generated on the virtual plane 142.
In one or more examples, the computer 128 (e.g., the model generator 112) is programmed to determine the first dimensions 146 between the planar data set 144 and the first virtual shim-surface 108, such as between the third grid of points 190 and the first grid of points 186, for use as the first thickness 228 of the first shim 224.
In one or more examples, the computer 128 (e.g., the model generator 112) is programmed to determine the second dimensions 148 between the planar data set 144 and the second virtual shim-surface 110, such as between the third grid of points 190 and the second grid of points 188, for use as the second thickness 230 of the second shim 226.
In one or more examples, the computer 128 (e.g., the model generator 112) is programmed to select the planar data set 144 at an approximately central location between the first virtual shim-surface 108 and the second virtual shim-surface 110. However, the virtual plane 142 and, thus, the planar data set 144 can be situated in non-central location as needed to satisfy a maximum or minimum thickness requirement for either of the first shim 224 and/or the second shim 226.
In one or more examples, the computer 128 (e.g., the model generator 112) determines the dimensions 120 of the space 116 between the first virtual shim-surface 108 and the second virtual shim-surface 110. The double-contoured shim 200 includes the thickness 220 that varies as a function of the dimensions 120 of the space 116.
In one or more examples, the computer 128 (e.g., the model generator 112) is programmed to determine the first virtual shim-surface contour 122 of the first virtual shim-surface 108. In one or more examples, the computer 128 (e.g., the model generator 112) is programmed to the second virtual shim-surface contour 124 of the second virtual shim-surface 110.
In one or more examples, the manufacturing system 134 fabricates the first contoured shim-surface 212 of the first shim 224 that includes the first shim-surface contour 238. The first shim-surface contour 238 varies as a function of the first virtual shim-surface contour 122.
In one or more examples, the manufacturing system 134 fabricates the second contoured shim-surface 214 of the second shim 226 that includes the second shim-surface contour 240. The second shim-surface contour 240 varies as a function of the second virtual shim-surface contour 124.
In one or more examples, the measurement system 136 generates the first measurement data 104. In one or more examples, the measurement system 136 generates the second measurement data 106. In one or more examples, the measurement system 136 is a metrology system. In one or more examples, the measurement system 136 includes one or more instances of the scanner 174 (e.g., a plurality of scanners) and/or one or more instances of the probe 176 (e.g., a plurality of probes).
In one or more examples, the shim model 118, such as the first shim model 166 and the second shim model 168, are based on the measurement data 180 collected by the measurement system 136 from the components to be shimmed. In one or more examples, the measurement system 136 includes an optical 3D coordinate measuring machine that is configured to measure (e.g., in its own frame of reference) 3D coordinates of optically reflective elements in its field of view and then store a high-density point cloud representing the scanned surface. In one or more examples, the measurement system 136 includes a plurality of scanners and/or probes that are used to acquire positional data (e.g., X,Y,Z-coordinate data) that can be used to compute the locations surfaces of the components in the frame of reference of the 3D coordinate measuring machine. In one or more examples, a control computer (e.g., the computer 128) is configured to receive point cloud data from the optical 3D coordinate measuring machine and also receive commands and data input by a system operator via a user interface. In one or more examples, the computer 128 is configured (e.g., programmed) to perform at least some of the steps identified in the method 1000 (
In one or more examples, the computer 128 (e.g., the surface generator 102) is programmed to align the first measurement data 104 with first nominal-location data 138 and aligns the second measurement data 106 with second nominal-location data 140. In one or more examples, the first nominal-location data 138 and the second nominal-location data 140 are in the form of the engineering model that specifies the locations of the first component 202 and the second component 204 in the final assembly of the structure 236.
In one or more examples, the computer 128 (e.g., the surface generator 102) is programmed to select a first data set 130 of the first measurement data 104 that corresponds to the first mating-surface area 216 of the first mating-surface 206. The first data set 130 is used to generate at least one of the first virtual mating-surface 158 and/or the first virtual shim-surface 108. In one or more examples, the first data set 130 is an example of the first grid of points 186.
