CN111144046A - Assembly gap determining method based on thin-wall part external mold line control - Google Patents
Assembly gap determining method based on thin-wall part external mold line control Download PDFInfo
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Abstract
A method for determining the assembling clearance and the padding amount based on the control of an external mold line of a thin-wall part of an airplane comprises the steps of firstly, obtaining the geometric information or the actual pre-assembling shape of a framework, an internal mold line and an external mold line of a skin (wall plate) by using digital measuring equipment, carrying out partitioning and characteristic reconstruction on collected point clouds, then, calculating a coordinate transformation matrix through positioning features such as positioning surfaces, positioning holes and the like of all parts, unifying the coordinates of actually measured data points to a global coordinate system, carrying out assembling positioning based on rigid hypothesis, finally, carrying out flexible optimal fitting on the external mold line of an actually measured model and a theoretical external mold line to simulate an ideal state required to be reached by assembling, and calculating the clearance amount between the internal mold line and the framework under the state. The invention improves the efficiency and the precision of the assembly process, reduces the time for repeatedly trial assembly of products and reduces the cost of a special measuring tool and a shape-preserving tool.
Description
Technical Field
The invention relates to an assembly technology, in particular to an efficient and automatic assembly method of an airplane thin-wall part, and specifically relates to an assembly gap determination method based on outer mold line control of the airplane thin-wall part through virtual assembly.
Background
The typical structure of aerospace products is a framework-thin wall shell structure. In order to ensure the pneumatic performance and streamline shape of the appearance, the deviation of the outer mold line from a theoretical value must be controlled within a certain range, however, the parts forming the framework are numerous, the reasons influencing the appearance of the framework are numerous, and the outer mold line is difficult to control due to the accumulation of errors. The design of modern aviation industry requires that an assembly gap is formed between an assembled metal framework and a matched thin-wall part, and the errors of framework assembly and thin-wall part machining are corrected by adding a gasket in the assembly gap, so that an outer mold line is controlled within a required range. The problem with this assembly process is that it is very time consuming and thin-walled parts are prone to deformation from assembly forces and quality problems, which add difficulty to the determination of the assembly gap.
Disclosure of Invention
The invention aims to provide an assembly gap determining method based on external mold line control of an airplane thin-wall part, aiming at the problems that the existing padding process is time-consuming, the thin-wall part is easy to deform under the action of assembly force and the quality is easy to occur. The method reduces the necessity of real object trial assembly and the use of a special detection tool, and can greatly reduce the time and cost required by geometric quality inspection.
The technical scheme of the invention is as follows:
the method is characterized in that firstly, a digital measuring device is used for obtaining the initial shape of a part to be assembled, then, an actually measured finite element model is constructed to analyze the assembling process, and finally, the assembling clearance and cushion adding amount is calculated according to the assembled shape.
The method comprises the following specific steps:
the first step is as follows: acquiring an initial shape of a part to be assembled by using a digital measuring system;
step 1.1: acquiring geometric information or actual preassembly shapes of the framework, the inner mold line and the outer mold line by using a three-dimensional laser scanner;
step 1.2: smoothing and extracting the obtained dense point cloud;
step 1.3: carrying out blocking and characteristic reconstruction on the collected point cloud so as to obtain an actual measurement model of the skeleton and the skin or the wallboard;
the second step is that: analyzing the assembly process by constructing an actually measured finite element model;
step 2.1: and unifying the coordinates of the measured data points to a global coordinate system, and performing assembly fitting based on rigid hypothesis. Establishing positioning relations among parts and between the parts and the clamp through positioning characteristics of positioning surfaces, positioning holes and the like of the parts, calculating a coordinate transformation matrix, and unifying a coordinate system through the coordinate transformation relation;
step 2.2: matching an outer mold line of an actually measured model with a theoretical outer mold line in outer mold line flexible best fitting to simulate an ideal state required to be reached by assembly;
the third step: calculating the assembling clearance and cushion adding amount according to the assembled shape;
calculating the gap amount between the inner mold line and the framework under the state that the outer mold line of the actual measurement model is overlapped with the theoretical outer mold line; and then calculating a sensitivity matrix and an overall rigidity matrix of the part to obtain the gap amount between the inner mold line and the framework under the state that the outer mold line is superposed with the theoretical outer mold line.
