FITTING DOUBLERS USING GAP MAPPING

• US 20090154775A1
• Filed: 07/30/2008
• Published: 06/18/2009
• Est. Priority Date: 12/17/2007
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Hansen, Jeffrey M., Georgeson, Gary E., Fogarty, Michael D., Lea, Scott W., Evens, Michael W.
• Granted Patent: US 9,034,128 B2
• Time in Patent Office: Days
• US Class Current: 382/108
• CPC Class Codes: B29C 66/95 by measuring or controlling specific variables not covered by groups B29C66/91 - B29C66/94
• CPC Class Codes: B29C 70/38 Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns application heads for tyres B29D30/28
• CPC Class Codes: B29L 2031/3076 Aircrafts blades, propellers B29L2031/08
• CPC Class Codes: B64F 5/10 Manufacturing or assembling aircraft, e.g. jigs therefor
• CPC Class Codes: G01B 11/14 for measuring distance or clearance between spaced objects or spaced apertures G01B11/26 takes precedence; rangefinders G01C3/00
• CPC Class Codes: G01B 11/24 for measuring contours or curvatures

Abstract

A method and apparatus are used to fit a metallic or composite doubler on an uneven surface. A three dimensional digital map of the gap between the doubler and the uneven surface is generated by digitally scanning the uneven surface. The digital map is then used to fabricate a stack of adhesive plies tailored to substantially fill the gap between the doubler and the uneven surface.

Claims

1. Apparatus used in fabricating a stack of adhesive plies for attaching a doubler to a surface on a structure, comprising:

a digital scanner for scanning the surface on the structure and for producing a first set of digital data representing the contour of the surface;

a second set of digital data representing a surface on the doubler intended to be attached to the surface on the structure; and

,

a computer for mapping the gap between the doubler surface and the surface on the structure using the first and second sets of digital data, and for segmenting the mapped gap into layers corresponding to the adhesive plies.

2. The apparatus of claim 1, further comprising:

a cutter controlled by the computer for automatically cutting the adhesive plies from a sheet of adhesive based on the segmented layers.

3. The apparatus of claim 1, further comprising:

a printer controlled by the computer for printing full-size patterns corresponding to the segmented layers.

4. The apparatus of claim 1, wherein:

the surface of the structure is uneven, and

the digital scanner is a laser.

5. A method of fabricating a stack of adhesive plies used to attach a doubler to a surface on a structure, comprising:

generating a first set of digital data representing the surface on the structure;

generating a second set of digital data representing a surface on the doubler that is intended to be attached to the surface of the structure;

mapping the gap between the doubler surface and the surface of the structure;

segmenting the mapped gap into patterned layers corresponding to the adhesive plies; and

,

using the patterned layers to produce the adhesive plies.

6. The method of claim 5, wherein:

the surface of the structure is uneven, and

generating the first set of digital data is performed by digitally scanning the uneven surface of the structure.

7. The method of claim 5, wherein generating the second set of digital data is performed by digitally scanning one of:

a surface of the doubler, and

the surface of a tool used to fabricate the doubler.

8. The method of claim 5, wherein mapping the gap between the doubler surface and the surface of the structure includes comparing the first and second sets of digital data.

9. The method of claim 5, wherein segmenting the mapped gap into patterned layers corresponding to the adhesive plies includes selecting a thickness for the adhesive plies.

10. The method of claim 5, wherein:

segmenting the mapped gap into patterned layers corresponding to the adhesive plies includes generating a file representing the patterns, and

using the patterned layers to produce the adhesive plies includes using the file representing the patterns to automatically control a cutter used to cut the patterns from a sheet of adhesive.

11. The method of claim 5, wherein using the patterned layers to produce the adhesive plies includes:

printing the patterns, and

using the printed patterns as guides for cutting the adhesives plies from a sheet of adhesive.

12. The method of claim 5, further comprising:

using an automatically controlled cutter to cut the adhesive plies from a sheet of adhesive based on the shapes of the patterned layers.

13. A method of fitting a doubler on a surface, comprising:

generating a three dimensional digital map of the gap between the doubler and the surface; and

,

using the digital map to fabricate a stack of adhesive plies tailored to substantially fill the gap between the doubler and the surface.

14. The method of claim 13, wherein:

the surface is uneven, and

generating a three dimensional digital map includes digitally scanning the surface of the structure.

15. The method of claim 13, wherein generating a three dimensional digital map includes:

generating a first set of digital data representing the surface on the structure,

generating a second set of digital data representing a surface on the doubler that is intended to be fitted to the surface of the structure, and

comparing the first and second sets of digital data.

16. The method of claim 15, wherein generating the second set of digital data is performed by digitally scanning a surface of one of:

the doubler, and

the surface of a tool used to fabricate the doubler.

17. The method of claim 15, wherein generating the first set of digital data includes using a laser to scan the surface of the structure.

18. The method of claim 13, further comprising:

segmenting the digital map into a plurality of patterned layers, and

wherein using the digital map to fabricate a stack of adhesive plies includes cutting the adhesive plies from a sheet of adhesive using the patterned layers as guides.

19. The method of claim 13, further comprising:

using the digital map to orient the adhesive plies relative to each other and to determine their order within the stack.

20. A method of applying a doubler to an uneven surface of a structure, comprising:

forming a doubler having a surface intended to be applied to the uneven surface of the structure;

generating a three dimensional map of the gap between the surface of the doubler and the uneven surface of the structure;

segmenting the three dimensional map into a plurality of layers each having a pattern;

using the pattern of the layers to fabricate a stack of adhesive plies that substantially fill the gap;

filling the gap with the stack of adhesive plies; and

,

placing the doubler on the uneven surface of the structure overlying the stack of adhesive plies.

21. The method of claim 20, wherein generating a map of the gap includes:

generating a first set of digital data representing the uneven surface of the structure,

generating a second set of digital data representing the surface of the doubler, and

comparing the first and second sets of digital data.

22. The method of claim 21, wherein generating the first set of digital data includes digitally scanning the uneven surface of the structure.

23. The method of claim 21, wherein generating the second set of digital data includes digitally scanning the surface of the doubler.

24. A method of applying a doubler over a surface of an aircraft, comprising:

generating a first set of digital data representing the surface on the structure by digitally scanning the surface;

generating a second set of digital data representing a surface on the doubler;

generating a three dimensional map of a gap between the surface of the aircraft and the surface of the doubler, including comparing the first and second sets of data;

segmenting the three dimensional map into patterned layers, including generating a file representing the patterned layers;

using the file representing the patterned layers to produce a stack of adhesive plies, including cutting the plies from a sheet of adhesive;

filling the gap with the stack of adhesive plies; and

placing the doubler on the surface of the aircraft overlying the stack of adhesive plies.

25. Apparatus used in fabricating a stack of adhesive plies used to attaching a doubler to a surface on an aircraft skin, comprising:

a digital scanner for scanning the surface on the skin and producing a first set of digital data representing the contour of the surface;

a second set of digital data representing a surface on the doubler intended to be attached to the skin;

a computer;

a computer program for controlling the computer and for mapping the gap in three dimensions between the surface of the doubler and the surface of the skin and segmenting the mapped gap into patterned layers; and

,

a cutter controlled by the computer for automatically cutting the adhesive plies from a sheet of adhesive based on the shape of the patterned layers.