BACKGROUND INFORMATION
1. Field:
[0001] The present disclosure relates generally to manufacturing and, in particular, to manufacturing composite structures. Still more particularly, the present disclosure relates to methods and apparatuses for assembling a composite structure with a liquid shim.
2. Background:
[0002] In manufacturing a composite structure, different parts are connected to each other to form the composite structure. For example, composite materials may be laid up in the shape of a composite part. The dimensions of these parts are carefully designed and the layout of composite materials is configured to result in desired dimensions when the composite parts are cured or consolidated.
[0003] In some cases, a desired level of thickness may not always be obtained. For example, when a composite part is formed, the actual dimensions of the composite part may not be as close as desired to the specified dimensions. As a result, when the composite part is assembled with other composite parts, a gap may be present.
[0004] One solution is to discard the composite part and manufacture a new composite part as a replacement. This solution may provide a composite part with the desired dimensions that reduces or eliminates the gap when the composite part is assembled with other composite parts.
[0005] This solution, however, may take more time than desired when composite parts are discarded and remanufactured. Additionally, this type of solution also may increase the expense of manufacturing the composite structure to a level that is higher than desired.
[0006] Another solution involves creating a composite part to fill the gap. This composite part may fill the gap for aesthetic purposes and also may provide structural features within the composite structure.
[0007] One type of shim that may be used is a liquid shim. With a liquid shim, a fluid material is placed into the gap. This fluid material may then be cured. This curing often occurs at room temperature. The time needed for curing at room temperature, however, may be longer than desired. For example, curing may take 2 to 3 hours. Waiting this amount of time between different operations in forming a composite structure and using that composite structure to form assemblies or some other object may be greater than desired.
[0008] The speed at which a liquid shim cures may be increased with the application of heat. However, if the heat applied is not at the correct temperature or does not have the desired temperature at different locations, the liquid shim may not perform as desired after curing. As a result, additional time and expense may occur if heating is not applied in a desired manner.
[0009] Therefore, it would be desirable to have a method and apparatus that take into account at least some of the issues discussed above, as well as other possible issues.
SUMMARY
[0010] An embodiment of the present disclosure provides a method for forming a shim. A liquid shim material with a magnetically permeable material is applied in a location for the shim between a plurality of composite parts. A magnetic field is applied to the magnetically permeable material in the location. The magnetic field is configured to heat the liquid shim material to a temperature to cause the liquid shim material to become solid and form the shim.
[0011] Another embodiment of the present disclosure provides another method for forming a shim. A liquid shim material with a magnetically permeable material is applied in a location for the shim between a plurality of parts. A magnetic field is applied to the magnetically permeable material in the location. The magnetic field is configured to heat the liquid shim material to a temperature to cause the liquid shim material to become solid and form the shim.
[0012] Yet another embodiment of the present disclosure provides an apparatus comprising a liquid shim material with a magnetically permeable material applied in a location for a shim between a plurality of composite parts and a magnetic field generator. The magnetic field generator is configured to apply a magnetic field to the magnetically permeable material in the location. The magnetic field is configured to heat the liquid shim material to a temperature to cause the liquid shim material to become solid and form the shim.
[0013] In still another illustrative embodiment, an aircraft comprises a first part, a second part, and a shim. The second part includes a portion configured to be adjacent to the first part upon attachment thereto, wherein the second part is at least partially separated from the first part by a gap due to variances in fabrication. The shim is disposed in the gap between the first part and the second part, wherein the shim comprises a magnetically permeable material disposed therein, and the shim is solidified in place in the gap between the first part and the second part from exposing the magnetically permeable material to a magnetic field.
[0014] The features and functions can be achieved independently in various embodiments of the present disclosure or may be combined in yet other embodiments in which further details can be seen with reference to the following description and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The novel features believed characteristic of the illustrative embodiments are set forth in the appended claims. The illustrative embodiments, however, as well as a preferred mode of use, further objectives and features thereof, will best be understood by reference to the following detailed description of an illustrative embodiment of the present disclosure when read in conjunction with the accompanying drawings, wherein:
Figure 1 is an illustration of a manufacturing environment in the form of a block diagram in accordance with an illustrative embodiment;
Figure 2 is an illustration of a composite wing in accordance with an illustrative embodiment;
Figure 3 is an illustration of a cross-section of a composite wing in accordance with an illustrative embodiment;
Figure 4 is a more detailed illustration of a portion of a composite wing in accordance with an illustrative embodiment;
Figure 5 is an illustration of a liquid shim material in a gap in accordance with an illustrative embodiment;
Figure 6 is an illustration of an exposed view of a liquid shim material with a magnetically permeable material in accordance with an illustrative embodiment;
Figure 7 is an illustration of a shim formed from a liquid shim material in accordance with an illustrative embodiment;
Figure 8 is an illustration of a liquid shim material in a gap in accordance with an illustrative embodiment;
Figure 9 is an illustration of a shim formed from a liquid shim material in accordance with an illustrative embodiment;
Figure 10 is an illustration of a flowchart of a process for forming a shim in accordance with an illustrative embodiment;
Figure 11 is an illustration of a flowchart of a process for forming a shim using smart susceptors in accordance with an illustrative embodiment;
Figure 12 is another illustration of a flowchart of a process for forming a shim using smart susceptors in accordance with an illustrative embodiment;
Figure 13 is an illustration of an aircraft manufacturing and service method in the form of a block diagram in accordance with an illustrative embodiment; and
Figure 14 is an illustration of an aircraft in the form of a block diagram in which an illustrative embodiment may be implemented.
