US 2018/0067476 A1 · PREDICTIVE SHIMMING OF JOINTS

Abstract

A method and a system are provided for predicting and creating a shim for use in a joint where two parts, such as a skin and a substructure, are assembled together. Digital models for the skin and the substructure may be used as nominal maps of the outlines and profiles of the parts. The skin may be inspected, e.g., by nondestructive means, such as ultrasound, to determine as-built thickness profile for comparison to the skin's digital model of the thickness profile. Mating areas of the skin and substructure may be determined from their digital models of their outlines. Deviations in the mating areas of the as-built thickness of the skin from the digital model of the skin may be used to generate a digital model of a shim. The shim may be constructed from its digital model by additive manufacturing techniques that may involving machining or 3D printing.

Claims20

Dependent claims

A method for creating a shim for use in mounting a skin to a substructure, the skin defining an inner surface, an outer surface opposite the inner surface, and a skin thickness between the inner and outer surfaces, the substructure defining a mating surface for the skin, wherein a digital model associated with the skin includes a nominal map of the skin thickness, the shim to be configured to fill any gaps greater than a design allowance in a mating area between the inner surface of the skin and the substructure, the method comprising the steps of:

a. nondestructively inspecting the skin at a plurality of locations of at least one of the skin inner and outer surfaces to gather a data set relating to the skin thickness;
b. calculating, using the data set, a set of as-built thickness values for the skin for at least a portion of the plurality of locations;
c. determining the mating area of the inner surface of the skin with the mating surface of the substructure;
and
d. generating a set of shim dimension data by calculating in the mating area of the inner surface of the skin a set of deviations greater than the design allowance of the set of as-built thickness values from the nominal map of the skin thickness.

2 more elements

A method for making a shim for use in mounting a first part to a second part, wherein at least one of the first part and the second part defines a first designed thickness profile, the method arranged to construct the shim with an outline and a profile customized to fill a gap greater than a design allowance between the first part and the second part, the method comprising the steps of:

a. nondestructively inspecting at least one of the first part and the second part to gather a data set;
b. calculating, using the data set, an as-built thickness profile of at least a portion of at least one of the first part and the second part;
c. virtually overlaying the first part on the second part to determine a mating area of the first part with the second part;
d. calculating in the mating area for at least one of the first part and the second part a set of deviations greater than a design allowance of the as-built thickness profile from the designed thickness profile;
and
e. constructing the shim to have the outline and profile to match the set of deviations in the mating area.

3 more elements

A system for creating a shim for use in assembling a first part defining a first mating surface to a second part defining a second mating surface, wherein a first digital model, including a first nominal map in two horizontal dimensions and in a thickness dimension, is associated with the first part, and wherein a second digital model, including a second nominal map in two horizontal dimensions, is associated with the second part, the shim to be configured with an outline and a profile customized to fill a gap greater than a design allowance between the mating surfaces of the first part and the second part, the system comprising:

a. a nondestructive inspection system configured to inspect the first part to gather a data set relating to the first part;
b. a computer coupled to the nondestructive inspection system and configured to receive the data set relating to the first part and to store the first nominal map of the first part, the second nominal map of the second part, and the design allowance, the computer including a processing element configured to calculate, from the data set relating to the first part, an as-built thickness profile for at least a portion of the first part, and to virtually overlay the first nominal map of the first part on the second nominal map of the second part to determine a mating area of the first part and the second part, and to generate in the mating area a set of shim dimension data by calculating a set of deviations greater than the design allowance of the as-built thickness profile of the first part from the nominal map of the first part.

Dependencies are inferred from the claim text.

Predictive shimming of joints

Life of this patent

Predictive shimming of joints

Life of this patent

Abstract

Claims20