The details are as follows:
an assembly gap determining method based on external mold line control of an airplane thin-wall part comprises the following steps:
(1) the geometry information or actual pre-assembled shape of the skeleton, inner mold line and outer mold line is first obtained using a digital measurement system. Specifically, point cloud data acquired by a digital measuring device is processed, i.e., denoised, simplified and blocked. And reconstructing by adopting a NURBS curved surface fitting method so as to obtain an actual measurement model of the framework and the skin (wall plate).
(2) In order to ensure the accuracy and effectiveness of positioning fitting in the process of assembling thin-wall parts, the invention provides a best fitting algorithm which is a successive approximation process essentially and comprises a fitting process based on rigid hypothesis and a best fitting process based on flexibility. Firstly, positioning is carried out on two holes and one surface through positioning characteristics of positioning surfaces, positioning holes and the like of parts, positioning relations among the parts and between the parts and a clamp are established, a coordinate transformation matrix is calculated, and a coordinate system is unified through the coordinate transformation relation. After the initial positioning based on the rigid body hypothesis is completed, flexible optimal fitting based on the outer model line is carried out, a finite element model based on a triangulated grid unit is established, the model reflects the actual shape and material characteristics before the flexible optimal fitting, and then a group of outer model line constraints are redefined as displacement boundary conditions on the basis of the initial positioning characteristics of the rigid body hypothesis to simulate the control of the outer model line after the assembly is completed.
(3) Once the flexible best fit is completed, i.e. a deformation geometric figure or a predicted assembled shape is generated, mathematical calculation analysis is carried out to obtain the definition of the deviation of the outer mold line and the gap between the inner mold line and the framework, and then the sensitivity matrix and the overall rigidity matrix of the part are calculated, so that the gap amount between the inner mold line and the framework under the state that the outer mold line is overlapped with the theoretical outer mold line can be obtained.
The invention has the beneficial effects that:
the invention reduces the necessity of real object trial assembly and the use of a special detection tool, can greatly reduce the time and cost required by geometric quality inspection, provides a new idea for assembly under more complicated component geometry and loading conditions, can be easily applied to the assembly of large-scale non-rigid and rigid parts, and well solves the problems that the cushioning process is time-consuming, and thin-wall parts are easy to deform under the action of assembly force, and are easy to have quality defects and the like.
The invention discloses an assembly method based on thin-wall part external mold line control, which can predict an assembly gap by virtually installing a thin-wall part to a final assembly state of the thin-wall part. Specifically, after a digital measurement system is used for measuring the shape before assembly, an actually measured finite element model is generated to analyze the assembly process, and finally the assembly gap and pad adding amount is obtained.
Compared with the prior art, the method reduces the necessity of real object trial assembly and the use of a special detection tool, and can greatly reduce the time and cost required by geometric quality inspection. In addition, the method can not only predict the final shape of the assembly, but also enable the existing parts to meet specific geometric requirements without changing the manufacturing process by adjusting the assembly process.
Drawings
FIG. 1 is a process of creating a measured model of the present invention;
FIG. 2 is a process of the present invention for locating and fitting thin-walled parts;
FIG. 3 is a rigidity assumption based assembly orientation of the present invention;
FIG. 4 is an outer mold line flexibility best fit process of the present invention;
FIG. 5 is an assembled carcass, skin (wall panel) and gasket construction of the present invention;
FIG. 6 is a drawing of the actual outer mold line, inner mold line and skeleton definition of the present invention.
Detailed Description
The invention is further described below with reference to the figures and examples.
As shown in fig. 1-6.
A method for determining an assembly clearance based on thin-wall part external mold line control comprises the following steps:
the method comprises the following steps that firstly, an initial shape of a part to be assembled is obtained by using a digital measuring system;
the geometry information or actual pre-assembly shape of the skeleton, inner mold line and outer mold line is obtained using a digital measurement system. The measuring system consists of digital measuring equipment, scanning measuring software and a measuring tool. The point cloud data acquired by the digital measurement system needs to be subjected to post-processing steps, namely denoising, simplification and blocking. In the aspect of point cloud data denoising, selecting and removing noise points deviating from the shape of an object; in the aspect of point cloud data simplification, a simplified algorithm based on a grid is adopted; in the aspect of point cloud blocking, model decomposition is realized by adopting a method based on boundary characteristics.