DETAILED DESCRIPTION
[0016] The illustrative embodiments recognize and take into account one or more different considerations. For example, the illustrative embodiments recognize and take into account that placing one or more heating elements in one or more locations relative to the liquid shim material may allow for desired heating of the liquid shim material. For example, the liquid shim material may be heated more evenly to the same temperature when the one or more heating elements are placed in one or more desired locations.
[0017] Thus, the illustrative embodiments provide a method and apparatus for forming a shim. A liquid shim material with a magnetically permeable material is applied in a location for a shim between a plurality of composite parts. A magnetic field is applied to the magnetically permeable material in a location configured to heat the liquid shim material to a temperature to cause the liquid shim material to become solid and form the shim. In this manner, a shim may be formed to provide a desired fit between the plurality of composite parts.
[0018] With reference now to the figures, and in particular, with reference to Figure 1, an illustration of a manufacturing environment is depicted in the form of a block diagram in accordance with an illustrative embodiment. As depicted, manufacturing environment
100 may be used to manufacture structure
102 from a plurality of parts
104. In this illustrative example, structure
102 may take the form of composite structure
106 and the plurality of parts
104 is a plurality of composite parts
108. In these illustrative examples, composite parts
108 may be comprised of fiber reinforced materials, such as a fiber reinforced polymer, and in particular, a carbon fiber reinforced plastic (CFRP).
[0019] In this illustrative example, gap
110 may be present in location
112 between the plurality of composite parts
108. As depicted, gap
110 may have a size that is undesirable. Gap
110 may result in the plurality of composite parts
108 not having a desired level of performance when assembled to form composite structure
106.
[0020] In this illustrative example, the desired level of performance for the plurality of composite parts
108 may take various forms. For example, the desired level of performance may be at least one of loading, preciseness of aerodynamic configurations, airflow over surfaces, and other suitable types of performance.
[0021] In this illustrative example, shim manufacturing system
116 may be used to form shim
118 in location
112 between the plurality of composite parts
108. In particular, shim
118 may be formed to fill gap
110 in location
112 between the plurality of composite parts
108.
[0022] As depicted, shim manufacturing system
116 includes manipulator
120 and heating system
122. As depicted, manipulator
120 is a hardware component configured to apply liquid shim material
124 to location
112 for shim
118 between the plurality of composite parts
108. In these illustrative examples, liquid shim material
124 may have shape
125 when applied to location
112. In other words, liquid shim material
124 may be pre-formed into shape
125 for shim
118 before being applied to location
112.
[0023] Further, application of liquid shim material
124 may include magnetically permeable material
130 within liquid shim material
124 in some illustrative examples. The shape may be maintained using structures such as a release film, plastic strips, and other suitable structures that may aid in forming shape
125 for liquid shim material
124.
[0024] In the illustrative examples, manipulator
120 may take various forms. For example, manipulator
120 may include at least one of a human operator, a robotic arm, a crawler, or some other suitable type of device.
[0025] Liquid shim material
124 may be any material that may be heated to form a solid for shim
118. Liquid shim material
124 may be, for example, an epoxy in a liquid that may be shaped. This liquid may have different viscosities depending on the particular implementation. For example, the liquid may have a viscosity similar to a paste. In these illustrative examples, liquid shim material
124 may be selected as a material that may cure in about six hours to about 24 hours in an ambient temperature. Liquid shim material
124 may cure in less time when heated from about 150 degrees F to about 220 degrees F depending on the particular material used.
[0026] In this illustrative example, heating system
122 takes the form of induction heating system
126. Heating system
122 includes magnetic field generator
128 and magnetically permeable material
130.
[0027] Magnetic field generator
128 may comprise induction coil
132 and controller
134. Induction coil
132 is a hardware device configured to generate magnetic field
136 under the control of controller
134. Controller
134 is a hardware device and controls the application of current to induction coil
132 to control the generation of magnetic field
136.
[0028] In this illustrative example, magnetic field
136 interacts with magnetically permeable material
130 to cause magnetically permeable material
130 to generate heat
138. In particular, magnetic field
136 may be an electromagnetic flux field that interacts with magnetically permeable material
130.
[0029] In some illustrative examples, magnetically permeable material
130 may be in the form of a wire having a diameter of about 0.003 inches to about 0.020 inches. Of course, the diameter may vary for different applications. Magnetically permeable material
130 may generate heat when magnetic field
136 fluctuates at a frequency from about 20 kHz to about 500 kHz. The fluctuation of magnetic field
136 may result in heat from electric resistance caused by the flow of current induced within magnetically permeable material
130. The temperatures in which heating does not pass may be from about 140 degrees F to about 420 degrees F, depending on the particular material selected in these illustrative examples. For example, the heating may decrease to about zero such that the temperature remains at substantially the same temperature at that time. Of course, other diameters and other temperatures may be used depending on the particular implementation.
