CN118057387A

CN118057387A - System and method for predictive assembly

Info

Publication number: CN118057387A
Application number: CN202311381921.2A
Authority: CN
Inventors: B·雷尼森; P·L·弗里曼; C·C·拉扎尔; C·M·斯穆特
Original assignee: Boeing Co
Current assignee: Boeing Co
Priority date: 2022-11-18
Filing date: 2023-10-23
Publication date: 2024-05-21

Abstract

The application relates to a system and a method for predictive assembly. A computer-implemented system for predictive assembly includes a model generator and a model analyzer. The model generator generates a first model of the first component and a second model of the second component before the first component and the second component are coupled together. The model analyzer analyzes the first model and the second model to determine a size of a space between the first mating surface of the first component and the second mating surface of the second component after the first component and the second component are coupled together.

Description

System and method for predictive assembly

Priority

The present application claims priority from U.S. application Ser. No.63/384,257, filed 11/18 of 2022.

Technical Field

The present disclosure relates generally to predictive assembly, and more particularly, to systems and methods for predictive assembly using machined surfaces or filler materials (such as shims).

Background

During manufacture of the object, the various surfaces mate when the components are coupled together. In some cases, there are one or more gaps between the mating surfaces. It may be desirable to substantially fill these gaps with filler material. The process of filling these gaps with filler material (such as shims) is commonly referred to as "shimming" or "repair". Conventional shimming methods include mating surfaces, measuring the gap between the mating surfaces, and making shims based on the gap measurement. Predictive assembly is the process of predicting the filler material required to fill the gap between mating surfaces. For example, the surface geometry of the component is measured, the geometry information is used to determine the size of the gap that will exist between the mating surfaces, and the filler material is made based on the determined size. However, conventional predictive assembly methods may not adequately predict the size of the gap between mating surfaces, such as when one or more of the components has a geometry that is different from the geometry after it is coupled to another component during measurement. Accordingly, those skilled in the art continue to conduct research and development efforts in the field of predictive assembly.

Disclosure of Invention

Examples of a system for predicting assembly, a method for predicting assembly, a computer program product for predicting assembly, and a method for determining size of a filler and/or making a filler are disclosed. The following is a non-exhaustive list of examples that may or may not be claimed in accordance with the present disclosure.

In an example, the disclosed system includes a model generator that generates a first model of a first component and a second model of a second component before the first component and the second component are coupled together. The system also includes a model analyzer that analyzes the first model and the second model to determine a size of a space between the first mating surface of the first component and the second mating surface of the second component after the first component and the second component are coupled together.

In an example, the disclosed method is performed using an example of the disclosed system.

In an example, the disclosed method includes the steps of: (1) Generating a first model of the first component and a second model of the second component before the first component and the second component are coupled together; and (2) analyzing the first model and the second model to determine a size of a space between the first mating surface of the first component and the second mating surface of the second component after the first component and the second component are coupled together.

In an example, the disclosed system implements the disclosed method.

In an example, a filler is made according to the disclosed methods.

In an example, a portion of an aircraft is fabricated according to the disclosed methods, the portion including a filler.

In an example, the disclosed computer program product includes a non-transitory computer-readable medium including program code that, when executed by one or more processors, causes the one or more processors to perform operations comprising: (1) Generating a first model of the first component from the first data before the first component is coupled to the second component; (2) Generating a second model of the second component from the second data before the second component is coupled to the first component; and (3) analyzing the first model and the second model to determine a size of a space between the first mating surface of the first component and the second mating surface of the second component after the first component and the second component are coupled together.

In an example, the disclosed method includes the steps of: (1) Generating a first model of the first component and a second model of the second component before the first component and the second component are coupled together; (2) Filtering out deformation of at least one of the first and second components before the first and second components are coupled together; and (3) sizing a filler that fits between the first mating surface of the first component and the second mating surface of the second component after the first component and the second component are coupled together.

Other examples of the disclosed systems, methods, and computer program products will become apparent from the following detailed description, the accompanying drawings, and the appended claims.

Drawings

FIG. 1 is a schematic block diagram of an example of a manufacturing environment;

FIG. 2 is a schematic block diagram of an example of an analysis environment;

FIG. 3 is a schematic illustration of an example of an aircraft;

FIG. 4 is a schematic diagram of an example of a portion of an object manufactured by joining components;

FIG. 5 is a graphical illustration of an example of a first model representing a first component and a portion of a second model representing a second component;

FIG. 6 is a graphical illustration of an example of a first model representing a first component and a portion of a second model representing a second component;

FIG. 7 is a graphical illustration of an example of a modified nominal model representing a first component and a portion of a second model representing a second component;

FIG. 8 is a graphical illustration of an example of the overall offset between the first model and the nominal model in an XYZ coordinate system;

FIG. 9 is a graphical illustration of an example of the overall deviation between the first model and the nominal model in the UVW coordinate system;

FIG. 10 is a graphical illustration of an example of formal deviation between a first model and a nominal model in a UVW coordinate system;

FIG. 11 is a graphical illustration of an example of ripple deviation between a first model and a nominal model in a UVW coordinate system;

FIG. 12 is a graphical illustration of an example of ripple offset between a first model and a nominal model in an XYZ coordinate system;

FIG. 13 is a flow chart of an example of a method for predictive assembly;

FIG. 14 is a flow chart of an example of a method for determining the size of a filler;

FIG. 15 is a block diagram of an example of a data processing system;

FIG. 16 is a flow chart of an example of an aircraft manufacturing method; and

Fig. 17 is a schematic block diagram of an example of an aircraft.

Detailed Description

Referring generally to fig. 1-15, as an example, the present disclosure relates to systems and methods for predictive assembly or predictive shimming. More particularly, the systems and methods relate to active predictive assembly or active predictive shimming, which for purposes of this disclosure refers to an improvement in the method of predictive assembly or shimming by which pre-assembly deformation of components is removed and the shape of the gap between the mating surfaces after assembly can be predicted so that a filler can be made to substantially fill the gap. As an example, the pre-assembled deformation of the component is a "filtered out portion" of the three-dimensional (3D) measurement data of the component, thereby enabling the 3D measurement data to be used to actively predict the size of filler needed to fill the gap between the mating surfaces of the joined components.

The present disclosure recognizes that conventional manual caulking methods may not accurately capture variations in the surface of the joined components. The present disclosure also recognizes that it is desirable to have a system and method for predicting the shape of a filler member or gasket required to fill a gap between two surfaces that have been mated, wherein at least one of these surfaces exhibits a degree of deformation. Furthermore, conventional predictive assembly methods or predictive shimming methods may not adequately account for deformation of the component when measured, resulting in an excessively thick shim. The disclosed systems and methods use data filtering (such as a robust gaussian area regression filter) on 3D measurement data representing a component to robustly filter out deformations of the component while preserving corrugations (e.g., peaks and valleys) of mating surfaces associated with gap filling or shimming. The shape representing the corrugations is compensated (offset) to produce a minimum thickness filling that is made prior to assembly of the components. The filler accurately fills local variations between the two components and substantially reduces the need for additional filler material or caulking to fill all gaps between adjacent structures.

Referring to FIG. 1, an example of a manufacturing environment 172 is illustrated. The manufacturing environment 172 is an example of a manufacturing environment in which the object 180 is manufactured.

Referring to fig. 1, in one or more examples, the object 180 includes at least the first component 106 and the second component 110 or is manufactured using at least the first component 106 and the second component 110. In various other examples, any number of other components may also be used to form or fabricate object 180. The first component 106 includes a first mating surface 118 and the second component 110 includes a second mating surface 120. As used herein, "surface" refers to a continuous surface or a discontinuous surface formed from a plurality of surfaces.

Referring to fig. 1, in one or more examples, the first component 106 and the second component 110 are joined, attached, or otherwise coupled together such that the first mating surface 118 mates with the second mating surface 120. For example, the first component 106 and the second component 110 are joined using any suitable joining process 194, and thus the first mating surface 118 mates with the second mating surface 120.

Referring to fig. 1, in one or more examples, the joining process 194 includes any number of operations configured to physically attach the first component 106 and the second component 110 such that the first mating surface 118 mates with the second mating surface 120. For example, but not limited to, the joining process 194 may include at least one of securing, bonding, installing, welding, fastening, pinning, stitching, stapling, tying, gluing, or otherwise coupling the first component 106 and the second component 110 together.

Referring to fig. 1, in one or more examples, the first component 106 and the second component 110 are made of any suitable material or combination of materials. In one or more examples, the first component 106 and the second component 110 are made of the same material. In one or more examples, the first component 106 and the second component 110 are made of different materials. For example, and without limitation, the first and second components 106, 110 may be made of a metallic material, a composite material, a polymeric material, combinations thereof, and the like.

Referring to fig. 1, in one or more examples, each of the first component 106 and the second component 110, and thus each of the first mating surface 118 and the second mating surface 120, has a shape 146. As used herein, "shape" of a component or surface refers to the geometry of the component or surface, the size of the component or surface, and the morphology of the component or surface (morphology). For example, the shape of the component or surface may be a three-dimensional shape (e.g., shape 146) of the component or surface. In one or more examples, shape 146 includes form 198 and corrugations 184. As used herein, "form" refers to the overall or global shape of a component or surface, and "corrugation" refers to a local change or undulation in the shape of a component or surface.

Referring to fig. 1, in one or more examples, the shape 146 of one or more of the first component 106 and the second component 110, and thus one or more of the first mating surface 118 and the second mating surface 120, may change throughout the assembly process of the object 180. Thus, each of the first and second components 106, 110, and thus each of the first and second mating surfaces 118, 120, may have an initial shape 174 (e.g., shape 146 prior to the joining process 194) and an assembled shape 176 (e.g., shape 146 after the joining process 194).