In one or more examples, the computer 128 (e.g., the surface generator 102) is programmed to select a second data set 132 of the second measurement data 106 that corresponds to the second mating-surface area 218 of the second mating-surface 208. The second data set 132 is used to generate at least one of the second virtual mating-surface 160 and/or the second virtual shim-surface 110. In one or more examples, the second data set 132 is an example of the second grid of points 188.
In one or more examples, the manufacturing system 134 includes or takes the form of a subtractive manufacturing system 156. Examples of the subtractive manufacturing system 156 include machines configured for lathe-turning, milling, drilling, boring, sawing, grinding, sanding, routing, and any other appropriate machining process that involves shaping a workpiece by removing material.
In one or more examples, the manufacturing system 134 includes or takes the form of an additive manufacturing system 154. Examples of the additive manufacturing system 154 include machines configured for material extrusion, binder jetting, material jetting, directed energy deposition, powder bed fusion, and any other one or more of various processes in which material is deposited, joined, or solidified under computer control, with material being added together, typically layer-by-layer, and construction of the three-dimensional object being based from a CAD model or a digital 3D model.
In either of the above examples, the first contoured shim-surface 212 of the first shim 224 is the machined side of the first shim 224 for mating with the first mating-surface 206 of the first component 202 and the first planar shim-surface 232 is the flat side of the first shim 224 for joining to the second shim 226. The second contoured shim-surface 214 of the second shim 226 is the machined side of the second shim 226 for mating with the second mating-surface 208 of the second component 204 and the second planar shim-surface 234 is the flat side of the second shim 226 for joining to the second shim 226.
In one or more examples, the manufacturing system 134 manufactures the double-contoured shim 200 as two filler members, such as the first shim 224 and the second shim 226. The first shim 224 includes the first thickness 228, the first contoured shim-surface 212, and the first planar shim-surface 232 that is opposite the first contoured shim-surface 212. The second shim 226 includes the second thickness 230, the second contoured shim-surface 214, and the second planar shim-surface 234 that is opposite the second contoured shim-surface 214.
In one or more examples, the manufacturing system 134 couples the first shim 224 and the second shim 226 together along the first planar shim-surface 232 and the second planar shim-surface 234. In one or more examples, the manufacturing system 134 applies an adhesive to at least one of the first planar shim-surface 232 and the second planar shim-surface 234 to couple the first shim 224 and the second shim 226 together.
In an alternate example, the manufacturing system 134, such as the additive manufacturing system 154, manufactures the double-contoured shim 200 as a single filler member. The single filler member of the double-contoured shim 200 includes the thickness 220, the first contoured shim-surface 212 including the first shim-surface contour 238, and the second contoured shim-surface 214 including the second shim-surface contour 240.
Referring now to
In one or more examples, the method 1000 includes a step of (block 1002) measuring the first mating-surface 206 of the first component 202. In one or more examples, measurements of the first mating-surface 206 are taken and the measurement data 180 is generated using the measurement system 136. In one or more examples, the method 1000 includes a step of (block 1004) measuring the second mating-surface 208 of the second component 204. In one or more examples, measurements of the second mating-surface 208 are taken and the measurement data 180 is generated using the measurement system 136.
In one or more examples, the method 1000 includes a step of (block 1006) generating the first measurement data 104. In one or more examples, the first measurement data 104 is taken from the measurement data 180 and/or is generated based on the measurements of the first mating-surface 206 using the measurement system 136 and/or the computer 128. In one or more examples, the method 1000 includes a step of (block 1008) generating the second measurement data 106. In one or more examples, the second measurement data 106 is taken from the measurement data 180 and/or is generated based on the measurements of the second mating-surface 208 using the measurement system 136 and/or the computer 128.
In one or more examples, the method 1000 includes a step of (block 1010) aligning the first measurement data 104 of the first mating-surface 206 and the second measurement data 106 of the second mating-surface 208. In an example, the step of (block 1010) aligning includes a step of (block 1012) aligning the first measurement data 104 with the first nominal-location data 138, for example, as represented by an engineering or nominal model of the first component 202 in the fully assembled condition. In one or more examples, the step of (block 1010) aligning includes a step of (block 1014) aligning the second measurement data 106 with second nominal-location data 140. for example, as represented by an engineering or nominal model of the first component 202 in the fully assembled condition.