[0030] In this illustrative example, magnetically permeable material
130 is located within liquid shim material
124. Magnetically permeable material
130 may be placed in at least one of liquid shim material
124 in location
112 prior to liquid shim material
124 being applied to location
112, on liquid shim material
124 after liquid shim material
124 is applied to location
112, or in some other manner.
[0031] As used herein, the phrase "at least one of," when used with a list of items, means different combinations of one or more of the listed items may be used and only one of each item in the list may be needed. For example, "at least one of item A, item B, or item C" may include, without limitation, item A or item A and item B. This example also may include item A, item B, and item C or item B and item C. The item may be a particular object, thing, or a category. In other words, at least one of means any combination of items and number of items may be used from the list but not all of the items in the list are required.
[0032] In other words, the application of liquid shim material
124 may be performed in various ways. Liquid shim material
124 may be placed into location
112 with shape
125. In other illustrative examples, liquid shim material
124 may be poured or squeezed out of a container into location
112 and shaped using a mold or other structures.
[0033] In this illustrative example, liquid shim material
124 may be selected to allow for shaping of liquid shim material
124. In other words, the viscosity of liquid shim material
124 may be such that liquid shim material
124 may flow at a rate that allows for application and heating within gap
110 in a desired manner. In other words, liquid shim material
124 may flow slowly enough such that liquid shim material
124 may maintain a substantially desired shape while being heated to form shim
118.
[0034] Magnetically permeable material
130 may be comprised of various types of materials. For example, magnetically permeable material
130 may be selected from at least one of an alloy, a cobalt, an iron alloy, a nickel and iron alloy, an iron and silicon alloy, an amorphous magnetic alloy, a crystalline magnetic alloy, or some other suitable material. Further, in this illustrative example, magnetically permeable material
130 may take the form of smart susceptor
140.
[0035] As depicted, smart susceptor 140 may be a magnetically permeable material that has a Curie temperature that is selected for a particular application. The Curie temperature may be selected such that heat generated by the magnetically permeable material in response to an alternating magnetic field decreases sufficiently such that the temperature reaches equilibrium. The heat generated may be about zero. For example, the selection may be such that the temperature is maintained substantially at a cure temperature for liquid shim material
124.
[0036] Further, magnetically permeable material
130 may have various forms of shapes. For example, magnetically permeable material
130 may have a shape selected from at least one of a wire, a strip, a plate, a sheet, or some other suitable shape. The particular shape selected may vary depending on the particular implementation. For example, a plate may be used for applications in which the avoidance of extraneous heating may be desired. Wires may be used when contours in the shape may be present with some massive complexity. Further, these different components may be segmented rather than one component. Further, different shapes may be used at the same time.
[0037] In these illustrative examples, magnetically permeable material
130 may be configured to generate heat
138 to at least cure temperature
142. Cure temperature
142 is the temperature at which liquid shim material
124 changes into a solid to form shim
118. In particular, magnetically permeable material
130 has Curie temperature
144. Curie temperature
144 for magnetically permeable material
130 is selected to be at least cure temperature
142 for liquid shim material
124 in this illustrative example.
[0038] As depicted, Curie temperature
144 is the temperature at which magnetic properties of magnetically permeable material
130 reduce. In particular, the magnetic properties may substantially disappear at Curie temperature
144. As a result, magnetically permeable material
130 may not increase in temperature much beyond Curie temperature
144. In these illustrative examples, magnetically permeable material
130 heats up to reach Curie temperature
144 at a desired rate.
[0039] With the selection of Curie temperature
144 based on cure temperature
142, magnetically permeable material
130 may be substantially self-controlling. In other words, the temperature that magnetically permeable material
130 reaches may be self-limiting with the selection of Curie temperature
144. In this manner, controller
134 may be simpler in design and implementation.
[0040] Thus, shim manufacturing system
116 may form shim
118 in gap
110 with a desired level of performance. In these illustrative examples, heating system
122 in the form of induction heating system
126 may generate heat
138 at the desired temperature within location
112. In other words, cure temperature
142 may have a desired profile throughout liquid shim material
124. The profile may be temperatures for portions of liquid shim material
124. In these illustrative examples, cure temperature
142 may be the same throughout all of liquid shim material
124 as applied to location
112 in which gap
110 is present.
[0041] With the use of magnetically permeable material
130, the heating of liquid shim material
124 may be performed more quickly than with currently used systems such as heat blankets, heat lamps, or other devices. Further, the heating of liquid shim material
124 may be made more evenly with respect to temperatures for curing liquid shim material
124. In the illustrative example, the shim is heated through the use of magnetically permeable material
130 while other structures in the area may be cooler as compared to currently used heating systems.
[0042] The illustration of manufacturing environment
100 in
Figure 1 is not meant to imply physical or architectural limitations to the manner in which an illustrative embodiment may be implemented. Other components in addition to or in place of the ones illustrated may be used. Some components may be unnecessary. Also, the blocks are presented to illustrate some functional components. One or more of these blocks may be combined, divided, or combined and divided into different blocks when implemented in an illustrative embodiment.