Referring to fig. 1, in one or more examples, at least one of the first component 106 and the second component 110, and thus at least one of the first mating surface 118 and the second mating surface 120, may undergo or exhibit a degree of deformation 162 on the shape 146. As used herein, "deformation" refers to a temporary change in form 198 of shape 146. In the examples disclosed herein, the deformation 162 is substantially removed from the shape 146 of the component after the assembly of the object 180 or as a result of the assembly of the object 180 (e.g., after the joining process 194). As an example, the deformation 162 is represented by an initial shape 174 and not an assembled shape 176.

Referring to fig. 1, in one or more examples, the first component 106 is susceptible to or exhibits a degree of deformation 162 (e.g., global deformation) after fabrication such that the first mating surface 118 also exhibits a degree of deformation 162. For example, the first component 106 may be flexible such that the first mating surface 118 is also flexible. As an example, the first component 106 may temporarily bend, deform, flex, sag, or otherwise change shape without causing any undesirable permanent effects to the first component 106 or the first mating surface 118. Such temporary changes in shape (e.g., deformation 162) may be due to a number of factors, such as size, geometry, weight, boundary conditions, gravity, etc., of the first component 106 after it is manufactured. Thus, in these examples, the shape 146 of the first component 106, and thus the first mating surface 118, may vary throughout the manufacturing process of the object 180. For example, the first component 106 and thus the first mating surface 118 may have an initial shape 174 before assembling the object 180 and an assembled shape 176 after assembling the object 180. In these examples, the initial shape 174 and the assembled shape 176 are different and are the result of the deformation 162.

Referring to fig. 1, in one or more examples, the second component 110 is not susceptible to or exhibits deformation 162 after manufacture such that the second mating surface 120 also does not exhibit deformation 162. For example, the second component 110 may be rigid such that the second mating surface 120 is also rigid. As an example, the second component 110 may not bend, deform, flex, sag, or otherwise change shape without causing any undesirable permanent effects to the second component 110 or the second mating surface 120. Thus, the shape 146 of the second component 110, and thus the second mating surface 120, may not change throughout the manufacturing process of the object 180. For example, the second component 110 and thus the second mating surface 120 may have an initial shape 174 before assembling the object 180 and an assembled shape 176 after assembling the object 180. In these examples, the initial shape 174 and the assembled shape 176 are the same.

Referring to fig. 1, in one or more examples, the second component 110 provides or serves as a support structure for an object 180 to which the first component 106 is coupled. Thus, after coupling the first and second components 106, 110 together, the first component 106, and thus the first mating surface 118, has an assembled shape 176. For example, the assembly force may pull the deformation 162 out of the first component 106 during assembly of the object 180. The magnitude of the difference between the initial shape 174 and the assembled shape 176 may be due to a number of factors, such as the load and/or force applied to the first component 106 during the joining process 194, the number of attachment points between the first component 106 and the second component 110, the orientation of the first component 106 and/or the second component 110, and other factors that may affect the shape 146 of the first component 106 before, during, and/or after the joining process 194.

Referring to fig. 1, in other examples, the second component 110 is susceptible to or exhibits a degree of deformation 162 (e.g., global deformation) after fabrication such that the second mating surface 120 also exhibits a degree of deformation 162. For example, the second component 110 may be flexible such that the second mating surface 120 is also flexible. As an example, the second component 110 may temporarily bend, deform, flex, sag, or otherwise change shape without causing any undesirable permanent effects to the second component 110 or the second mating surface 120. Such temporary changes in shape (e.g., deformation 162) may be due to a number of factors, such as size, geometry, weight, boundary conditions, gravity, etc., of the second component 110 after it is manufactured. Thus, in these examples, the shape 146 of the second component 110, and thus the second mating surface 120, may change throughout the manufacturing process of the object 180. For example, the second component 110 and thus the second mating surface 120 may have an initial shape 174 before assembling the object 180 and an assembled shape 176 after assembling the object 180. In these examples, the initial shape 174 and the assembled shape 176 are different and are the result of the deformation 162.

Referring to fig. 1, in one or more examples, a plurality of gaps 116 may exist between the first mating surface 118 and the second mating surface 120. As used herein, "plurality" refers to one or more. In this manner, the plurality of gaps 116 includes one gap 116 or a plurality of gaps 116. For purposes of this disclosure, "gap" refers to an open space between assigned surfaces. Thus, the gap 116 may also be referred to as space.

Referring to fig. 1, in one or more examples, the gap 116 (e.g., each of the plurality of gaps 116) has a dimension 114. Generally, the dimension 114 of the gap 116 refers to a measurable parameter or shape of the gap 116, such as its thickness, length, width, etc. More specifically, the dimension 114 of the gap 116 refers to the thickness of the gap 116 or the linear distance between the first mating surface 118 and the second mating surface 120.

Referring to fig. 1, in one or more examples, a plurality of fillers 144 are located between the first mating surface 118 and the second mating surface 120 to substantially fill the gap 116. The filler 144 (e.g., each of the plurality of fillers 144) has a dimension 196. The dimension 196 of the filler 144 corresponds to or is otherwise based on the dimension 114 of the gap 116. The filler 144 comprises or takes the form of any suitable filler member or filler material adapted to substantially fill the one or more gaps 116 between the mating surfaces within acceptable tolerances. The filler 144 may be made or fabricated using any suitable process and/or using any suitable material (such as a metal, metal alloy, composite, plastic, combinations thereof, etc.), depending on the implementation. In one or more examples, the filler 144 is in the form of or takes the form of a gasket.

In some cases, it may be desirable to manufacture the filler 144 prior to the joining process 194 and assembling the object 180. It may also be desirable to manufacture the filler 144 in a location that is different from the manufacturing environment 172 of the assembled object 180. Accordingly, it is desirable to predict a dimension 114 (e.g., 3D shape information) of a gap 116 that will be formed between the first mating surface 118 and the second mating surface 120 after the first component 106 and the second component 110 are coupled together.

Thus, as disclosed herein, a system 100 (fig. 2) for predicting assembly or active shimming is used to predict the size 114 of the gaps 116, the number of gaps 116, and other information related to the gaps 116, and thus the size 196 of the filler 144, the number of filler 144, and other information related to the filler 144. The filler 144 having the dimension 196 may then be manufactured based on the dimension 114 of the gap 116 predicted prior to the joining process 194.

Referring to FIG. 2, an example of an analysis environment 182 is illustrated. The analysis environment 182 is an example of an analysis environment in which the system 100 is implemented to actively predict the size 196 (e.g., 3D shape information) of the filler 144 (fig. 1). In one or more examples, the analysis environment 182 is remote from the manufacturing environment 172 or at a separate location relative to the manufacturing environment 172. However, in other examples, at least a portion of the system 100 is located in the manufacturing environment 172 or implemented in the manufacturing environment 172, and at least another portion of the system 100 is located in the analysis environment 182 or implemented in the analysis environment 182. In other examples, the entire system 100 is implemented in the manufacturing environment 172.

Referring to FIG. 2, in one or more examples, the system 100 includes a computer 148 or is implemented using the computer 148. For example, system 100 is a computer-implemented system. In one or more examples, computer 148 executes instructions 170 to perform operations performed by system 100. In these examples, computer 148 may include one or more computers, computing devices, or computing systems. When the computer 148 includes more than one computer, the computers may communicate with each other using any number of wired, wireless, optical, or other types of communication links.

Referring to fig. 2, in one or more examples, the system 100 includes a model generator 102. The model generator 102 generates (e.g., is configured or adapted to generate) a first model 104 of a first component 106 (fig. 1). Model generator 102 also generates (e.g., is configured or adapted to generate) a second model 108 of a second component 110 (fig. 1).

Referring to fig. 1 and 2, in one or more examples, the first model 104 is generated before the first component 106 and the second component 110 are coupled together. In one or more examples, the first model 104 represents the first component 106 having the initial shape 174 and thus the first mating surface 118. In one or more examples, the initial shape 174 of the first component 106 is different from the assembled shape 176 (e.g., the final shape after the joining process 194) and includes the deformations 162 in the shape 146 of the first component 106 (e.g., the first component 106 is flexible).

Referring to fig. 1 and 2, in one or more examples, the second model 108 is generated before the first component 106 and the second component 110 are coupled together. In one or more examples, the second model 108 represents the second component 110 having the initial shape 174 and thus the second mating surface 120. In one or more examples, the initial shape 174 of the second component 110 is the same as the assembled shape 176 (e.g., the final shape after the joining process 194) and does not include the deformations 162 in the shape 146 of the second component 110 (e.g., the second component 110 is rigid).

Referring to fig. 2, in one or more examples, the system 100 includes a model analyzer 112. The model analyzer 112 analyzes (e.g., is configured or adapted to analyze) the first model 104 and the second model 108 to determine (e.g., predict) a size 114 of a gap 116 to be formed between a first mating surface 118 of the first component 106 and a second mating surface 120 of the second component 110 after the first component 106 and the second component 110 are coupled together (e.g., after the joining process 194).

Thus, in the example of the mating surfaces of the coupling components changing shape upon assembly, the example of the system 100 considers the post-assembly shape of the components and predicts the gap geometry based on the manufactured shape of the components. In one or more examples, the system 100 facilitates actively removing the deformation 162 from the shape 146 of the first component 106 during a predictive assembly operation. Thus, the prediction of the size 114 of the gap 116 to be formed between the first and second mating surfaces 118, 120, and thus the prediction of the size 196 of the filler 144 required to fill the gap 116, is performed using an approximation of the assembled shape 176 (e.g., the final shape after the joining process 194) of the first component 106.

