Abstract:
A system and method for simulating a structure is disclosed. An adjustable interior mockup for simulating a structure has a base with a first elongated side and a second elongated side, the first elongated side being nonadjacent the second elongated side; and an adjustable frame secured to the base. The adjustable frame includes a plurality of girder members secured along the first and second elongated sides to form an arc; a plurality of brackets; a plurality of arms having a latch attached to one end; and a sheet of fabric. The girders are securely fastened along the first elongated side of the base at predetermined intervals; the brackets are secured to the girders; the arms are received by the brackets and adjustably anchored to the girders via a fastener; and the latches engage the sheet of fabric, thus pulling the fabric into a shape that resembles the structure.

Description:
BACKGROUND 
       [0001]    The vehicular design industry continually strives to make vehicles lighter and more fuel efficient. The use of composite materials in the design and manufacture process has created a multitude of options in optimizing a vehicle&#39;s shape. Vehicular shapes have since become increasingly more complex. Ensuring a sufficient amount of usable space within the vehicle is an important consideration with new vehicle shapes. Both space maximization and passenger comfort are a concern. Of particular interest is aircraft fuselage design. 
         [0002]    Currently, reviewing digital mockups of the interior of an aircraft is the dominant method of performing an early evaluation of new aircraft design concepts. Two-dimensional floor plans provide preliminary dimensions for the inside of the aircraft. Three-dimensional models may also be used to get a better idea of how the inside of the aircraft might look, and more accurately show the amount of space that passengers are allotted inside the aircraft. Persons having an expert level of aircraft knowledge are required to read and interpret the plans. It is eventually necessary to have a life-size interior mockup of the aircraft in order for the designers and engineers to make educated decisions regarding spacing of seats, overhead bins, et cetera. 
         [0003]    Traditional interior mockups use machined materials to represent interior surfaces of an aircraft to allow designers to make cabin-sized adjustments to proposed interior arrangements before the final aircraft is built. The traditional mockups require significant time to construct, and are expensive. Furthermore, once the original mockup has been constructed, tests often identify unanticipated customer comfort aspects. The resulting modifications require an entire new set of machined materials. This re-fabrication adds to the cost, and can also delay projects. 
       SUMMARY 
       [0004]    The following presents a simplified summary of the invention in order to provide a basic understanding of some aspects of the invention. This summary is not an extensive overview of the invention. It is not intended to identify critical elements of the invention or to delineate the scope of the invention. Its sole purpose is to present some concepts of the invention in a simplified form as a prelude to the more detailed description that is presented below. 
         [0005]    In one embodiment, an adjustable interior mockup is disclosed for simulating a three-dimensional structure. The mockup includes a modifiable structural frame having a plurality of arms adjustably secured thereto, and a flexible panel. The plurality of arms is engagable with the flexible panel to simulate the three-dimensional structure. 
         [0006]    In one embodiment, an adjustable interior mockup for simulating a structure has a base, an adjustable frame and a sheet of fabric. The base has a first elongated side and a second elongated side, where the first elongated side is nonadjacent to the second elongated side. The adjustable frame is secured to the base and includes a plurality of girder members secured to the base and a plurality of arms adjustably secured to the girder members. 
         [0007]    In another embodiment, an adjustable interior mockup for simulating a structure has a base with a first elongated side and a second elongated side, the first elongated side being nonadjacent the second elongated side; and an adjustable frame secured to the base. The adjustable frame includes a plurality of girder members secured along the first and second elongated sides to form an arc; a plurality of brackets; a plurality of arms having a latch attached  to one end; and a sheet of fabric. The girders are securely fastened along the first elongated side of the base at predetermined intervals; the brackets are secured to the girders; the arms are received by the brackets and adjustably anchored to the girders via a fastener; and the latches engage the sheet of fabric, thus pulling the fabric into a shape that resembles the structure. 
         [0008]    In still another embodiment, a method for modifying a structural design is disclosed. The method has the following steps: (a) providing an adjustable frame attached to a base, (b) providing a sheet of fabric; (c) determining a first desirable change in the design of the structure; (d) adjusting the length of the arms having latches on the end to simulate the desired changes; (e) determining a second desirable change in the design of the structure; and (f) adjusting the length of the contoured branches to simulated the desired changes. The adjustable frame includes a plurality of girder members secured along the first and second elongated sides to form an arc; a plurality of brackets; a plurality of arms having a latch attached to one end; and a plurality of contoured branches. The girders are securely fastened along the first elongated side of the base at predetermined intervals; the brackets are secured to the girders; and the arms are received by the brackets and adjustably anchored to the girders via a fastener. The latches on the ends of the arms engage the fabric, pulling the fabric into the desired shape, and the contoured branches press against the fabric thereby simulating depressions in the design. The steps for adjusting the length of the arms include: loosening the fastener; moving the arm away from or towards the center of the adjustable frame as desired; and tightening the fastener to secure the arm in place. Position indicators on the arms indicate the length of the arm. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]    Illustrative embodiments of the present invention are described in detail below with reference to the attached figures.  