[0043] For example, although heating system
122 has been illustrated to include magnetic field generator
128 having controller
134 and induction coil
132, magnetic field generator
128 may include other components in addition to or in place of the ones depicted. For example, magnetic field generator
128 also may include a power source.
[0044] In another illustrative example, magnetically permeable material
130 may have one or more Curie temperatures in addition to Curie temperature
144. As a result, magnetically permeable material
130 may be controlled to reach various temperatures depending on the particular implementation.
[0045] With reference now to
Figure 2, an illustration of a composite wing is depicted in accordance with an illustrative embodiment. In this illustrative example, composite wing
200 is an example of composite structure
106 shown in block form in
Figure 1.
[0046] As depicted, composite wing
200 is shown in a partially completed state. As depicted, composite wing
200 includes skin panels
202 and support structure
204. Support structure
204 may include ribs and spars as well as other parts. As depicted, these different parts in composite wing
200 are composite parts.
[0047] In this illustrative example, a gap may be present between one or more skin panels
202 and support structure
204 when manufacturing composite wing
200. The gap may be filled using a shim that is formed in accordance with an illustrative embodiment.
[0048] With reference next to
Figure 3, an illustration of a cross-section of a composite wing is depicted in accordance with an illustrative embodiment. In this illustrative example, a cross-sectional view of composite wing
200 is shown taken along lines
3-3 in
Figure 2.
[0049] In this view, gap
300 is present between skin panel
302 in skin panels
202 and support structure
204. A more detailed view of section
304 is shown in
Figure 4 below.
[0050] In
Figure 4, a more detailed illustration of a portion of a composite wing is depicted in accordance with an illustrative embodiment. A more detailed view of section
304 is shown in this figure.
[0051] As depicted, gap
300 is in location
400 between skin panel
302 and rib
402 in support structure
204. Gap
300 may be reworked to minimize or eliminate gap
300 in accordance with an illustrative embodiment. In this manner, a better fit may be provided between skin panel
302 and rib
402.
[0052] Turning next to
Figure 5, an illustration of a liquid shim material in a gap is depicted in accordance with an illustrative embodiment. In this depicted example, liquid shim material
500 is shown placed within gap
300 and location
400 between a plurality of composite parts. In this example, the plurality of composite parts comprises skin panel
302 and rib
402.
[0053] In addition, magnetically permeable material
502 in the form of wires
504 is located within liquid shim material
500. In this illustrative example, wires
504 may be smart susceptors. As can be seen in this illustrative example, induction coil
506 is positioned over liquid shim material
500 in location
400 within gap
300. In this example, induction coil
506 is positioned substantially parallel to surface
508 of skin panel
302.
[0054] Induction coil
506 is configured to generate magnetic field
510. As can be seen in this particular example, magnetic field
510 extends through skin panel
302 and encompasses liquid shim material
500. Wires
504 extend substantially parallel to magnetic field
510 in this illustrative example.
[0055] Magnetically permeable material
502 in wires
504 may be comprised of various materials. In this illustrative example, magnetically permeable material
502 may be, for example, a ferromagnetic material with a level of nickel that provides a desired level of corrosion resistance. Further, wires
504 may have various diameters. In this illustrative example, a wire in wires
504 may have a diameter from about 0.003 inches to about 0.020 inches. Of course, other diameters may be used too.
[0056] Also, in this illustrative example, wires
504 have a circular cross-section. In other illustrative examples, wires
504 may have other cross-section shapes such as a triangle, a trapezoid, an oval, or some other suitable shape. The selection of the cross-section may depend on whether wires
504 are to remain within liquid shim material
500 after liquid shim material
500 has been cured. The curing causes liquid shim material
500 to take a solid form.
[0057] Magnetic field
510 generated by induction coil
506 causes wires
504 to generate heat. This heat may then heat liquid shim material
500 to cure liquid shim material
500 into a solid form. In particular, this heat is configured to cause liquid shim material
500 to form a solid. The heating may be caused by fluctuations in magnetic field
510.
[0058] As depicted, induction coil
506 may operate with frequency from about 20 kHz to about 500 kHz. .In these illustrative examples, the frequency may control the current depth in wires
504. As the temperature increases, at some point wires
504 change from a magnetic condition to a nonmagnetic condition. As a result, the power generated in wires
504 drops and wires
504 do not increase in temperature from heating.
[0059] In particular, the heat generated by magnetically permeable material
502 in wires
504 may reach a temperature that is at least the curing temperature for liquid shim material
500 to form a shim when liquid shim material
500 cures into a solid form. This temperature may be selected through controlling magnetic field
510, the selection of the Curie temperature for magnetically permeable material
502 in wires
504, or some combination thereof. In these illustrative examples, the temperature at which wires
504 do not increase in temperature also may be a function of the diameter of wires
504. Increasing the diameter of wires
504 increases the temperature at which wires
504 stop heating.