Advantages of the disclosed predictive assembly process enabled by system 100 include, but are not limited to: filling the gap based on the surface profile of the component, minimizing the thickness of the filler used to fill the gap, taking the filling force into account to pull out deformation (e.g., global deflection) prior to filler installation, and designing and manufacturing the filler prior to assembly.

Referring to fig. 3, an example of an aircraft 1200 is illustrated. In one or more examples, the aircraft 1200 includes a fuselage 1218 (e.g., a body) and wings 1220 attached to the fuselage 1218. The aircraft 1200 includes a propulsion system 1208 (e.g., an engine) attached to, for example, a wing 1220. The fuselage 1218 has a nose section 1222 and a tail section 1224. Aircraft 1200 includes a horizontal stabilizer 1228 and a vertical stabilizer 1226 attached to tail section 1224.

Referring to fig. 1 and 3, in one or more examples, a fuselage 1218 is an example of an object 180. The fuselage 1218 includes an outer barrel 1230 and an inner frame 1232. In these examples, barrel 1230 is an example of first component 106 and frame 1232 is an example of second component 110. Frame 1232 is coupled to barrel 1230 and serves as a support structure for fuselage 1218. It is appreciated that the initial shape of the barrel 1230 may exhibit deformation 162 due to the size and weight of the barrel 1230 prior to the frame 1232 being coupled to the barrel 1230. After the frame 1232 is coupled to the barrel 1230, the barrel 1230 may have a final shape that is different from the initial shape.

Referring to fig. 1 and 3, in one or more examples, a wing 1220 is an example of an object 180. Wing 1220 may also be referred to as a wing structure or wing box. Wing 1220 includes an outer panel assembly 1234 and an inner stiffener assembly 1236. The panel assembly 1234 includes a plurality of panels and may also be referred to as a wing skin. Stiffener assembly 1236 includes a plurality of spars, ribs, and the like. In these examples, panel assembly 1234 is an example of first component 106 and stiffener assembly 1236 is an example of second component 110. Stiffener assembly 1236 is coupled to panel assembly 1234 and serves as a support structure for wing 1220. It is appreciated that the initial shape of the panel assembly 1234 may exhibit deformation 162 due to the size and weight of the panel assembly 1234 before the stiffener assembly 1236 is coupled to the panel assembly 1234. After stiffener assembly 1236 is coupled to panel assembly 1234, panel assembly 1234 may have a final shape that is different from the initial shape.

Referring to fig. 4, an example of a portion of an object 180 formed by the first component 106 coupled to the second component 110 is illustrated. When the first component 106 coupled to the second component 110 is coupled together, the first mating surface 118 mates with the second mating surface 120. After coupling to the second component 110 and the first component 106 together and the first mating surface 118 mated with the second mating surface 120, a plurality of gaps 116 may be formed between the first mating surface 118 and the second mating surface 120.

Referring to fig. 5, an example of an analysis process of the first model 104 and the second model 108 is graphically illustrated to estimate a dimension 114 of a gap 116 between the first mating surface 118 and the second mating surface 120, such as used in a conventional predictive shimming process. In this illustrative example, the first model 104 represents at least a portion of the first component 106, such as the first mating surface 118. The second model 108 represents at least a portion of a second component 110, such as a second mating surface 120. The first model 104 represents the first component 106, and thus the first mating surface 118 as manufactured, but manufactured prior to assembly of the object 180 (e.g., prior to the joining process 194). Similarly, the second model 108 represents the second component 110, and thus the second mating surface 120 as manufactured, but manufactured prior to assembly of the object 180 (e.g., prior to the joining process 194).

Referring to fig. 5, in one or more examples, the first model 104 represents the first component 106 and the first mating surface 118 in an initial shape 174 (e.g., shape 146 prior to the joining process 194), which includes, for example, deformations 162 and corrugations 184 in the shape 146. As an example, the first component 106 is flexible and undergoes a degree of deformation 162 (e.g., global variation in form 198), and the first mating surface 118 includes corrugations 184 (e.g., local variation in surface profile), which are represented by the first model 104.

Referring to fig. 5, in one or more examples, the second model 108 represents the second component 110 and the second mating surface 120 in the initial shape 174 (e.g., the shape 146 prior to the joining process 194), which, for example, does not include the deformations 162 and the corrugations 184 in the shape 146. As an example, the second component 110 is rigid and does not undergo the deformation 162, and the second mating surface 120 does not include the corrugations 184.

Referring to fig. 5, the gap 116 to be formed between the first mating surface 118 and the second mating surface 120 after the joining process 194 is represented by the space between the representation of the first mating surface 118 and the representation of the second mating surface 120 in the first model 104 and the second model 108, respectively. The dimension 114 of the gap 116 is estimated or calculated from the linear distance between a first mating surface 118 represented in the first model 104 and a second mating surface 120 represented in the second model 108. It will be appreciated that in this illustrative example of a conventional predictive shimming process, the size 114 of the gap 116 predicted by the process may be greater than the size 114 of the gap 116 that would actually exist when the object 180 is assembled (e.g., after the joining process 194), and thus, the size 196 of the filler 144 that is made to fill the gap 116 would be too large (e.g., too thick).

Referring to fig. 6, an example of the first model 104 and the second model 108 is graphically illustrated. In one or more examples, the space 200 between the first mating surface 118 and the second mating surface 120 represented by the first model 104 and the second model 108, respectively, represents an area or distance between the first mating surface 118 and the second mating surface 120 associated with or formed by the deformation 162 in the shape 146 of the first component 106 (e.g., global variation in form 198). Typically, after assembly of the object 180 or in response to assembly of the object 180 (e.g., after the joining process 194), the space 200 is closed or otherwise removed. Accordingly, it is desirable to estimate the size 114 of the gap 116 without deformation 162 in the shape 146 of the first component 106. After the first and second components 106, 110 are coupled together (e.g., after the joining process 194), the system 100 advantageously facilitates removal of the deformation 162 based on a calculation of the size 114 of the gap 116 to be formed between the first and second mating surfaces 118, 120.

Referring to fig. 7, an example of an analysis process is graphically illustrated to estimate a dimension 114 of a gap 116 between a first mating surface 118 and a second mating surface 120, such as used in the predictive assembly process or the new active predictive shimming process disclosed herein. In this illustrative example, the deformations 162 in the shape 146 of the first component 106 (e.g., global changes in form 198) are removed according to an analysis process such that only the corrugations 184 in the shape 146 of the first mating surface 118 (e.g., local changes in surface profile) are considered in determining the size 114 of the gap 116.

Referring to fig. 7, as will be described in greater detail herein, in one or more examples, the first model 104 is replaced with a modified nominal model 190 that represents the first component 106. The modified nominal model 190 represents at least a portion of the first component 106, such as the first mating surface 118. The second model 108 represents at least a portion of a second component 110, such as a second mating surface 120. The modified nominal model 190 represents the first component 106 and thus the first mating surface 118 as manufactured, but manufactured after the object 180 is assembled (e.g., after the joining process 194). Similarly, the second model 108 represents the second component 110, and thus the second mating surface 120 as manufactured, but manufactured after the object 180 is assembled (e.g., after the joining process 194).

Referring to fig. 7, in one or more examples, the modified nominal model 190 represents the first component 106 and the first mating surface 118 in the assembled shape 176 (e.g., the final shape after the joining process 194), which does not include the deformations 162 in the shape 146, but does include the corrugations 184, for example. As an example, the deformation 162 (e.g., global change in form 198) represented by the space 200 (fig. 6) in the shape 146 of the first component 106 has been removed (as would be pulled by the joining process 194), and the first mating surface 118 includes the corrugations 184 (e.g., local change in surface profile) represented by the modified nominal model 190.

Referring to fig. 7, in one or more examples, the second model 108 represents the second component 110 and the second mating surface 120 in the assembled shape 176 (e.g., the final shape after the joining process 194), which does not include, for example, the deformations 162 and the corrugations 184 in the shape 146. As an example, the second component 110 is rigid and does not undergo the deformation 162, and the second mating surface 120 does not include the corrugations 184.

Referring to fig. 7, the gap 116 to be formed between the first mating surface 118 and the second mating surface 120 is represented by the space between the representation of the first mating surface 118 and the representation of the second mating surface 120 in the modified nominal model 190 and the second model 108, respectively. The size 114 of the gap 116 is estimated or calculated by the linear distance between the first mating surface 118 represented in the modified nominal model 190 and the second mating surface 120 represented in the second model 108. It will be appreciated that in this illustrative example of a predictive assembly process or a new active predictive shimming process, the dimension 114 of the gap 116 predicted by the process (referred to herein as the predicted dimension 188 shown in fig. 2) is substantially equal to the dimension 114 of the gap 116 that would actually exist upon assembly of the object 180 (e.g., after the joining process 194), and thus, the dimension 196 of the filler 144 that is made to fill the gap 116 will be appropriately sized.

Referring to fig. 2, in one or more examples, the model analyzer 112 determines (e.g., is configured or adapted to determine) an overall deviation 122 in a normal direction 150 between the first model 104 and a nominal model 124 of the first component 106. In one or more examples, the model analyzer 112 performs (e.g., is configured or adapted to perform) a best fit alignment, also referred to as best fit analysis 186, between the first model 104 and the nominal model 124 of the first component 106 to determine the overall deviation 122. In one or more examples, the model analyzer 112 determines (e.g., is configured or adapted to determine) an overall dimension 164 of the overall deviation 122 in the normal direction 150.