In one or more examples, the method 1000 includes a step of (block 1016) filtering the measurement data 180. As an example, the measurement data 180 is filtered, trimmed, or is otherwise reduced for more efficient and accurate data processing results. In one or more examples, the measurement data 180, such as the first measurement data 104 and the second measurement data 106, are filtered and/or trimmed after alignment (e.g., block 1010).
In one or more examples, the method 1000 includes a step of (block 1018) generating the three-dimensional geometry data 114. In one or more examples, the three-dimensional geometry data 114 is representative of the space 116 between the first virtual mating-surface 158 and the second virtual mating-surface 160. In one or more examples, the three-dimensional geometry data 114 is representative of the shim model 118 that fills the space 116 between the first virtual mating-surface 158 and the second virtual mating-surface 160.
In one or more examples, the method 1000 includes a step of (block 1020) generating the shim model 118. In one or more examples, the shim model 118 is generated using the three-dimensional geometry data 114. However, the shim model 118 can be generated in any one of various techniques, such as using a predictive shimming process. While certain illustrative example techniques are described herein, other three-dimensional modelling and/or data processing techniques can be used to determine the three-dimensional geometry of the space 116 between the first virtual mating-surface 158 and the second virtual mating-surface 160, the first virtual shim-surface contour 122 of the first virtual shim-surface 108, the second virtual shim-surface contour 124 of the second virtual shim-surface 110, the dimensions 120 between such surfaces, and the like. The shim model 118 is a digital representation of the double-contoured shim 200 needed to substantially fill the space 116 between the first virtual mating-surface 158 and the second virtual mating-surface 160 of the first virtual component 182 and the second virtual component 184 after alignment (e.g., block 1010). The shim model 118 is designed or generated such that the double-contoured shim 200 fabricated based on the shim model 118 includes an appropriate size, shape, and geometry to substantially fill the gap 210 between the first mating-surface 206 of the first component 202 and the second mating-surface 208 of the second component 204 when the structure 236 is fully assembled. The shim model 118 is designed or generated such that the double-contoured shim 200 fabricated based on the shim model 118 includes opposing surfaces having contours that mate with or substantially match contours of the first mating-surface 206 and the second mating-surface 208.
In one or more examples, the method 1000 includes a step of (block 1022) generating the virtual plane 142. In one or more examples, according to the method 1000, the virtual plane 142 divides the shim model 118 into the first shim model 166 and the second shim model 168. In one or more examples, according to the method 1000, the virtual plane 142 divides the space 116 into the first portion 162 and the second portion 164. In these examples, the first shim model 166 substantially fills the first portion 162 of the space 116 between the virtual plane 142 and the first virtual mating-surface 158. The second shim model 168 substantially fills the second portion 164 of the space 116 between the virtual plane 142 and the second virtual mating-surface 160.
In one or more examples, the method 1000, such as the step of (block 1022) generating the virtual plane 142, includes a step of generating the planar data set 144 that corresponds to the virtual plane 142. As an example, the planar data set 144 is representative of the third grid of points 190 generated on the virtual plane 142. In one or more examples, the first dimensions 146 are generated (e.g., block 1026) between the planar data set 144 and the first virtual shim-surface 108 and are used as or to represent the first thickness 228 of the first shim 224. Similarly, the second dimensions 148 are generated (e.g., block 1028) between the planar data set 144 and the second virtual shim-surface 110 and are used as or to represent the second thickness 230 of the second shim 226.
In one or more examples, the method 1000 includes a step of selecting the planar data set 144 at an approximately central location between the first virtual shim-surface 108 and the second virtual shim-surface 110.
In one or more examples, the method 1000 includes a step of (block 1024) generating the first virtual shim-surface 108. In one or more examples, the first virtual shim-surface 108 is generated from the first measurement data 104. The first virtual shim-surface 108 is complementary to or substantially matches the first virtual-surface portion 170 of the first virtual mating-surface 158. In one or more examples, the method 1000 includes a step of (block 1026) generating the second virtual shim-surface 110. In one or more examples, the second virtual shim-surface 110 is generated from the second measurement data 106. The second virtual shim-surface 110 is complementary to or substantially matches the second virtual-surface portion 172 of the second virtual mating-surface 160.