And reconstructing geometric characteristics of the parts by using the collected point clouds of the parts, and constructing an actual measurement model for subsequent assembly analysis and external mold line control. The invention adopts a NURBS surface fitting method to reconstruct. The method comprises the steps of conducting curved surface reconstruction on each sub-point cloud on the basis of point cloud blocking, then combining all reconstructed surface patches through Boolean operation to form a whole surface model, and finally conducting solid filling to obtain a complete actual measurement model (figure 1).
The second step is that: analyzing the assembly process by constructing an actually measured finite element model;
the principle of the thin-wall part positioning fitting is to transform a local coordinate system into a global coordinate system. However, there are uncertainties such as assembly deformation during the assembly of thin-walled parts, so new methods must be studied to take into account the effects of these uncertainties to ensure the accuracy and effectiveness of the positioning fit. The best fitting algorithm provided by the invention is a successive approximation process in nature, and comprises a fitting process based on rigid hypothesis and a best fitting process based on flexibility. After the fitting is completed, the rigid transformation matrix and the flexible finite element model node coordinates are output (fig. 2).
Positioning of assembly based on the assumption of rigidity: at present, on the premise of digital assembly, two holes and one surface are adopted for positioning parts. The surface is a main positioning reference (A), the hole I is a second positioning reference (B), and the hole II is a third positioning reference (C). First, the main part positioning surface (a) and the positioning reference (a') are bonded and positioned by an ICP algorithm (fig. 3).
Then, the translation is carried out through the vector from the second positioning reference (B) of the part to the positioning reference (B').
And finally, calculating the rotation angle according to the third positioning reference (C) and the positioning reference (C') of the part.
The overall transformation matrix of the part from initial to final assembly is:
performing flexible best fit: after the initial positioning based on the rigid body assumption is completed, flexible best fitting based on the outer model line is performed. Establishing a finite element model based on a triangulated mesh unit, wherein the model reflects the actual shape and material characteristics before flexible best fitting, and then defining a group of outer mold line constraints as boundary conditions on the basis of the assumed initial positioning characteristics of a rigid body so as to simulate the shape of the assembled outer mold line. For example, the location of the locating holes that must be constrained during assembly is determined for the skin (panel), hole-to-hole locating datum (B), and hole-to-hole locating datum (C). For i nodes D on the outer mold line surface of the gridiAt each position of the node, the nodes should be forced to be placed on the theoretical outer mold line after assembly. Then, in performing the finite element analysis, each set D is forced by deriving the rotation and translation law definitions by applying a set of displacement boundary conditionsiAll nodes in (a) move on the theoretical outer mold line. The resulting deformed mesh represents the predicted post-assembly shape of the component, leading to node CjAnd (4) coordinates. Node CjThe coordinates reflect the shape of the inner mold line with the ideal outer mold line guaranteed (fig. 4).
The third step: calculating the assembling clearance and cushion adding amount according to the assembled shape;
the assembled carcass and skin (panel) is shown in fig. 5. The assembly gap shown in the figures may vary depending on the assembly tolerances of the backbone (fig. 5).
The outer mold line deviation refers to the normal deviation between the outer mold line of the actual thin-wall part and the theoretical outer mold line. The clearance between the inner mold line and the framework refers to the normal clearance value between the inner mold line of the thin-wall part and the framework appearance. Specifically, there are two curved surfaces SIMLAnd SudsFor curved surface SIMLPoint C onjCan be on a curved surface SudsFind the nearest point Pj。|PjCjThe length of |, is from the curved surface SIMLTo the curved surface SudsAt point CjThe distance of (c). Curved surface SudsUpper nearest point PjCan be expressed as (fig. 6):
Pj=argmin||Cj-P||,P∈Suds(5)
Cjthe fit clearance value of a point is defined as:
Gj=||Pj-Cj|| (6)
the sensitivity matrix of the part may be generated by creating a Finite Element Model (FEM) of the measured model for assembly phase simulation. The part freedom is defined as the point in the part actual measurement model, the positioning connection of the fixture and the part, the part requirement and the freedom of each point. These points are converted into corresponding nodes of the finite element model, so that the sensitivity matrix for only the point of interest is extracted as follows:
wherein K is the overall stiffness matrix; delta CjIs a point C on the inner moulding linejThe amount of change in (c); delta DiIs point D on the outer mold lineiThe amount of change in (c); f is a point DiThe force of (2).