For purposes of this disclosure, the nominal model 124 refers to a Computer Aided Design (CAD) model of the first component 106 that represents the nominal or design geometry of the first component 106, and thus the first mating surface 118. It is understood that the shape 146 of the first component 106 represented in the nominal model 124 does not include the deformations 162 (global changes in form 198) or the corrugations 184 (local changes in surface profile).

Referring to fig. 8, an example of the overall deviation 122 in the normal direction 150 between the first model 104 and the nominal model 124 of the first component 106 is graphically illustrated. Performing a best fit analysis 186 (such as least squares alignment) between the first mating surface 118 represented in the first model 104 and the first mating surface 118 represented in the nominal model 124 provides an overall deviation 122 in the normal direction 150 between the first model 104 (e.g., under build conditions) and the nominal model 124 (e.g., design conditions). The overall dimension 164 is represented by or calculated as a value 130 relative to the XYZ coordinate system 126 (e.g., a linear distance measurement in the normal direction 150).

Referring to fig. 2, in one or more examples, a system 100 (such as a computer 148) executing instructions 170 includes a User Interface (UI) 202. The graphical illustration of the overall deviation 122 and the overall dimension 164 of the overall deviation 122 depicted in fig. 8 is an example of a graphical representation displayed to the user by the UI 202.

Referring to fig. 2, the global deviation 122 includes both large scale (e.g., global or global) shape differences and small scale surface variations. The large scale shape change representation 198 and is referred to herein as form deviation 132. The small scale surface variations represent the undulations 184 and are referred to herein as undulation deviations 134. As disclosed herein, the system 100 advantageously achieves the dimension 114 of the gap 116 to be formed between the first and second mating surfaces 118, 120, and thus, the dimension 196 of the filler 144 that is fabricated to fill the gap 116 will be determined based only on small dimensional variations (corrugations 184).

Referring to fig. 2, in one or more examples, the model analyzer 112 maps (e.g., is configured or adapted to map) the global deviation 122 from the XYZ coordinate system 126 to the UVW coordinate system 128 such that the value 130 of the global dimension 164 of the global deviation 122 is represented along the W axis 152 of the UVW coordinate system 128. In one or more examples, the coordinate map 192 includes any suitable conformal mapping or rendering technique.

Referring to fig. 9, an example of an overall deviation 122 mapped from an XYZ coordinate system 126 (fig. 8) to a UVW coordinate system 128 is graphically illustrated. In one or more examples, the data representing the overall deviation 122 changes (e.g., maps or maps) from the x, y, z coordinate points to the u, v, w coordinate points. A two-dimensional (2D) coordinate system is used such that the u, v coordinates represent a position on the first component 106 and the w coordinates represent a deviation from a nominal geometry. This operation effectively removes the "designed shape" from the first component 106 such that the W-axis 152 deviates from the design geometry only. The graphical illustration of the overall deviation 122 and the overall dimension 164 of the overall deviation 122 depicted in fig. 9 is an example of a graphical representation displayed to the user by the UI 202.

Referring to fig. 2, in one or more examples, the model analyzer 112 filters (e.g., is configured or adjusted to filter) the value 130 of the overall dimension 164 of the overall deviation 122 into a formal deviation 132 and a ripple deviation 134. In one or more examples, the system 100 (such as the computer 148) executing the instructions 170 includes a filter 154 that performs a filtering process. In one or more examples, the model analyzer 112 filters the values 130 using a low pass filter 156. In one or more examples, the model analyzer 112 filters the values 130 using a robust gaussian regression filter 158. In one or more examples, a filter 154 (such as the low pass filter 156 or the robust gaussian regression filter 158) operates on the u, v, w point clouds to filter the data into form 198 and ripple 184. Because the design curvature has been effectively removed, a first order regression function (e.g., planar regression) is selected and used for local fitting.

Referring to fig. 10, an example of values 130 of form deviation 132 and form dimension 166 as mapped to UVW coordinate system 128 and filtered from overall dimension 164 of overall deviation 122 is graphically illustrated. As depicted in the illustrative example, the value 130 of the form dimension 166 of the form deviation 132 (fig. 10) is approximately equal to the value 130 of the overall dimension 164 of the overall deviation 122 (fig. 9). This is because the global change in form 198 (form deviation 132) due to deformation 162 represents a large portion of the overall deviation 122 from the design geometry. The graphical illustrations of the form deviation 132 and the form dimension 166 of the form deviation 132 depicted in fig. 10 are examples of graphical representations displayed to a user by the UI 202.

Referring to fig. 11, an example of values 130 of ripple offset 134 and ripple size 168 as mapped to UVW coordinate system 128 and filtered from overall size 164 of overall offset 122 is graphically illustrated. As depicted in the illustrative example, the value 130 of the ripple dimension 168 of the ripple offset 134 (fig. 11) is several orders of magnitude smaller than the value 130 of the overall dimension 164 of the overall offset 122 (fig. 9). This is because the local variation of the corrugations 184 (the corrugation offset 134) due to small scale variations in the surface profile of the first mating surface 118 represents a small portion of the overall offset 122 from the design geometry. The graphical illustrations of the form deviation 132 and the form dimension 166 of the form deviation 132 depicted in fig. 11 are examples of graphical representations displayed to a user by the UI 202.

Referring to fig. 2, in one or more examples, the model analyzer 112 modifies (e.g., is configured or adapted to modify) the nominal model 124 by the ripple offset 134. The nominal model 124 as modified by the corrugation offset 134 represents the first mating surface 118 of the first component 106 after the first component 106 and the second component 110 are coupled together. The nominal model 124 as modified by the ripple offset 134 is also referred to herein as a modified nominal model 190. In one or more examples, the model analyzer 112 maps (e.g., is configured or adapted to map) the ripple offset 134 from the UVW coordinate system 128 to the XYZ coordinate system 126 such that the value 130 of the ripple dimension 168 of the ripple offset 134 is represented as a distance 160 relative to the nominal model 124.

Referring to fig. 12, an example of a ripple offset 134 as mapped from UVW coordinate system 128 (fig. 11) back to XYZ coordinate system 126 and a value 130 represented as a ripple dimension 168 relative to distance 160 of nominal model 124 in normal direction 150 is graphically illustrated. In one or more examples, the data representing the ripple offset 134 changes (e.g., maps or plots) from the u, v, w coordinate points back to the x, y, z coordinate points. The ripple 184 in the calculated w-coordinate is used as the distance 160 to add to the nominal model 124 or subtract from the nominal model 124 to obtain the profile of the filler or shim, estimate the predicted dimension 188 of the filler 144, or otherwise estimate the dimension 114 of the gap 116 that will be formed between the first mating surface 118 and the second mating surface 120 after the first component 106 and the second component 110 are coupled together (e.g., after the joining process 194). The ripple offset 134 and the graphical illustration of the ripple size 168 as the distance 160 depicted in fig. 12 are examples of graphical representations displayed to the user by the UI 202.

Referring to fig. 2, in one or more examples, the system 100 includes a measurement system 136. The measurement system 136 generates first data 138 representative of at least a portion of the first mating surface 118 of the first component 106. The measurement system 136 generates second data 140 representative of at least a portion of the second mating surface 120 of the second component 110. The first data 138 and the second data 140 are generated before the first component 106 and the second component 110 are coupled together and the first mating surface 118 mates with the second mating surface 120.

Referring to fig. 2, in one or more examples, the measurement system 136 includes or takes the form of a scanning device for scanning the first component 106 (such as at least a portion of the first mating surface 118) and generating the first data 138. The measurement system 136 includes or takes the form of a scanning device for scanning the second component 110 (such as at least a portion of the second mating surface 120) and generating the second data 140. The scanning device may take the form of, for example, but not limited to, a laser system, an optical measurement device, or some other type of system. The laser system may be, for example, a lidar scanner. The optical measuring device may be, for example, a three-dimensional optical measuring device. In another illustrative example, measurement system 136 takes the form of a photogrammetry system.

In one or more examples, the first component 106 and the second component 110 may be manufactured in different locations and/or measured (e.g., scanned) in different locations. Thus, in one or more examples, the measurement system 136 includes more than one scanning device, wherein each of the scanning devices is co-located with or dedicated to a manufacturing or measurement environment associated with a respective one of the first component 106 and the second component 110.

Referring to fig. 1 and 2, in one or more examples, the first data 138 includes data or 3D shape information about the first component 106 and, thus, about the shape 146 (e.g., the initial shape 174) of the first mating surface 118. In one or more examples, the second data 140 includes data or 3D shape information about the second component 110 and, thus, about the shape 146 (e.g., the initial shape 174) of the second mating surface 120.

Referring to fig. 2, in one or more examples, the first data 138 and the second data 140 are in the form of three-dimensional point clouds. As an example, the first data 138 takes the form of a first three-dimensional point cloud having a sufficient density to capture the first component 106, and thus the shape 146 of the first mating surface 118, with a desired level of accuracy. Similarly, the second data 140 takes the form of a second three-dimensional point cloud having sufficient density to capture the second component 110 and thus the shape 146 of the second mating surface 120 with a desired level of accuracy.

Referring to fig. 2, in one or more examples, the model generator 102 generates (e.g., is configured or adapted to generate) a filler model 142 to fill one or more of the gaps 116 between the first mating surface 118 and the second mating surface 120 after the first component 106 and the second component 110 are coupled together. The filler 144 is made based on the filler model 142.