[0060] With the selection of magnetically permeable material
502 having a Curie temperature that is substantially close to the curing temperature of liquid shim material
500, the curing of liquid shim material
500 may be performed more easily in this illustrative example. The curing of liquid shim material
500 also may be performed more reliably. For example, with the use of magnetically permeable material
502, a more uniform heating may occur as compared to other heating systems. With other heating systems such as heating blankets, some portions of liquid shim material
500 may heat to different temperatures. For example, a portion of liquid shim material
500 that may be near a heat sink may be lower than desired as compared to other portions of liquid shim material
500 when a heat blanket is used.
[0061] The selection of the Curie temperature for magnetically permeable material
502 may provide for a self-controlling of a mechanism for the temperature reached by heat generated by magnetically permeable material
502. Once a Curie temperature is identified, magnetically permeable material
502 is selected based on the temperature.
[0062] In other words, the magnetic field generator may not need to be controlled to control the temperature generated by wires
504. The magnetic field generator may only need to be controlled to cause wires
504 to generate heat to the maximum temperature without requiring a regulator or feedback system. The Curie temperature is selected to be greater than the curing temperature in these illustrative examples. This type of selection of the Curie temperature may be performed such that wires
504 generate a desired amount of heat. The desired amount of heat may be at a level that compensates for heat that may be conducted from liquid shim material
500 into other structures such as support structure
204, skin panel
302, or both.
[0063] For example, the Curie temperature may be selected to be about 50 degrees F to about 75 degrees F above the temperature at which curing is desired. Of course, the particular temperature selected may vary depending on the material. In the illustrative example, this temperature may be dependent on the type of alloy that is selected for use in wires
504.
[0064] Turning next to
Figure 6, an illustration of an exposed view of a liquid shim material with a magnetically permeable material is depicted in accordance with an illustrative embodiment. In this example, an exposed view in the direction of lines
6-6 in
Figure 5 is shown. In this exposed view, skin panel
302 and induction coil
506 are not shown.
[0065] In this view, magnetically permeable material
502 in wires
504 are illustrated as running substantially parallel to each other. Wires
504 are located within liquid shim material
500 in this particular example.
[0066] With reference next to
Figure 7, an illustration of a shim formed from a liquid shim material is depicted in accordance with an illustrative embodiment. In this illustrative example, shim
700 results from the curing of liquid shim material
500 in
Figure 5. In this particular example, magnetically permeable material
502 remains within shim
700.
[0067] Turning now to
Figure 8, an illustration of a liquid shim material in a gap is depicted in accordance with an illustrative embodiment. As depicted, liquid shim material
800 is placed into gap
300 in location
400.
[0068] In this illustrative example, induction coil
802 and magnetically permeable material
804 in the form of wires
806 are located in layer
808. As depicted, layer
808 is placed in contact with liquid shim material
800.
[0069] In this illustrative example, induction coil
802 in layer
808 is configured to generate magnetic field
809. In response to magnetic field
809, wires
806 in layer
808 generate heat for curing liquid shim material
800.
[0070] In this illustrative example, wires
806 have a cross-section with a rectangular shape. In this particular example, thickness
810 of layer
808 may be negligible with respect to the formation of a shim in gap
300. Further, skin panel
302 may be removed during the curing of liquid shim material
800 such that liquid shim material
800 has thickness
810 to fill gap
300 between skin panel
302 and rib
402.
[0071] In other illustrative examples, induction coil
802 may be located outside of layer
808 while magnetically permeable material
804 in the form of wires
806 may remain in layer
808. The location of induction coil
802 may be on top of skin panel
302 or at any location in which magnetic field
809 may be generated by induction coil
802 such that wires
806 in layer
808 generate heat for curing liquid shim material
800.
[0072] With reference now to
Figure 9, an illustration of a shim formed from a liquid shim material is depicted in accordance with an illustrative embodiment. In this illustrative example, layer
808 has been removed after curing of liquid shim material
800 to form shim
900. Parts such as skin panel
302 may be connected to composite wing
200 from
Figure 2 to finish manufacturing of composite wing
200. As can be seen, layer
808 is absent from composite wing
200 in this particular example.
[0073] The illustration of the formation of a shim using a liquid shim material in
Figures 2-
9 are not meant to imply limitations to the manner in which other illustrative embodiments may be implemented. For example, although a shim has been shown as being formed between a skin panel and a rib, a shim may be formed in accordance with an illustrative embodiment between other parts. For example, a shim may be formed in the gap between a skin panel and a spar. A shim also may be formed between other components such as a wing to body joint area, a horizontal stabilizer to body joint, a vertical stabilizer to body joint, a floor beam to fuselage joint, and other suitable components.
[0074] Also, the different components shown in
Figures 2-9 may be combined with components in
Figure 1, used with components in
Figure 1, or a combination of the two. Additionally, some of the components in
Figures 2-9 may be illustrative examples of how components shown in block form in
Figure 1 can be implemented as physical structures.
[0075] With reference now to
Figure 10, an illustration of a flowchart of a process for forming a shim is depicted in accordance with an illustrative embodiment. The process illustrated in
Figure 10 may be implemented in manufacturing environment
100 using shim manufacturing system
116 in
Figure 1.