Decomposing the overall stiffness matrix K:
substituting equation 8 into equation 7 yields:
[ΔCj]=-[K11]-1[K12][ΔDi](9)
substituting equation 9 into equation 6 yields Δ D under the deformation of the outer mold lineiIn the case of (2), the clearance between the inner mold line and the framework:
the present invention is not concerned with parts which are the same as or can be implemented using prior art techniques.
Claims (4)
1. The method is characterized in that firstly, a digital measuring device is used for obtaining the initial shape of a part to be assembled, then, an actually measured finite element model is constructed to analyze the assembling process, and finally, the assembling clearance and cushion adding amount is calculated according to the assembled shape.
2. The method according to claim 1, characterized in that it comprises the following steps:
the first step is as follows: acquiring an initial shape of a part to be assembled by using a digital measuring system;
step 1.1: acquiring geometric information or actual preassembly shapes of the framework, the inner mold line and the outer mold line by using a three-dimensional laser scanner;
step 1.2: smoothing and extracting the obtained dense point cloud;
step 1.3: carrying out blocking and characteristic reconstruction on the collected point cloud so as to obtain an actual measurement model of the skeleton and the skin or the wallboard;
the second step is that: analyzing the assembly process by constructing an actually measured finite element model;
step 2.1: unifying the coordinates of the actually measured data points to a global coordinate system, and performing assembly fitting based on rigid hypothesis; establishing positioning relations among parts and between the parts and the clamp through positioning characteristics of positioning surfaces, positioning holes and the like of the parts, calculating a coordinate transformation matrix, and unifying a coordinate system through the coordinate transformation relation;
step 2.2: matching an outer mold line of an actually measured model with a theoretical outer mold line in outer mold line flexible best fitting to simulate an ideal state required to be reached by assembly;
the third step: calculating the assembling clearance and cushion adding amount according to the assembled shape;
calculating the gap amount between the inner mold line and the framework under the state that the outer mold line of the actual measurement model is overlapped with the theoretical outer mold line; and then calculating a sensitivity matrix and an overall rigidity matrix of the part to obtain the gap amount between the inner mold line and the framework under the state that the outer mold line is superposed with the theoretical outer mold line.
3. The method as claimed in claim 2, wherein the measured model of the skeleton and skin or wall panel is obtained by using a digital measurement system to obtain the geometric information or actual pre-assembled shape of the skeleton, inner mold lines and outer mold lines, measuring and collecting the point cloud data, de-noising, simplifying and partitioning the point cloud data, and reconstructing the point cloud data by using a NURBS surface fitting method.
4. The method as claimed in claim 2, wherein the assembly process is analyzed by two steps of a fitting process based on a rigid hypothesis and a best fit process based on flexibility to ensure the accuracy and effectiveness of the positioning fit during the assembly process of the thin-walled parts; when the rigid body is supposed to be fitted, firstly, positioning is carried out by adopting two holes and one surface through the positioning characteristics of the positioning surface and the positioning hole of the part, the positioning relation among the parts and between the parts and the clamp is established, a coordinate transformation matrix is calculated, and a coordinate system is unified through the coordinate transformation relation; after the initial positioning based on the rigid body hypothesis is completed, performing flexible optimal fitting based on the outer model line, establishing a finite element model based on a triangulated grid unit, wherein the model reflects the actual shape and material characteristics before flexible optimal fitting, and then redefining a group of outer model line constraints as displacement boundary conditions on the basis of the initial positioning characteristics of the rigid body hypothesis to simulate the control of the outer model line after the assembly is completed; and (3) completing flexible fitting, namely generating a deformation geometric figure or a predicted assembled shape, performing mathematical calculation analysis to obtain the definition of the deviation of the outer mold line and the clearance between the inner mold line and the framework, and then calculating the sensitivity matrix and the total rigidity matrix of the part to obtain the clearance between the inner mold line and the framework under the state that the outer mold line is superposed with the theoretical outer mold line.
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