Referring to fig. 2 and 15, in one or more examples, model generator 102 and model analyzer 112 take the form of program code 918 executed by data processing system 900.

Referring to fig. 1-12 in general and fig. 13 in particular, as an example, the present disclosure also relates to a method 1000 for predictive assembly or active shimming. More specifically, the method 1000 includes a process of predicting the size 114 of the gap 116, a process of predicting the size 196 of the filler 144 or otherwise determining the size of the filler 144, and a process of making the filler 144. In one or more examples, at least a portion of the operations of method 1000 are performed or implemented using system 100.

Referring to fig. 13, in one or more examples, the method 1000 includes the step of generating a first model 104 of a first component 106 (block 1002). The method 1000 includes the step of generating a second model 108 of the second component 110 (block 1004). The steps of generating the first model 104 (block 1002) and generating the second model 108 (block 1004) are performed before the first component 106 and the second component 110 are coupled together. The method 1000 further includes the step of analyzing the first model 104 and the second model 108 to determine a size 114 of a gap 116 between the first mating surface 118 of the first component 106 and the second mating surface 120 of the second component 110 after the first component 106 and the second component 110 are coupled together (block 1006). As an example, the method 1000 includes a step of determining (e.g., calculating) a size 114 of a gap 116 between a first mating surface 118 of the first component 106 and a second mating surface 120 of the second component 110 based on analysis performed on the first model 104 and the second model 108 (block 1008).

Referring to fig. 13, in one or more examples, a method 1000, such as the step of analyzing (block 1006), includes the step of determining (e.g., calculating) an overall deviation 122 in the normal direction 150 between the first model 104 and the nominal model 124 of the first component 106 (block 1010). In one or more examples, the method 1000, such as the step of determining (block 1010), includes the step of performing a best fit alignment between the first model 104 and the nominal model 124 of the first component 106 to determine the overall deviation 122 (block 1012). In one or more examples, the method 1000, such as the step of analyzing (block 1010), includes the step of determining (e.g., calculating) the overall dimension 164 of the overall deviation 122 in the normal direction 150 (block 1014).

Referring to fig. 13, in one or more examples, a method 1000, such as the step of analyzing (block 1010), includes the step of mapping the global deviation 122 from the XYZ coordinate system 126 to the UVW coordinate system 128 such that the value 130 of the global dimension 164 of the global deviation 122 is represented along the W axis 152 (block 1016).

Referring to fig. 13, in one or more examples, a method 1000, such as the step of analyzing (block 1010), includes the step of filtering the values 130 of the overall dimension 164 of the overall deviation 122 for the shaped deviation 132 and the ripple deviation 134 (block 1018). In one or more examples, according to method 1000, the step of filtering (block 1018) is performed using low pass filter 156 or includes the step of performing or implementing low pass filter 156 (block 1020). In one or more examples, according to the method 1000, the step of filtering (block 1018) is performed using the robust gaussian regression filter 158 or includes the step of performing or implementing the robust gaussian regression filter 158 (block 1022).

Referring to fig. 13, in one or more examples, a method 1000, such as the step of analyzing (block 1010), includes the step of modifying the nominal model 124 with the ripple deviation 134 such that the nominal model 124 as modified by the ripple deviation 134 represents the first mating surface 118 of the first component 106 after the first component 106 and the second component 110 are coupled together (block 1024). In one or more examples, the method 1000, such as the step of modifying (block 1024), includes the step of mapping the ripple offset 134 from the UVW coordinate system 128 to the XYZ coordinate system 126 such that the value 130 of the ripple dimension 168 of the ripple offset 134 is represented as a distance 160 relative to the nominal model 124 (block 1026). In one or more examples, the step of modifying (block 1024) includes the step of adding the distance 160 to the nominal model 124 and/or subtracting the distance 160 from the nominal model 124 such that the modified nominal model 190 represents the first component 106 having the assembled shape 176, thereby providing the dimension 114 (e.g., profile, shape, and thickness) of the gap 116 and thus the dimension 114 (e.g., profile, shape, and thickness) of the filler 144 (block 1028).

Referring to fig. 13, in one or more examples, the method 1000 includes the step of generating first data 138 representative of at least a portion of the first mating surface 118 of the first component 106 (block 1030). The step of generating the first data 138 (block 1030) is performed before the first component 106 and the second component 110 are coupled together. The first model 104 is generated using the first data 138. In one or more examples, the method 1000 includes a step of generating second data 140 representative of at least a portion of the second mating surface 120 of the second component 110 (block 1032). The step of generating the second data 140 (block 1032) is performed before the first component 106 and the second component 110 are coupled together. A second model 108 is generated using the second data 140.

Referring to fig. 12, in one or more examples, the method 1000 includes the step of generating a filler model 142 to fill a gap 116 between the first mating surface 118 and the second mating surface 120 after the first component 106 and the second component 110 are coupled together (block 1034). In one or more examples, the method 1000 includes a step of fabricating the filler 144 based on the filler model 142 (block 1036).

Referring to fig. 12, in one or more examples, the method 1000 includes the step of coupling the first component 106 and the second component 110 together (block 1038). In one or more examples, the step of coupling (block 1038) is performed using the joining process 194 such that the first mating surface 118 mates with the second mating surface 120. In one or more examples, a plurality of gaps 116 are formed between the first mating surface 118 and the second mating surface 120. In one or more examples, the method 1000 includes a step of filling the gap 116 with the filler 144 (block 1040). In one or more examples, because the filler 144 has a size 196 that is suitable for substantially filling the gap 116 as predicted according to the method 1000, the step of coupling (block 1038) and the step of filling (1040) are performed simultaneously. As an example, the filler 144 is coupled to the first mating surface 118 of the first component 106, and then the second component 110 is coupled to the first component 106 such that the first mating surface 118 mates with the second mating surface 120 and substantially fills any gap 116 with the filler 144. In one or more examples, according to method 1000, the three-dimensional shape 146 of the first component 106 changes after the first component 106 and the second component 110 are coupled together.

Referring to fig. 2 and 13, in one or more examples, method 1000 is implemented using computer 148. For example, method 1000 is a computer-implemented method. In one or more examples, system 100 is a computer-implemented system configured or adapted to implement method 1000.

Referring to fig. 1, a filler 144 is also disclosed. In one or more examples, the filler 144 is fabricated according to the method 1000. In one or more examples, the filler 144 is fabricated using the system 100. The filler 144 takes the form of a solid member made of any suitable material, such as a metal, metal alloy, plastic, composite, or the like. Any number of fillers 144 may be manufactured based on the predicted dimensions 188 (e.g., three-dimensional shape information) prior to the joining process 194. The filler 144 may be manufactured using any number of manufacturing processes including, but not limited to, at least one of machining, cutting, bending, hammering, casting, three-dimensional printing, aerosol jet deposition, inkjet deposition, or some other type of forming process.

Referring to fig. 3, a portion of an aircraft 1200 is also disclosed. A portion of the aircraft 1200 includes or otherwise utilizes a plurality of fillers 144 made according to the method 1000 or using the system 100.

Referring to fig. 1-12 in general and fig. 14 in particular, as an example, the present disclosure also relates to a method 2000 of determining the size of a filler 144 for fabrication. In one or more examples, at least a portion of the operations of method 2000 are performed or implemented using system 100.

Referring to fig. 14, in one or more examples, the method 2000 includes the step of generating a first model 104 of the first component 106 (block 2002). The method 2000 includes the step of generating a second model 108 of the second component 110 (block 2004). The steps of generating the first model 104 (block 2002) and generating the second model 108 (block 2004) are performed before the first component 106 and the second component 110 are coupled together. The method 2000 includes the step of filtering out deformations 162 of at least one of the first component 106 and the second component 110 before the first component 106 and the second component 110 are coupled together (block 2006). The method 2000 includes the step of determining a size 114 (e.g., a predicted size 188) of the filler 144 that fits between the first mating surface 118 of the first component 106 and the second mating surface 120 of the second component 110 after the first component 106 and the second component 110 are coupled together (block 2008).

Referring to fig. 13 and 14, in one or more examples, the step of filtering out the deformation 162 of at least one of the first component 106 and the second component 110 before the first component 106 and the second component 110 are coupled together (block 2006) is an example of the step of analyzing the first model 104 and the second model 108 of the method 1000 (block 1006). In one or more examples, the step of determining the size 114 of the filler 144 (block 2008) is an example of the step of determining the size 114 of the gap 116 (block 1008) and the step of generating the filler model 142 of the method 1000 (block 1034).

Referring to fig. 14, in one or more examples, method 1000 includes a step of fabricating a plurality of fills 144 based on a predicted size 196 (e.g., predicted size 188) of the fills 144 (block 2010). In one or more examples, the method 2000 includes the step of coupling the first component 106 and the second component 110 together (block 2012). In one or more examples, the step of coupling (block 2012) is performed using the joining process 194 such that the first mating surface 118 mates with the second mating surface 120. In one or more examples, a plurality of gaps 116 are formed between the first mating surface 118 and the second mating surface 120. In one or more examples, the method 2000 includes a step of filling the gap 116 with the filler 144 (block 2014). In one or more examples, because the filler 144 has a size 196 that is suitable for substantially filling the gap 116 as predicted according to the method 1000, the step of coupling (block 2012) and the step of filling (block 2014) are performed simultaneously. As an example, the filler 144 is coupled to the first mating surface 118 of the first component 106, and then the second component 110 is coupled to the first component 106 such that the first mating surface 118 mates with the second mating surface 120 and substantially fills any gap 116 with the filler 144.