In one or more examples, the method 1000 includes a step of determining the first virtual shim-surface contour 122 of the first virtual shim-surface 108. In one or more examples, the method 1000 includes a step of determining the second virtual shim-surface contour 124 of the second virtual shim-surface 110. In one or more examples, the method 1000 includes a step of selecting the first data set 130 of the first measurement data 104 that corresponds to the first mating-surface area 216 of the first mating-surface 206 to generate the first virtual shim-surface 108 and/or to determine the first virtual shim-surface contour 122 of the first virtual shim-surface 108. In one or more examples, the method 1000 includes a step of selecting the second data set 132 of the second measurement data 106 that corresponds to the second mating-surface area 218 of the second mating-surface 208 to generate the second virtual shim-surface 110 and/or to determine the first virtual shim-surface contour 122 of the first virtual shim-surface 108.
In one or more examples, the method 1000 includes a step of (block 1028) generating the first dimensions 146. The first dimensions 146 are representative of the geometry of the dimensions of the first portion 162 of the space 116 between the first virtual shim-surface 108 and the virtual plane 142. In one or more examples, the method 1000 includes a step of (block 1030) generating the second dimensions 148. The second dimensions 148 are representative of the second portion 164 of the space 116 between the second virtual shim-surface 110 and the virtual plane 142.
In one or more examples, the method 1000 includes a step of (block 1032) manufacturing the double-contoured shim 200. In one or more examples, according to the method 1000, the step of (block 1032) manufacturing the double-contoured shim 200 includes subtractively manufacturing the double-contoured shim 200. In one or more examples, according to the method 1000, the step of (block 1032) manufacturing the double-contoured shim 200 includes additively manufacturing the double-contoured shim 200.
In one or more examples, according to the method 1000, the step of (block 1032) manufacturing includes a step of (block 1034) fabricating the first shim 224. The first shim 224 is fabricated based on the first shim model 168. The first shim 224 includes the first contoured shim-surface 212. The first contoured shim-surface 212 is complementary to or substantially matches the first mating-surface area 216 of the first mating-surface 206. The first shim 224 also includes the first planar shim-surface 232. The first planar shim-surface 232 is opposite the first contoured shim-surface 212.
In one or more examples, according to the method 1000, the step of (block 1032) manufacturing includes a step of (block 1036) fabricating the second shim 226. The second shim 226 is fabricated based on the second shim model 168. The second shim 226 includes the second contoured shim-surface 214. The second contoured shim-surface 214 is complementary to or substantially matches the second mating-surface area 218 of the second mating-surface 208. The second shim 226 also includes the second planar shim-surface 234. The second planar shim-surface 234 is opposite the second contoured shim-surface 214.
In one or more examples, according to the method 1000, the first shim 224 is fabricated to include the first thickness 228. The first thickness 228 varies as a function of the first dimensions 146. In one or more examples, according to the method 1000, the second shim 226 is fabricated to include the second thickness 230. The second thickness 230 varies as a function of the second dimensions 148.
In one or more examples, according to the method 1000, the first shim 224 is fabricated to include the first contoured shim-surface 212 of the first shim 224 and the first planar shim-surface 232. The first contoured shim-surface 212 includes the first shim-surface contour 238. The first shim-surface contour varies as a function of the first virtual shim-surface contour 122. In one or more examples, according to the method 1000, the second shim 226 is fabricated to include the second contoured shim-surface 214 and the second planar shim-surface 234. The second contoured shim-surface 214 includes the second shim-surface contour 240. The second shim-surface contour 240 varies as a function of the second virtual shim-surface contour 124.
In one or more examples, according to the method 1000, the first shim 224 and/or the second shim 226 can be additively manufactured. In one or more examples, according to the method 1000, the first shim 224 and/or the second shim 226 can be substractively manufactured.
In one or more examples, according to the method 1000, the step of (block 1032) manufacturing includes a step of (block 1038) coupling the first shim 224 and the second shim 226 together. The first shim 224 and the second shim 226 are coupled together along the first planar shim-surface 232 and the second planar shim-surface 234. In one or more examples, according to the method 1000, the step of (block 1032) coupling the first shim 224 and the second shim 226 together, includes a step of adhesively bonding the first planar shim-surface 232 and the second planar shim-surface 234 together.