[0076] The process begins by applying a liquid shim material with a magnetically permeable material in a location for a shim between a plurality of composite parts (operation
1000). In operation
1000, the magnetically permeable material is placed in at least one of in the liquid shim material in the location prior to the liquid shim material being applied to the location, or on the liquid shim material after the liquid shim material is applied to the location. Further, the liquid shim material may have a shape desired for the shim when applied to the location.
[0077] In other illustrative examples, the liquid shim material may be applied to the location in a manner that forms the shape desired for the shim. For example, a release film, plastic strips, or other structures may be used to form a mold for the shim.
[0078] The process then applies a magnetic field to the magnetically permeable material (operation
1002), with the process terminating thereafter. In operation
1002, the magnetic field is configured to heat the liquid shim material to a temperature to cause the liquid shim material to become solid and form the shim.
[0079] Turning now to
Figure 11, an illustration of a flowchart of a process for forming a shim using smart susceptors is depicted in accordance with an illustrative embodiment. The process illustrated in
Figure 10 may be implemented in manufacturing environment
100 using shim manufacturing system
116 in
Figure 1.
[0080] The process begins by identifying a gap between a plurality of parts that have been positioned relative to each other to form a structure (operation
1100). The process then forms a liquid shim material with a smart susceptor wire array (operation
1102). In this illustrative example, materials may be used to form the liquid shim material. These materials may take various forms. For example, two materials may be mixed such that they begin to cure after mixing. As another illustrative example, the liquid shim material may be a temperature in which curing did not occur. When the material reaches room temperature, curing of the liquid shim material may occur. The liquid shim material may have various viscosities. For example, the liquid shim material may have a viscosity similar to clay or a paste. The smart susceptor wire array is an array of wires including a magnetically permeable material.
[0081] The liquid shim material with the smart susceptor wire array is placed into the location where the gap is located between the different parts (operation
1104). Of course, other materials such as release films, plastic layers, or other structures may be used to provide a mold for the liquid shim material with the smart susceptor wire array.
[0082] An induction coil is positioned relative to the location where the liquid shim material with the smart susceptor wire array is located (operation
1106). The process generates a magnetic field using the induction coil to cause the smart susceptor wire array to generate heat (operation
1108). The process continues to generate the magnetic field until the liquid shim material has cured to form a shim (operation
1110).
[0083] The process then disassembles the parts (operation
1112). The process removes any excess material from the shim along with a release film or other materials (operation
1114). The different parts are then reassembled and connected to each other to form the structure
(1116), with the process terminating thereafter.
[0084] With reference next to
Figure 12, another illustration of a flowchart of a process for forming a shim using smart susceptors is depicted in accordance with an illustrative embodiment. The process illustrated in
Figure 12 may be implemented in manufacturing environment
100 using shim manufacturing system
116 in
Figure 1.
[0085] The process begins by identifying a gap between a plurality of parts that have been positioned relative to each other to form a structure (operation
1200). The process then forms a liquid shim material (operation
1202).
[0086] The liquid shim material and an induction heating system are placed into the location where the gap is located between the different parts (operation
1204). Of course, other materials such as release films, plastic layers, and other structures may be used to provide a mold for the liquid shim material with the acceptor wire array. In this illustrative example, the induction heating system is a layer including a smart susceptor wire array and an induction coil. This layer may be placed on top of the liquid shim material in this illustrative example.
[0087] The process generates a magnetic field using the induction coil to cause the smart susceptor wire array in the induction heating system to generate heat (operation
1206). The process continues to generate the magnetic field until the liquid shim material has cured to form a shim (operation
1208).
[0088] The process then disassembles the parts (operation
1210). The process removes the heating system and any excess material from the shim along with a release film or other materials (operation
1212). The different parts are then reassembled and connected to each other to form the structure
(1214), with the process terminating thereafter.
[0089] The flowcharts and block diagrams in the different depicted embodiments illustrate the architecture, functionality, and operation of some possible implementations of apparatuses and methods in an illustrative embodiment. In this regard, each block in the flowcharts or block diagrams may represent a module, a segment, a function, and/or a portion of an operation or step.
[0090] In some alternative implementations of an illustrative embodiment, the function or functions noted in the blocks may occur out of the order noted in the figures. For example, in some cases, two blocks shown in succession may be executed substantially concurrently, or the blocks may sometimes be performed in the reverse order, depending upon the functionality involved. Also, other blocks may be added in addition to the illustrated blocks in a flowchart or block diagram.
[0091] For example, although the different operations illustrated in
Figure 9 have been described with respect to composite parts, the different illustrative examples may be applied to other types of parts other than composite parts. Further, the parts in a structure may be mixed between composite and non-composite parts in accordance with an illustrative embodiment.
[0092] As another example, the heating system may only include a layer in which the smart susceptor wire array is present. The induction coil is positioned over the part. In this example, the layer is still removed after the shim has been formed from the liquid shim material.
[0093] Illustrative embodiments of the disclosure may be described in the context of aircraft manufacturing and service method
1300 as shown in
Figure 13 and aircraft
1400 as shown in
Figure 14. Turning first to
Figure 13, an illustration of an aircraft manufacturing and service method is depicted in the form of a block diagram in accordance with an illustrative embodiment. During pre-production, aircraft manufacturing and service method
1300 may include specification and design
1302 of aircraft
1400 in
Figure 14 and material procurement
1304.