           [0010]      FIG. 1  is a perspective view of the invention, according to one embodiment. 
           [0011]      FIG. 2  is a close-up perspective view of the invention of  FIG. 1  showing the frame in greater detail. 
           [0012]      FIG. 3  is another close-up perspective view of the invention of  FIG. 1  showing the frame in greater detail with a representative cutout. 
           [0013]      FIG. 4  is another close-up perspective view of the invention of  FIG. 1  showing a strut member. 
           [0014]      FIG. 5  is yet another close-up perspective view of the invention of  FIG. 1  showing the front face of a bracket and a clamp. 
           [0015]      FIGS. 6A and 6B  show additional close-up perspective views of the invention of  FIG. 1  showing an arm engaging a rod in alternate embodiments. 
           [0016]      FIG. 7  is still yet another close-up perspective view of the invention of  FIG. 1 , showing a contoured branch. 
           [0017]      FIG. 8  is a side view of the invention of  FIG. 1 . 
       
    
    
     DETAILED DESCRIPTION 
       [0018]    Embodiments of the present invention provide a type of adjustable interior cabin mockup assembly for modeling the actual size and shape of a vehicle. While reference herein is made to the use of an adjustable mockup assembly in aircraft design and manufacture, it shall be understood that the invention may have application in other industries needing a cost-effective and quicker method of creating models of products. 
         [0019]    With reference to  FIG. 1 , in one embodiment, an adjustable interior mockup assembly  10  includes a base  100 , an adjustable frame  200 , and a flexible panel  300 , which, in an embodiment, is an elastic fabric material. It should be noted that the term “panel” as used herein,  unless otherwise specified, may comprise any material that is flexible when acted on by forces and is thus repositionable. 
         [0020]    The base  100  may have at least an upper flat surface  115  parallel to the ground. The base  100  supports the weight of the frame  200  as shown in  FIGS. 1&amp;3 . The base may further include a first side surface  105  and a second side surface  110  opposite the first side surface  105  to aid in attaching the frame  200  to the base  100  by receiving fasteners  225 . Wheels  120  may be attached to the base  100  for easy transportation of the mockup assembly  10 . 
         [0021]    As shown in the figures, the adjustable frame  200  is a complex structure for supporting the flexible panel  300  and may include a plurality of longitudinally-spaced, radially extending girders  205  (or frame stations  205 ), a plurality of laterally-spaced struts  210  (or stringers  210 ) spanning between and secured to the girders  205 , and a plurality of arms  215  outwardly supported by double-sided brackets  220  that flank the girders  205 . The arms  215  are held into place via mechanical couplers  230 , for example, clamps or vices. The girders  205  serve as the main structural component of the mockup assembly  10 . The girders  205  extend upwardly and outwardly from the base  100 , and may be shaped to resemble any general structure to be simulated. For example, the girders  205  may be curved to resemble the circular shape of an aircraft cabin, as shown in  FIGS. 2-8 . Alternately, the girders  205  may take a square shape, or be more oval in shape. 
         [0022]    The girders  205  may take a variety of forms to create the shape of the structure. For example, each girder  205  may be formed from a single member that extends from the base&#39;s first side  105  to the second side  110 . Alternately, the girder  205  may be formed of multiple members extending from either side  105 ,  110  of the base  100  and spliced together as necessary. The girders  205  may be constructed of any appropriate material, including but not  limited to wood, steel, hard plastic, et cetera. Each girder  205  may be fastened to the base  100  using any appropriate method. For example, L-shaped fastening plates  225  (as shown in  FIG. 3 ) may be secured to the girders  205  and the base  100  to hold the girders  205  in place. 
         [0023]    Multiple girders  205  may be attached along each of the first and second sides  105 ,  110  of the base  100  at predefined intervals. The intervals between the girders  205  may depend on the length of the structure and the shape of the structure being replicated. In some embodiments, additional girders  205  may be required on the sides of the base  100  adjacent the first and second sides  105 ,  110 . 
         [0024]    The frame  200  is further fortified by the strut members  210  that span across the girders  205  lengthwise along the first and second sides  105 ,  110 . As illustrated in  FIGS. 2-4 , the struts  210  may span across several girders  205  as appropriate.  FIG. 4  illustrates how the struts  210  may aid in splicing together multiple girder members  205 A,  205 B. Outwardly projecting ends  206 A,  206 B may stick out of the girders  205  and be configured to fit into holes cut into the struts  210  for receiving the ends  206 A,  206 B. The struts  210  may additionally have cut-outs configured to receive and support arms  215  as shown in  FIG. 4 . The struts  210  may be generally held into place via the ends  206 A,  206 B and the arms  215 , though the strut  210  may additionally be secured into place using any acceptable fastening means. 