In one or more examples, the method 1000 includes a step of determining a minimum allowable dimension 150 for each one of the first dimensions 146 of the first shim 224 and the second dimensions 148 of the second shim 226. In one or more examples, the method 1000 includes a step of determining a maximum allowable dimension 152 for each one of the first dimensions 146 of the first shim 224 and/or the second dimensions 148 of the second shim 226. In one or more examples, the location of the virtual plane 142 between and relative to the first virtual mating-surface 158 and the second virtual mating-surface 160 and/or between and relative to the first virtual shim-surface 108 and the second virtual shim-surface 110 can be selected and/or adjusted based on the maximum allowable dimension 152 and the minimum allowable dimension 150.
Referring now to
In one or more examples, the method 2000 includes a step of (block 2002) manufacturing the double-contoured shim 200. In one or more examples, the step of (block 2002) manufacturing includes designing and fabricating the double-contoured shim 200 according to the method 1000 and/or using the system 100. Any number of the double-contoured shim 200 can be fabricated depending on and corresponding to the number of instances of the gap 210 between the first mating-surface 206 of the first component 202 and the second mating-surface 208 of the second component 204. In one or more examples, the method 2000 includes a step of (block 2004) installing the double-contoured shim 200 in the gap 210 between the first mating-surface 206 of the first component 202 and the second mating-surface 208 of the second component 204. In one or more examples, the method 2000 includes a step of (block 2006) assembling the first component 202, the second component 204, and the double-contoured shim 200 to form the finally assembled structure 236.
Referring now to
In one or more examples, the double-contoured shim 200 includes the first shim 224 and the second shim 226. The first shim 224 includes the first thickness 228, the first contoured shim-surface 212, and the first planar shim-surface 232. The first contoured shim-surface 212 is complementary to or substantially matches a first mating-surface contour 242 of the first mating-surface 206 of the first component 202. The first planar shim-surface 232 is opposite the first contoured shim-surface 212. The second shim 226 includes the second thickness 230, the second contoured shim-surface 214, and the second planar shim-surface 234. The second contoured shim-surface 214 is complementary to or substantially matches a second mating-surface contour 244 of the second mating-surface 208 of the second component 204. The second planar shim-surface 234 is opposite the second contoured shim-surface 214. The first shim 224 and the second shim 226 are coupled together along the first planar shim-surface 232 and the second planar shim-surface 234.
Accordingly, in one or more examples, the double-contoured shim 200 includes the first contoured shim-surface 212 and the second contoured shim-surface 214. The second contoured shim-surface 214 is opposite the first contoured shim-surface 212. The double-contoured shim 200 has a thickness 220. The thickness 220 includes the first thickness 228 and the second thickness 230. The first contoured shim-surface 212 is complementary to or substantially matches the first mating-surface contour 242 of the first mating-surface area 216 of the first mating-surface 206. The second contoured shim-surface 214 is complementary to or substantially matches the second mating-surface contour 244 of the second mating-surface area 218 of the second mating-surface 208.
In the illustrative examples, the double-contoured shim 200 is fabricated as two, discrete filler members (e.g., the first shim 224 and the second shim 226) that are coupled together. However, in other examples, the double-contoured shim 200 can be fabricated as a single, unitary filler member. In these examples, the double-contoured shim 200 is fabricated based on the shim model 118 and includes the thickness 220, the first contoured shim-surface 212, and the second contoured shim-surface 214 opposite the first contoured shim-surface 212. For example, the double-contoured shim 200 that includes the thickness 220, the first contoured shim-surface 212, and the second contoured shim-surface 214 can be manufactured as a single, unitary filler member using any one of various additive manufacturing techniques or processes.
Referring now to
In one or more examples, the data processing system 900 is used to implement the system 100. For example, the data processing system 900 may be used to implement computer 128 (
In one or more examples, the data processing system 900 includes a communications framework 902, which provides communications between the processor 904, storage devices 916, a communications unit 910, an input/output unit 912, and a display 914. In some cases, the communications framework 902 is implemented as a bus system.