[0094] During production, component and subassembly manufacturing
1306 and system integration
1308 of aircraft
1400 in
Figure 14 takes place. Thereafter, aircraft
1400 in
Figure 14 may go through certification and delivery
1310 in order to be placed in service
1312. While in service
1312 by a customer, aircraft
1400 in
Figure 14 is scheduled for routine maintenance and service
1314, which may include modification, reconfiguration, refurbishment, and other maintenance or service.
[0095] Each of the processes of aircraft manufacturing and service method
1300 may be performed or carried out by a system integrator, a third party, and/or an operator. In these examples, the operator may be a customer. For the purposes of this description, a system integrator may include, without limitation, any number of aircraft manufacturers and major-system subcontractors; a third party may include, without limitation, any number of vendors, subcontractors, and suppliers; and an operator may be an airline, a leasing company, a military entity, a service organization, and so on.
[0096] With reference now to
Figure 14, an illustration of an aircraft is depicted in the form of a block diagram in which an illustrative embodiment may be implemented. In this example, aircraft
1400 is produced by aircraft manufacturing and service method
1300 in
Figure 13 and may include airframe
1402 with plurality of systems
1404 and interior
1406. Examples of systems
1404 include one or more of propulsion system
1408, electrical system
1410, hydraulic system
1412, and environmental system
1414. Any number of other systems may be included. Although an aerospace example is shown, different illustrative embodiments may be applied to other industries, such as the automotive industry.
[0097] Different parts in the different systems in aircraft
1400 may be assembled using an illustrative embodiment. The assembly of these parts may result in one or more gaps that result from manufacturing variances. These variances may be variances in dimensions of one or more of the parts for aircraft
1400.
[0098] For example, without limitation, aircraft
1400 may include a first part and a second part assembled adjacent to each other. The second part includes a portion configured to be adjacent to the first part upon attachment thereto. The second part is at least partially separated from said first part by a gap due to variances in fabrication. A shim is disposed in the gap between the first part and the second part. The shim comprises a magnetically permeable material disposed therein, and the shim material is solidified in place in the gap between the first part and said second part from exposing the magnetically permeable material to a magnetic field.
[0099] In some illustrative examples, the first part and the second part may be selected from different types of parts. For example, the first part and the second part may each be selected from one of a composite part, a metal part, a honeycomb sandwich panel, a skin panel, a plastic part, a wood part, a ceramic part, or other suitable types of parts.
[0100] In particular, the first part and the second part may be made of the same or different types of materials. For example, the first part may be a composite part while the second part is a metal part. Of course, any combination of materials for parts may be used with the shim in accordance with an illustrative embodiment.
[0101] Apparatuses and methods embodied herein may be employed during at least one of the stages of aircraft manufacturing and service method
1300 in
Figure 13. In one illustrative example, components or subassemblies produced in component and subassembly manufacturing
1306 in
Figure 13 may be fabricated or manufactured in a manner similar to components or subassemblies produced while aircraft
1400 is in service
1312 in
Figure 13. As yet another example, one or more apparatus embodiments, method embodiments, or a combination thereof may be utilized during production stages, such as component and subassembly manufacturing
1306 and system integration
1308 in
Figure 13. One or more apparatus embodiments, method embodiments, or a combination thereof may be utilized while aircraft
1400 is in service
1312 and/or during maintenance and service
1314 in
Figure 13. The use of a number of the different illustrative embodiments may substantially expedite the assembly of and/or reduce the cost of aircraft
1400.
[0102] For example, an illustrative embodiment may be implemented during component and subassembly manufacturing
1306. For example, an illustrative embodiment may be implemented to form shims in wing assemblies. An illustrative embodiment also may be implemented during maintenance and service
1314. For example, composite structures manufactured during maintenance and service
1314 for replacement of deposit structures, upgrading composite structures, refurbishing composite structures, or other purposes may include shims formed in accordance with an illustrative embodiment.
[0103] In this manner, the manufacturing, maintenance, and other operations during the life cycle of aircraft
1400 may be performed more quickly with an illustrative embodiment. As a result, the cost, of manufacturing and maintaining aircraft
1400 may be reduced.
[0104] Thus, the illustrative examples provide a method and apparatus for forming a shim. In the illustrative examples, a liquid shim material is applied to a location in which the fit between parts is not as great as desired. In particular, a gap may be present between several parts. Inductive heating is used to heat the liquid shim material to form the shim for the parts.
[0105] With the use of magnetically permeable materials, these materials may be placed in locations relative to the liquid shim material to provide a desired level of heating throughout the liquid shim material to form a shim. As described above, the magnetically permeable materials may be located within the liquid shim material or external to the liquid shim material.