Referring to fig. 2 and 14, in one or more examples, method 2000 is implemented using computer 148. For example, method 2000 is a computer-implemented method. In one or more examples, system 100 is a computer-implemented system configured or adapted to implement method 2000.

Referring to fig. 15, the present disclosure also relates to a computer program product 922, as an example. The computer program product 922 includes a non-transitory computer-readable medium 920 that includes program code 918, which when executed by the one or more processors 904, causes the one or more processors 904 to perform operations.

Referring to fig. 13-15, in one or more examples, the operations include generating the first model 104 of the first component 106 from the first data 138 before the first component 106 is coupled to the second component 110. The operations include generating a second model 108 of the second component 110 from the second data 140 before the second component 110 is coupled to the first component 106.

In one or more examples, the operations include filtering out the deformations 162. The operations include analyzing the first model 104 and the second model 108 to determine a dimension 114 of a gap 116 between a first mating surface 118 of the first component 106 and a second mating surface 120 of the second component 110 after the first component 106 and the second component 110 are coupled together. In one or more examples, the operations include determining a size 114 of the gap 116. In one or more examples, the operations include determining a size 196 of the filler 144.

In one or more examples, the operations include determining an overall deviation 122 in a normal direction 150 between the first model 104 and a nominal model 124 of the first component 106. In one or more examples, the operations include performing a best fit alignment between the first model 104 and a nominal model 124 of the first component 106 to determine the overall deviation 122. In one or more examples, the operations include determining an overall dimension 164 of the overall deviation 122 in the normal direction 150.

In one or more examples, the operations include mapping the global deviation 122 from the XYZ coordinate system 126 to the UVW coordinate system 128 such that the value 130 of the global dimension 164 of the global deviation 122 is represented along the W axis 152.

In one or more examples, the operations include filtering the value 130 of the overall dimension 164 of the overall deviation 122 for the shaped deviation 132 and the ripple deviation 134. In one or more examples, filtering is performed using a low pass filter 156. In one or more examples, filtering is performed using a robust gaussian regression filter 158.

In one or more examples, the operations include modifying the nominal model 124 with the ripple offset 134 such that the nominal model 124 as modified by the ripple offset 134 represents the first mating surface 118 of the first component 106 after the first component 106 and the second component 110 are coupled together.

In one or more examples, the operations include mapping the ripple offset 134 from the UVW coordinate system 128 to the XYZ coordinate system 126 such that a value 130 of a ripple dimension 168 of the ripple offset 134 is represented as a distance 160 relative to the nominal model 124.

In one or more examples, the operations include generating the filler model 142 to fill the gap 116 between the first mating surface 118 and the second mating surface 120 after the first component 106 and the second component 110 are coupled together. The filler 144 is made based on the filler model 142.

Referring to fig. 2, in one or more examples, system 100 may be implemented using software, hardware, firmware, or a combination thereof. When software is used, the operations performed by system 100 may be implemented using, for example, but not limited to, program code configured to run on a processor unit. When firmware is used, the operations performed by system 100 may be implemented using, for example, but not limited to, program code and data, and stored in persistent memory for execution on a processor unit.

When hardware is employed, the hardware may include one or more circuits that operate to perform operations performed by the system 100. Depending on the implementation, the hardware may take the form of circuitry, integrated circuits, application Specific Integrated Circuits (ASICs), programmable logic devices, or some other suitable type of hardware device configured to perform any number of operations.

The programmable logic device may be configured to perform certain operations. The device may be permanently configured to perform these operations or may be reconfigurable. The programmable logic device may take the form of, for example, but not limited to, a programmable logic array, programmable array logic, field programmable logic array, field programmable gate array, or some other type of programmable hardware device.

In some illustrative examples, the operations and processes performed by system 100 may be performed using organic components integrated with inorganic components. In some cases, the operations and processes may be performed entirely by organic components other than humans. For example, circuitry in an organic semiconductor may be used to perform these operations and processes.

With reference to FIG. 15, in one or more examples, computer 148 (FIG. 2) includes a data processing system 900 or takes the form of data processing system 900. In one or more examples, the data processing system 900 includes a communication framework 902 that provides communications between at least one processor 904, one or more storage devices 916 (such as memory 906 and/or persistent storage 908), a communication unit 910, an input/output unit 912 (I/O unit), and a display 914. In this example, communication framework 902 takes the form of a bus system.

The processor 904 is configured to execute instructions 170 (fig. 2) of software loadable into the memory 906. In one or more examples, the processor 904 is a plurality of processor units, a multi-processor core, or some other type of processor, depending on the particular implementation.

Memory 906 and persistent storage 908 are examples of storage 916. A storage device is any hardware capable of storing information, such as, but not limited to, at least one of data, program code in functional form, or other suitable information based on temporary or permanent, or both temporary and permanent. In one or more examples, the storage device 916 may also be referred to as a computer-readable storage device. Memory 906 is, for example, random access memory or any other suitable volatile or non-volatile storage device. Persistent storage 908 may take various forms depending on the particular implementation.

For example, persistent storage 908 may contain one or more components or devices. For example, persistent storage 908 is a hard drive, solid state drive, flash memory, rewritable optical disk, rewritable magnetic tape, or some combination of the above. The media used by persistent storage 908 also may be removable. For example, a removable hard disk drive may be used for persistent storage 908.

The communication unit 910 provides communication with other systems or devices, such as the measurement system 136 or other computer systems. In one or more examples, the communication unit 910 is a network interface card.

Input/output unit 912 allows for the input and output of data with other devices that may be connected to data processing system 900. By way of example, input/output unit 912 provides connection for user input through at least one of a keyboard, a mouse, or some other suitable input device. Further, the input/output unit 912 may send output to a printer. Display 914 provides a mechanism to display information to a user. For example, user interface 202 is displayed to a user by display 914.

Instructions (e.g., instructions 170) for at least one of the operating system, applications, or programs may be located in storage device 916, storage device 916 being in communication with processor 904 through communication framework 902. The processes of the various examples and operations described herein may be performed by processor 904 using computer implemented instructions, which may be located in a memory such as memory 906.

The instructions 170 are referred to as program code, computer usable program code, or computer readable program code that may be read and executed by a processor of the processor 904. Program code in different examples may be implemented on different physical or computer readable storage media, such as memory 906 or persistent storage 908.

In one or more examples, program code 918 is located in a functional form on computer readable media 920. Computer readable media 920 is selectively removable and may be loaded onto data processing system 900 or transferred to data processing system 900 for execution by processor 904. In one or more examples, the program code 918 and the computer readable medium 920 form a computer program product 922. In one or more examples, computer-readable medium 920 is a computer-readable storage medium 924.

In one or more examples, the computer-readable storage medium 924 is a physical or tangible storage device for storing the program code 918, rather than a medium that propagates or transmits the program code 918.

Alternatively, the program code 918 may be transferred to the data processing system 900 using a computer readable signal medium. The computer readable signal medium may be, for example, a propagated data signal with program code 918. For example, the computer-readable signal medium may be at least one of an electromagnetic signal, an optical signal, or any other suitable type of signal. These signals may be transmitted over at least one of a communication link, such as a wireless communication link, a fiber optic cable, a coaxial cable, a wire, or any other suitable type of communication link.

The different components illustrated for data processing system 900 are not meant to provide architectural limitations to the manner in which different examples may be implemented. The different examples may be implemented in a data processing system that includes components in addition to or in place of the components illustrated for data processing system 900. Other components shown in fig. 15 may be different from the example shown. Different examples may be implemented using any hardware device or system capable of executing program code 918.

In addition, various components of computer 148 and/or data processing system 900 may be described as modules. For the purposes of this disclosure, the term "module" includes hardware, software, or a combination of hardware and software. As an example, a module may include one or more circuits configured to perform or implement the described functions or operations (e.g., method 1000 and/or method 2000) of the implemented processes described herein. As another example, a module includes a processor, a storage device (e.g., memory), and a computer-readable storage medium having instructions that, when executed by the processor, cause the processor to perform or implement the described functions and operations. In one or more examples, the modules take the form of program code 918 and a computer-readable medium 920 together form a computer program product 922. In one or more examples, model generator 102 and model analyzer 112 are implemented as modules.

The system 100, method 1000, method 2000, and computer program product 922 generate a model for a filler (such as a gasket or other filler member) required to fill a gap between mating surfaces of components being joined. In one or more examples, the system 100 includes an automated manufacturing system capable of manufacturing a filler based on a model of the filler such that the filler is manufactured with a desired level of accuracy as specified by the model. By predicting the shape of the filler more accurately, the filler can be manufactured off-site prior to the installation and assembly of the components during the manufacture of the object. Further, the amount of rework that may need to be performed during installation of the filler may be reduced, and the need to manufacture a new (e.g., secondary) filler once the caulking process has begun may be reduced.

Referring now to fig. 16 and 17, examples of the system 100, method 1000, method 2000, and/or computer program product 922 described herein may be associated with an aircraft manufacturing and service method 1100 or used in the context of an aircraft manufacturing and service method 1100, as shown in the flowcharts of fig. 16 and aircraft 1200, as schematically illustrated in fig. 3 and 17. For example, aircraft 1200 and/or aircraft manufacturing and service method 1100 may include an object 180 (fig. 1), such as fuselage 1218, wing 1220, etc., made using filler 144 to fill gap 116 between mating surfaces, where filler 144 is shaped and made using system 100 and/or according to method 1000 or method 2000.