In one or more examples, the processor 904 is configured to execute instructions for software to perform a number of operations. The processor 904 includes at least one of a number of processors, a multi-processor core, or some other type of processor, depending on the implementation. In some examples, the processor 904 takes the form of a hardware unit, such as a circuit system, an application specific integrated circuit (ASIC), a programmable logic device, or some other suitable type of hardware unit.
In one or more examples, instructions for the operating system, applications, and programs run by the processor 904 are located in the storage devices 916. The storage devices 916 are in communication with the processor 904 through the communications framework 902. As used herein, a storage device, also referred to as a computer-readable storage device, is any piece of hardware capable of storing information on a temporary basis, a permanent basis, or both. This information may include, but is not limited to, data, program code, other information, or some combination thereof.
The memory 906 and persistent storage 908 are examples of the storage devices 916. In one or more examples, the memory 906 takes the form of, for example, a random-access memory or some type of volatile or non-volatile storage device. In one or more examples, the persistent storage 908 includes any number of components or devices. For example, the persistent storage 908 includes a hard drive, a flash memory, a rewritable optical disk, a rewritable magnetic tape, or some combination of the above. The media used by the persistent storage 908 may or may not be removable.
The communications unit 910 allows the data processing system 900 to communicate with other data processing systems, devices, or both. The communications unit 910 may provide communications using physical communications links, wireless communications links, or both.
The input/output unit 912 allows input to be received from and output to be sent to other devices connected to the data processing system 900. For example, the input/output unit 912 may allow user input to be received through a keyboard, a mouse, some other type of input device, or a combination thereof. As another example, the input/output unit 912 may allow output to be sent to a printer connected to the data processing system 900.
The display 914 is configured to display information to a user. The display 914 may include, for example, without limitation, a monitor, a touch screen, a laser display, a holographic display, a virtual display device, some other type of display device, or a combination thereof.
In this illustrative example, the processes of the different illustrative embodiments may be performed by the processor 904 using computer-implemented instructions. These instructions may be referred to as program code, computer-usable program code, or computer-readable program code and may be read and executed by one or more processors in the processor 904.
In these examples, program code 918 is located in a functional form on computer-readable media 920, which is selectively removable, and may be loaded onto or transferred to the data processing system 900 for execution by the processor 904. The program code 918 and the computer-readable media 920 together form the computer program product 922. In this illustrative example, the computer-readable media 920 may be computer-readable storage media 924 or computer-readable signal media.
In one or more examples, the computer-readable storage media 924 is a physical or tangible storage device used to store the program code 918 rather than a medium that propagates or transmits the program code 918. The computer-readable storage media 924 may be, for example, without limitation, an optical or magnetic disk or a persistent storage device that is connected to the data processing system 900.
Alternatively, the program code 918 may be transferred to the data processing system 900 using computer-readable signal media. The computer-readable signal media may be, for example, a propagated data signal containing the program code 918. This data signal may be an electromagnetic signal, an optical signal, or some other type of signal that can be transmitted over physical communications links, wireless communications links, or both.
The illustration of the data processing system 900 in
Referring now to
Referring to
Referring to
Each of the processes of the manufacturing and service method 1100 illustrated in
Examples of the system 100, the method 1000, the method 2000, and the double-contoured shim 200 shown and described herein, may be employed during any one or more of the stages of the manufacturing and service method 1100 shown in the flow diagram illustrated by
The preceding detailed description refers to the accompanying drawings, which illustrate specific examples described by the present disclosure. Other examples having different structures and operations do not depart from the scope of the present disclosure. Like reference numerals may refer to the same feature, element, or component in the different drawings. Throughout the present disclosure, any one of a plurality of items may be referred to individually as the item and a plurality of items may be referred to collectively as the items and may be referred to with like reference numerals. Moreover, as used herein, a feature, element, component, or step preceded with the word “a” or “an” should be understood as not excluding a plurality of features, elements, components, or steps, unless such exclusion is explicitly recited.