[0106] Illustrative, non-exclusive examples of inventive subject matter according to the present disclosure are described in the clauses A1-D21, below:
A1. A method for forming a shim (118), the method comprising:
applying (1000) a liquid shim material (124) with a magnetically permeable material (130) in a location (112) for the shim (118) between a plurality of composite parts (108); and
applying (1002) a magnetic field (136) to the magnetically permeable material (130) in the location (112), wherein the magnetic field (136) is configured to heat the liquid shim material (124) to a temperature to cause the liquid shim material (124) to become solid and form the shim (118).
A2. The method of clause A1 further comprising:
positioning a magnetic field generator (128) such that the magnetic field generator (128) applies the magnetic field (136) to the magnetically permeable material (130).
A3. The method of any of clauses Al- A2, wherein applying the liquid shim material (124) with the magnetically permeable material (130) in the location (112) for the shim (118) between the plurality of composite parts (108) comprises:
applying the liquid shim material (124) to the location (112); and
placing the magnetically permeable material (130) in the location (112).
A4. The method of any of clauses A1-A3, wherein the magnetically permeable material (130) is placed in at least one of in the liquid shim material (124) in the location (112) prior to the liquid shim material (124) being applied to the location (112) or on the liquid shim material (124) after the liquid shim material (124) is applied to the location (112).
A5. The method of any of clauses A1-A4 further comprising:
removing the magnetically permeable material (130) after heating the liquid shim material (124) to form the shim (118).
A6. The method of any of clauses A1-A5, wherein the magnetically permeable material (130) has a shape (125) selected from at least one of a wire, a strip, a plate, or a sheet.
A7. The method of clause A6, wherein the wire has a diameter from about 0.003 inches to about 0.020 inches.
A8. The method of any of clauses A2-A7, wherein the magnetic field generator (128) and the magnetically permeable material (130) form a layer (808) placed in contact with the liquid shim material (124).
A9. The method of clause A8, wherein the layer (808) is configured to be removed after the liquid shim material (124) becomes solid to form the shim (118).
A10. The method of any of clauses A1-A9, wherein the magnetically permeable material (130) is a smart susceptor (140).
A11. The method of any of clauses A1-A10, wherein the magnetically permeable material (130) is selected from at least one of an alloy, a cobalt, an iron alloy, a nickel and iron alloy, an iron and silicon alloy, an amorphous magnetic alloy, or a crystalline magnetic alloy.
B12. A method for forming a shim (118), the method comprising:
applying (1000) a liquid shim material (124) with a magnetically permeable material (130) in a location (112) for the shim (118) between a plurality of parts (104); and
applying (1002) a magnetic field (136) to the magnetically permeable material (130) in the location (112), wherein the magnetic field (136) is configured to heat the liquid shim material (124) to a temperature to cause the liquid shim material (124) to become solid and form the shim (118).
C13. An apparatus comprising:
a liquid shim material (124) with a magnetically permeable material (130) applied in a location (112) for a shim (118) between a plurality of composite parts (108); and
a magnetic field generator (128) configured to apply a magnetic field (136) to the magnetically permeable material (130) in the location (112), wherein the magnetic field (136) is configured to heat the liquid shim material (124) to a temperature to cause the liquid shim material (124) to become solid and form the shim (118).
C14. The apparatus of clause C13, wherein the magnetic field generator (128) is positioned such that the magnetic field generator (128) applies the magnetic field (136) to the magnetically permeable material (130).
C15. The apparatus of any of clauses C13-C14, wherein the magnetically permeable material (130) is placed in at least one of in the liquid shim material (124) in the location (112) prior to the liquid shim material (124) being applied to the location (112) or on the liquid shim material (124) after the liquid shim material (124) is applied to the location (112).
C16. The apparatus of any of clauses C13-C15, wherein the magnetically permeable material (130) is removed after heating the liquid shim material (124) to form the shim (118).
C17. The apparatus of any of clauses C13-C16, wherein the magnetically permeable material (130) has a shape (125) selected from at least one of a wire, a strip, a plate, or a sheet.
C18. The apparatus of clause C17, wherein the wire has a diameter from about 0.003 inches to about 0.020 inches.
C19. The apparatus of any of clauses C13-C18, wherein the magnetic field generator (128) and the magnetically permeable material (130) form a layer (808).
C20. The apparatus of clause C19, wherein the layer (808) is configured to be removed after the liquid shim material (124) becomes solid to form the shim (118).
D21. An aircraft (1400) comprising:
a first part;
a second part includes a portion configured to be adjacent to the first part upon attachment thereto, wherein the second part is at least partially separated from the first part by a gap (110) due to variances in fabrication; and
a shim (118) disposed in the gap (110) between the first part and the second part, wherein the shim (118) comprises a magnetically permeable material (130) disposed therein, and the shim (118) is solidified in place in the gap (110) between the first part and the second part from exposing the magnetically permeable material (130) to a magnetic field (136).
[0107] The description of the different illustrative embodiments has been presented for purposes of illustration and description, and is not intended to be exhaustive or limited to the embodiments in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art. Further, different illustrative embodiments may provide different features as compared to other illustrative embodiments. The embodiment or embodiments selected are chosen and described in order to best explain the principles of the embodiments, the practical application, and to enable others of ordinary skill in the art to understand the disclosure for various embodiments with various modifications as are suited to the particular use contemplated.