Referring to fig. 3 and 17, an example of an aircraft 1200 is illustrated. The aircraft 1200 includes a fuselage 1202 having an interior 1206. Aircraft 1200 includes a plurality of on-board systems 1204 (e.g., advanced systems). Examples of on-board systems 1204 of aircraft 1200 include propulsion system 1208, hydraulic system 1212, electrical system 1210, and environmental system 1214. In other examples, the on-board system 1204 further includes one or more control systems 1216 coupled to the fuselage 1202 of the aircraft 1200, such as flaps, spoilers, ailerons, slats, rudders, elevators, and decorative tabs. In still other examples, on-board system 1204 also includes one or more other systems, such as, but not limited to, a communication system, an avionics system, a software distribution system, a network communication system, a passenger information/entertainment system, a guidance system, a radar system, a weapons system, and the like. Aircraft 1200 may include various other structures that utilize filler 144.

Referring to fig. 16, during pre-production of aircraft 1200, method 1100 includes specification and design of aircraft 1200 (block 1102) and material procurement (block 1104). During production of aircraft 1200, component and subassembly manufacturing (block 1106) and system integration of aircraft 1200 occurs (block 1108). Thereafter, the aircraft 1200 undergoes authentication and delivery (block 1110) to be put into service (block 1112). Routine maintenance and service (block 1114) includes modification, reconfiguration, refurbishment, etc. of one or more systems of the aircraft 1200.

Each of the processes of the method 1100 illustrated in fig. 16 may be performed or implemented by a system integrator, a third party, and/or an operator (e.g., a customer). For purposes of this specification, a system integrator may include, but is not limited to, any number of spacecraft manufacturers and major-system subcontractors; the third party may include, but is not limited to, any number of vendors, subcontractors, and suppliers; and the operator may be an airline, leasing company, military entity, service organization, and so on.

Examples of the system 100, method 1000, method 2000, and computer program product 922 shown and described herein may be employed during any one or more stages of the manufacturing and service method 1100 shown in the flowchart illustrated in fig. 16. In an example, the component and subassembly manufacturing (block 1106) and/or system integration (block 1108) may be formed using the system 100 and/or the filler 144 designed, sized, and/or fabricated according to the method 1000 or method 2000. Furthermore, using the system 100 and/or designing, sizing, and/or manufacturing the filler 144 according to the method 1000 or the method 2000 may be implemented in a manner similar to the components or subassemblies produced while the aircraft 1200 is in service (block 1112). Further, the filler 144 designed, sized, and/or fabricated using the system 100 and/or according to the method 1000 or method 2000 may be utilized during system integration (block 1108) and authentication and delivery (block 1110). Similarly, the filler 144 that is designed, sized, and/or manufactured using the system 100 and/or according to the method 1000 or method 2000 may be utilized, for example, but not limited to, while the aircraft 1200 is in service (block 1112) and during maintenance and service (block 1114).

The foregoing detailed description makes reference to the accompanying drawings, which illustrate specific examples described in this disclosure. Other examples having different structures and operations do not depart from the scope of the present disclosure. The same reference numbers in different drawings may identify the same feature, element, or component. Any one of the plurality of items may be referred to individually throughout this disclosure as an item, and the plurality of items may be collectively referred to as an item, and may be referred to using the same reference numerals. Furthermore, as used herein, a feature, element, component, or step preceding the word "a" or "an" should be understood as not excluding plural features, elements, components, or steps, unless such exclusion is explicitly stated.

The foregoing provides illustrative, non-exhaustive examples, which may be, but are not necessarily, claimed in accordance with the subject matter of this disclosure. Reference herein to "an example" means that one or more features, structures, elements, components, characteristics, and/or operational steps described in connection with the example are included in at least one aspect, embodiment, and/or implementation of the subject matter according to this disclosure. Thus, the phrases "one example," "another example," "one or more examples," and similar language throughout this disclosure may, but do not necessarily, refer to the same example. Moreover, characterizing the subject matter of any one example may, but need not, include characterizing the subject matter of any other example. Moreover, the subject matter that characterizes any one example may be, but is not necessarily, combined with the subject matter that characterizes any other example.

As used herein, a system, apparatus, device, structure, article, element, component, or hardware that is "configured to" perform a specified function is actually able to perform that specified function without any change and that does not have the potential to perform the specified function merely after further modification. In other words, a 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" means an existing characteristic of a system, device, structure, article, element, component, or hardware that enables the system, device, structure, article, element, component, or hardware to perform a specified function without further modification. For the purposes of this disclosure, a system, apparatus, device, structure, article, element, component, or hardware described as "configured to" perform a particular function may additionally or alternatively be described as "adapted to" and/or "operative to" perform that function.

Unless otherwise indicated, the terms "first," "second," "third," and the like are used herein merely as labels and are not intended to impose order, position, or hierarchical requirements on the items to which these terms refer. Furthermore, references to, for example, a "second" item do not require or exclude the presence of, for example, a "first" or lower numbered item and/or, for example, a "third" or higher numbered item.

As used herein, the phrase "at least one" when used with a list of items means that different combinations of one or more of the listed items may be used, and that only one item of each item in the list may be required. For example, "at least one of item a, item B, and item C" may include, but is not limited to, item a, or item a and item B. The example may also include item a, item B, and item C, or item B and item C. In other examples, "at least one" may be, for example, but not limited to, two items a, one item B, and ten items C; four items B and seven items C; and other suitable combinations. As used herein, the term "and/or" and "/" symbol includes any and all combinations of one or more of the associated listed items.

For the purposes of this disclosure, the terms "coupled," "coupled," and similar terms refer to two or more elements engaged, linked, fastened, attached, connected, in communication, or otherwise associated (e.g., mechanically, electrically, fluidly, optically, electromagnetically) with each other. In various examples, elements may be directly or indirectly associated. As an example, element a may be directly associated with element B. As another example, element a may be indirectly associated with element B, e.g., via another element C. It should be understood that not all associations between all disclosed elements are necessarily represented. Thus, couplings other than those shown in the figures may also be present.

As used herein, the term "approximate" refers to or refers to conditions that are close to, but not entirely, the stated conditions but still perform the desired function or achieve the desired result. As an example, the term "approximately" refers to a condition that is within an acceptable predetermined tolerance or accuracy, such as a condition that is within 10% of the stated condition. However, the term "approximately" does not exclude conditions that are exactly the stated conditions. As used herein, the term "substantially" refers to a condition that is substantially the stated condition to perform a desired function or achieve a desired result.

The above-mentioned fig. 1 to 12, 15 and 17 may represent functional elements, features or components thereof, and do not necessarily imply any particular structure. Thus, modifications, additions, and/or omissions may be made to the structures illustrated. In addition, those skilled in the art will appreciate that not all elements, features, and/or components described and illustrated in the above-mentioned fig. 1-12, 15, and 17 need be included in each example, nor are all elements, features, and/or components described herein necessarily depicted in each illustrative example. Thus, some of the elements, features, and/or components described and illustrated in fig. 1-12, 15, and 17 may be combined in various ways without necessarily including other features described and illustrated in fig. 1-12, 15, and 17, other figures, and/or the accompanying disclosure, even if such a combination or combinations are not explicitly illustrated herein. Similarly, additional features not limited to the examples presented may be combined with some or all of the features shown and described herein. The schematic diagrams of the examples depicted in fig. 1-12, 15, and 17 mentioned above are not meant to imply architectural limitations with respect to the illustrative examples unless explicitly stated otherwise. Conversely, while one exemplary structure is illustrated, it should be understood that the structure may be modified as appropriate. Thus, modifications, additions, and/or omissions may be made to the structures illustrated. Furthermore, elements, features, and/or components that serve similar or at least substantially similar purposes are labeled with the same numerals in each of fig. 1-12, 15, and 17, and such elements, features, and/or components may not be described in detail herein with reference to each of fig. 1-12, 15, and 17. Similarly, not all elements, features, and/or components may be labeled in each of fig. 1-12, 15, and 17, but for consistency, reference numerals associated therewith may be utilized herein.

In the above-mentioned fig. 13, 14 and 16, the blocks may represent operations, steps and/or portions thereof, and the lines connecting the various blocks do not imply any particular order or dependency of the operations or portions thereof. It should be understood that not all dependencies between all disclosed operations need to be represented. Figures 13, 14 and 16 and the accompanying disclosure describing the operations of the disclosed methods set forth herein should not be construed as necessarily determining the order in which the operations are to be performed. Rather, although one exemplary order is indicated, it should be understood that the order of the operations may be modified as appropriate. Accordingly, the illustrated operations may be modified, added, and/or omitted, and certain operations may be performed in a different order or simultaneously. In addition, those skilled in the art will appreciate that not all operations described need to be performed.

The present application relates to the following clauses:

clause 1. A system, the system comprising:

A model generator that generates a first model of a first component and a second model of a second component before the first and second components are coupled together; and

A model analyzer that analyzes the first model and the second model to determine a size of a gap between a first mating surface of the first component and a second mating surface of the second component after the first component and the second component are coupled together.

Clause 2 the system of clause 1, wherein the model analyzer determines an overall deviation between the first model and a nominal model of the first component in a normal direction.

Clause 3 the system of clause 2, wherein the model analyzer performs a best fit alignment between the first model and the nominal model of the first component to determine the overall deviation.

Clause 4 the system of clause 2, wherein the model analyzer determines an overall dimension of the overall deviation in the normal direction.

Clause 5 the system of clause 4, wherein the model analyzer maps the global deviation from an XYZ coordinate system to a UVW coordinate system such that a value of the dimension of the global deviation is represented along a W axis.

Clause 6 the system of clause 5, wherein the model analyzer filters the values of the dimension of the total deviation for a shaped deviation and a ripple deviation.