Illustrative, non-exhaustive examples, which may be, but are not necessarily, claimed, of the subject matter according to the present disclosure are provided above. Reference herein to “example” means that one or more feature, structure, element, component, characteristic, and/or operational step described in connection with the example is included in at least one aspect, embodiment, and/or implementation of the subject matter according to the present disclosure. Thus, the phrases “an example,” “another example,” “one or more examples,” and similar language throughout the present disclosure may, but do not necessarily, refer to the same example. Further, the subject matter characterizing any one example may, but does not necessarily, include the subject matter characterizing any other example. Moreover, the subject matter characterizing any one example may be, but is not necessarily, combined with the subject matter characterizing any other example.
As used herein, a system, apparatus, device, structure, article, element, component, or hardware “configured to” perform a specified function is indeed capable of performing the specified function without any alteration, rather than merely having potential to perform the specified function after further modification. In other words, the system, apparatus, device, structure, article, element, component, or hardware “configured to” perform a specified function is specifically selected, created, implemented, utilized, programmed, and/or designed for the purpose of performing the specified function. As used herein, “configured to” denotes existing characteristics of a system, apparatus, structure, article, element, component, or hardware that enable the system, apparatus, structure, article, element, component, or hardware to perform the specified function without further modification. For purposes of this disclosure, a system, apparatus, device, structure, article, element, component, or hardware described as being “configured to” perform a particular function may additionally or alternatively be described as being “adapted to” and/or as being “operative to” perform that function.
Unless otherwise indicated, the terms “first,” “second,” “third,” etc. are used herein merely as labels, and are not intended to impose ordinal, positional, or hierarchical requirements on the items to which these terms refer. Moreover, reference to, e.g., a “second” item does not require or preclude the existence of, e.g., a “first” or lower-numbered item, and/or, e.g., a “third” or higher-numbered item.
As used herein, the phrase “at least one of”, when used with a list of items, means different combinations of one or more of the listed items may be used and only one of each item in the list may be needed. For example, “at least one of item A, item B, and item C” may include, without limitation, item A or item A and item B. This example also may include item A, item B, and item C, or item B and item C. In other examples, “at least one of”' may be, for example, without limitation, two of item A, one of item B, and ten of item C; four of item B and seven of item C; and other suitable combinations. As used herein, the term “and/or” and the “/” symbol includes any and all combinations of one or more of the associated listed items.
For the purpose of this disclosure, the terms “coupled,” “coupling,” and similar terms refer to two or more elements that are joined, linked, fastened, attached, connected, put in communication, or otherwise associated (e.g., mechanically, electrically, fluidly, optically, electromagnetically) with one another. In various examples, the elements may be associated directly or indirectly. As an example, element A may be directly associated with element B. As another example, clement A may be indirectly associated with element B, for example, via another element C. It will be understood that not all associations among the various disclosed elements are necessarily represented. Accordingly, couplings other than those depicted in the figures may also exist.
As used herein, the term “approximately” refers to or represents a condition that is close to, but not exactly, the stated condition that still performs the desired function or achieves the desired result. As an example, the term “approximately” refers to a condition that is within an acceptable predetermined tolerance or accuracy, such as to a condition that is within 10% of the stated condition. However, the term “approximately” does not exclude a condition that is exactly the stated condition. As used herein, the term “substantially” refers to a condition that is essentially the stated condition that performs the desired function or achieves the desired result.
In
Further, references throughout the present specification to features, advantages, or similar language used herein do not imply that all of the features and advantages that may be realized with the examples disclosed herein should be, or are in, any single example. Rather, language referring to the features and advantages is understood to mean that a specific feature, advantage, or characteristic described in connection with an example is included in at least one example. Thus, discussion of features, advantages, and similar language used throughout the present disclosure may, but do not necessarily, refer to the same example.
The described features, advantages, and characteristics of one example may be combined in any suitable manner in one or more other examples. One skilled in the relevant art will recognize that the examples described herein may be practiced without one or more of the specific features or advantages of a particular example. In other instances, additional features and advantages may be recognized in certain examples that may not be present in all examples. Furthermore, although various examples of the system 100, the method 1000, the double-contoured shim 200, and the method 2000 have been shown and described, modifications may occur to those skilled in the art upon reading the specification. The present application includes such modifications and is limited only by the scope of the claims.