         [0025]    The arms  215  may be further supported by the double-sided brackets  220  secured to the girders  205 . Each bracket  220  may include a front support  222  (as shown in  FIG. 5 ) which receives the arm  215  and a back support  224  (as shown in  FIG. 7 ). The brackets  220  flank the girders  205  such that the front support  222  is secured to one side of the girder  205  and the back support is secured to the opposite side, as illustrated in  FIG. 8 . A hole in the center of the front support  222  may receive the arm  215 , as shown in  FIG. 5 . The back support  224  may,  in addition to the struts  210 , aid in splicing together multiple girders  205 . However, the bracket  220  may include only a front support  222  secured directly to the girder  205 , if the back support  224  is unnecessary. 
         [0026]    The arm  215  may be held in place via the mechanical coupler  230  such as a clamp, for example. The clamp  230  may be secured to the bracket  220  to hold the arm  215  in the correct position. The length of the arm  215  may be adjusted by releasing the clamp  230  and moving the arm  215  back and forth within the hollowed center of the bracket&#39;s front support  222 . For ease of reference, the arms  215  may be equipped with position indicators  226  to indicate to the user the position of the clamp  230 . It may thus be apparent that a single adjustable frame  200  may be able to simulate several differently sized structures based on the specifications of a particular project. For example, in the aircraft fuselage illustrated in the figures, sliding the arm  215  further through the bracket&#39;s front support  222  decreases the size of the mockup fuselage; withdrawing the arm  215  increases the size of the fuselage. It may be appreciated by a person of skill in the art that adjusting the lengths of the arms  215  may be an automated process. Such automation may allow for quicker and more accurate placement and adjustment of the arms  215 . 
         [0027]    Although the fuselage may not have a straight shape, the shape of the fuselage can be replicated by varying the lengths of the arms  215  as necessary. It will also be noted that revisions in the structure can be easily accomplished simply by changing the lengths of the arms  215 . 
         [0028]    Each arm  215  may be equipped with a latch  240  on a distal end for grasping the fabric  300 . The latch  240  may be, for example, a hook  240 A (as shown in  FIG. 6A ) or a clasp defined by opposing rollers  240 B (as shown in  FIG. 6B ). Laterally spaced rods  305  may be sewn into, or otherwise secured to, the fabric  300 . The latch  240  may engage the rods  305 , thus pulling  the fabric  300  toward the frame  200  to the approximate shape of the structure to be replicated. Thus, together the frame  200  and the fabric  300  model the free space within the simulated structure. Modeling software, such as CATIA®, may be used to develop a template indicating approximately where the rods  305  should be secured to the fabric  300 . Alternately, the latches  240  may directly engage the fabric  300  without having rods  305 . 
         [0029]    The number of brackets  220  and arms  215  required may be determined by shape of the structure to be simulated. For example, as shown in  FIG. 1 , brackets  220  are secured at intervals around the entire length of the girders  205  to allow the latches  240  to pull the fabric  300  into an arc resembling the shape of an aircraft cabin. 
         [0030]    Many types of material  300  may be used to accomplish the flexible panel  300  in the mock-up assembly. As noted above, the panel  300  could comprise any material that is flexible when acted on by forces, and is thus repositionable. However, it may be realized by those skilled in the art that a fabric  300  having a high elasticity may be preferable so as to accommodate the stretching necessary to create an accurate representation of a structure and to allow for revisions to the design. Additionally, it may be realized that a fabric  300  that allows light to escape through the fabric may be preferable so that the light from the outside of the fabric may be sufficient to light the inside of the mock-up. 
         [0031]    As shown in  FIG. 7 , in addition to arms  215  with latches  240 , contoured branch  217  may be used to simulate depressions in the structure, such as overhead compartments. The contoured branch  217  may be substantially similar to the arms  215 , though the distal end of the contoured branch  217  may be equipped with a shaped end  219  rather than a latch  240 . The contoured branch  217  may be secured into the bracket  220  in the same manner as arm  215 . While the arms  215  pull the fabric  305  into the desired shape, the shaped end  219  of the  contoured branch  217  may press against the fabric  305  to form depressions in the fabric simulating, for example, overhead bins in an aircraft cabin. This may allow designers to quickly ascertain issues in the design and to make changes as necessary. 
         [0032]    The mock-up may be built to scale to hold furnishings such as aircraft compliant seats and tables. The frame  200  may be further configured to take into account door openings and other structural features. Once in the mockup is complete, designers can move throughout the structure and make adjustments as necessary. Revisions in the design of the structure can be easily and inexpensively made. 
         [0033]    Many different arrangements of the various components depicted, as well as components not shown, are possible without departing from the spirit and scope of the present invention. Embodiments of the present invention have been described with the intent to be illustrative rather than restrictive. Alternative embodiments will become apparent to those skilled in the art that do not depart from its scope. A skilled artisan may develop alternative means of implementing the aforementioned improvements without departing from the scope of the present invention. 
         [0034]    It will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations and are contemplated within the scope of the claims. Not all steps listed in the various figures need be carried out in the specific order described.