Clause 7 the system of clause 6, wherein the model analyzer filters the values using a low pass filter.

Clause 8 the system of clause 6, wherein the model analyzer filters the values using a robust gaussian regression filter.

Clause 9 the system of clause 6, wherein,

The model analyzer modifies the nominal model by the ripple deviation; and

The nominal model modified by the ripple deviation represents the first mating surface of the first component after the first component and the second component are coupled together.

The system of clause 10, wherein the model analyzer maps the ripple offset from the UVW coordinate system to the XYZ coordinate system such that a value of a ripple size of the ripple offset is expressed as a distance relative to the nominal model.

Clause 11 the system of clause 1, further comprising a measurement system to generate first data representing at least a portion of the first mating surface of the first component and second data representing at least a portion of the second mating surface of the second component prior to mating the first mating surface and the second mating surface.

Clause 12 the system of clause 1, wherein,

The model generator generates a filler model to fill the gap between the first mating surface and the second mating surface after the first component and the second component are coupled together; and

And manufacturing a filler based on the filler model.

Clause 13 the system of clause 1, wherein the model generator and the model analyzer are in the form of program code executed by a data processing system.

Clause 14. A method of making a filler using the system of clause 1.

Clause 15. A method of making a filler, the method comprising the steps of:

generating a first model of the first component and a second model of the second component before the first component and the second component are coupled together; and

The first model and the second model are analyzed to determine a size of a gap between a first mating surface of the first component and a second mating surface of the second component after the first component and the second component are coupled together.

Clause 16. The method according to clause 15, the method further comprising the steps of: an overall deviation in a normal direction between the first model and a nominal model of the first component is determined.

Clause 17 the method of clause 16, further comprising the steps of: a best fit alignment is performed between the first model and the nominal model of the first component to determine the overall deviation.

Clause 18 the method of clause 16, further comprising the steps of: an overall dimension of the overall deviation in the normal direction is determined.

Clause 19 the method according to clause 18, the method further comprising the steps of: the global deviation is mapped from an XYZ coordinate system to a UVW coordinate system such that the value of the dimension of the global deviation is represented along the W axis.

Clause 20 the method of clause 19, further comprising the steps of: filtering said values of said dimension of said overall deviation for a formative deviation and a ripple deviation.

Clause 21 the method of clause 20, wherein the filtering is performed using a low pass filter.

Clause 22 the method of clause 20, wherein the filtering is performed using a robust gaussian regression filter.

Clause 23 the method according to clause 20, the method further comprising the steps of: modifying the nominal model by the ripple offset such that the nominal model modified by the ripple offset represents the first mating surface of the first component after the first component and the second component are coupled together.

Clause 24 the method of clause 23, further comprising the steps of: the ripple offset is mapped from the UVW coordinate system to the XYZ coordinate system such that the value of the ripple size of the ripple offset is expressed as a distance relative to the nominal model.

Clause 25. The method according to clause 15, the method further comprising the steps of:

Generating first data representing at least a portion of the first mating surface of the first component before the first component and the second component are coupled together, wherein the first model is generated using the first data; and

Generating second data representing at least a portion of the second mating surface of the second component before the first component and the second component are coupled together, wherein the second model is generated using the second data.

Clause 26 the method according to clause 15, the method further comprising the steps of:

Generating a filler model to fill the gap between the first mating surface and the second mating surface after the first component and the second component are coupled together; and

And manufacturing a filler based on the filler model.

Clause 27 the method of clause 15, wherein the three-dimensional shape of the first component is changed after the first and second components are coupled together.

Clause 28 the method of clause 15, wherein the method is implemented using a computer.

Clause 29. A system implementing the method according to clause 15.

Clause 30. A filler made according to the method of clause 15.

Clause 31a portion of an aircraft comprising a filler made according to the method of clause 15.

Clause 32. A non-transitory computer-readable medium comprising program code that, when executed by one or more processors, causes the one or more processors to perform operations comprising:

generating a first model of the first component from the first data before the first component is coupled to the second component;

Generating a second model of the second component from second data before the second component is coupled to the first component; and

Clause 33, the non-transitory computer-readable medium of clause 32, wherein the operations further comprise: an overall deviation in a normal direction between the first model and a nominal model of the first component is determined.

Clause 34 the non-transitory computer-readable medium of clause 33, wherein the operations further comprise: a best fit alignment between the first model and the nominal model of the first component is performed to determine the overall deviation.

Clause 35 the non-transitory computer-readable medium of clause 33, wherein the operations further comprise: a dimension of the overall deviation in the normal direction is determined.

Clause 36 the non-transitory computer-readable medium of clause 35, wherein the operations further comprise: the global deviation is mapped from an XYZ coordinate system to a UVW coordinate system such that the value of the dimension of the global deviation is represented along the W axis.

Clause 37 the non-transitory computer-readable medium of clause 36, wherein the operations further comprise: filtering said values of said dimension of said overall deviation for a formative deviation and a ripple deviation.

Clause 38 the non-transitory computer readable medium of clause 37, wherein the filtering is performed using a low pass filter.

Clause 39 the non-transitory computer readable medium of clause 37, wherein the filtering is performed using a robust gaussian regression filter.

Clause 40 the non-transitory computer-readable medium of clause 37, wherein the operations further comprise: modifying the nominal model by the ripple offset such that the nominal model as modified by the ripple offset represents the first mating surface of the first component after the first component and the second component are coupled together.

Clause 41 the non-transitory computer-readable medium of clause 40, wherein the operations further comprise: the ripple offset is mapped from the UVW coordinate system to the XYZ coordinate system such that the value of the ripple size of the ripple offset is expressed as a distance relative to the nominal model.

Clause 42 the non-transitory computer readable medium of clause 40, wherein,

The operations further comprise: generating a filler model to fill the gap between the first mating surface and the second mating surface after the first component and the second component are coupled together; and

And manufacturing a filler based on the filler model.

Clause 43. A method of determining the size of a filler for fabrication, the method comprising the steps of:

generating a first model of the first component and a second model of the second component before the first component and the second component are coupled together;

Filtering out deformations of at least one of the first and second components before the first and second components are coupled together; and

A size of a filler that fits between a first mating surface of the first component and a second mating surface of the second component after the first component and the second component are coupled together is determined.

Furthermore, references throughout this specification to features, advantages, or similar language 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 the features and advantages, and similar language, throughout this disclosure may, but do not necessarily, refer to the same example.

In one or more other examples, the features, advantages, and characteristics of one example described may be combined in any suitable manner. 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. Further, while various examples of the system 100, method 1000, method 2000, and computer program product 922 have been shown and described, modifications may occur to those skilled in the art upon reading the specification. The application includes such modifications and is limited only by the scope of the claims.

Claims

1. A system (100), the system (100) comprising:

A model generator (102), the model generator (102) generating a first model (104) of a first component (106) and a second model (108) of a second component (110) before the first component (106) and the second component (110) are coupled together; and

-A model analyzer (112), the model analyzer (112) analyzing the first model (104) and the second model (108) to determine a dimension (114) of a gap (116) between a first mating surface (118) of the first component (106) and a second mating surface (120) of the second component (110) after the first component (106) and the second component (110) are coupled together.

2. The system (100) of claim 1, wherein the model analyzer (112) determines an overall deviation (122) in a normal direction (150) between the first model (104) and a nominal model (124) of the first component (106).

3. The system (100) of claim 2, wherein the model analyzer (112) performs a best fit alignment between the first model (104) and the nominal model (124) of the first component (106) to determine the overall deviation (122).

4. A method (1000) of making a filler (144), the method (1000) comprising the steps of:

generating a first model (104) of a first component (106) and a second model (108) of a second component (110) before the first component (106) and the second component (110) are coupled together; and

The first model (104) and the second model (108) are analyzed to determine a size (114) of a gap (116) between a first mating surface (118) of the first component (106) and a second mating surface (120) of the second component (110) after the first component (106) and the second component (110) are coupled together.

5. The method (1000) according to claim 4, the method (1000) further comprising the step of: an overall deviation (122) in a normal direction (150) between the first model (104) and a nominal model (124) of the first component (106) is determined.

6. The method (1000) according to claim 5, the method (1000) further comprising the step of: a best fit alignment is performed between the first model (104) and the nominal model (124) of the first component (106) to determine the overall deviation (122).

7. The method (1000) according to claim 5, the method (1000) further comprising the step of: an overall dimension (164) of the overall deviation (122) in the normal direction (150) is determined.

8. The method (1000) of claim 7, the method (1000) further comprising the step of: the global deviation (122) is mapped from an XYZ coordinate system (126) to a UVW coordinate system (128) such that a value (130) of the dimension (114) of the global deviation (122) is represented along a W-axis (152).

9. A non-transitory computer-readable medium (920) comprising program code (918) that, when executed by one or more processors (904), causes the one or more processors (904) to perform operations comprising:

generating a first model (104) of the first component (106) from the first data (138) before the first component (106) is coupled to the second component (110);

Generating a second model (108) of the second component (110) from second data (140) before the second component (110) is coupled to the first component (106); and

10. A method (2000) of determining the size of a filler (144) for fabrication, the method (2000) comprising the steps of:

Generating a first model (104) of a first component (106) and a second model (108) of a second component (110) before the first component (106) and the second component (110) are coupled together;

Filtering out deformations (162) of at least one of the first component (106) and the second component (110) before the first component (106) and the second component (110) are coupled together; and

-Determining the size (114) of the filler (144) fitted between a first mating surface (118) of the first component (106) and a second mating surface (120) of the second component (110) after the first component (106) and the second component (110) are coupled together.