CN112344868B

CN112344868B - Precision self-correction method and system for manufacturing aircraft wall plate

Info

Publication number: CN112344868B
Application number: CN202010774626.3A
Authority: CN
Inventors: 杨海成
Original assignee: Individual
Current assignee: Individual
Priority date: 2020-08-04
Filing date: 2020-08-04
Publication date: 2022-07-12
Anticipated expiration: 2040-08-04
Also published as: CN112344868A

Abstract

The application provides a precision self-correction method and system for manufacturing an aircraft panel. The precision self-correction method comprises the following steps: arranging a vision measuring system according to the process information of the aircraft wall plate; in the process of manufacturing a workpiece, the vision measuring system is used for monitoring in real time to obtain measuring data; comparing the acquired measurement data with theoretical data of the workpiece to acquire a real-time error; and adjusting the technological parameters of the flexible tool or the manufacturing equipment according to the real-time error. The precision self-correction method monitors deformation by using a mode of visually measuring depth of field data, and has a large measurement range and quick measurement response; the deformation data is fed back to the flexible tool, the flexibility of the flexible tool is fully utilized, the rigidity of the thin-wall part is improved, the machining vibration is reduced, and therefore the manufacturing precision is corrected.

Description

Precision self-correction method and system for manufacturing aircraft wall plate

Technical Field

The application relates to the field of aviation manufacturing, in particular to a precision self-correction method and system for manufacturing an aircraft panel.

Background

The aircraft wall plate has the characteristics of large size (such as 2500mm multiplied by 30000mm), thin thickness (such as 60mm) and the like, and belongs to a typical large thin-wall part. In the process of machining or assembling an aircraft panel, in order to ensure the accuracy of the final panel, the deformation of a workpiece during machining or assembling must be controlled within a certain range. At present, the deformation problem in the manufacturing process of the aircraft panel is usually solved by manually correcting after the manufacturing is finished. Under current process conditions, the accuracy of the profile of an aircraft panel is ensured by tooling, for example, by assembly jigs during assembly. The assembly fixture is a rigid positioning technology, and has no variability on the supporting curved surface of the aircraft wall plate, so that one tool can be only used for one part. This would significantly reduce manufacturing flexibility and efficiency, while also involving storage, maintenance, management, etc. of a large number of rigid jobs.

The rigid positioning technology is gradually replaced by the flexible positioning technology at present, the technology can be used for processing different parts, the manufacturing flexibility and efficiency can be greatly improved, and strong economic benefits are brought. However, the flexible tool is designed by taking the static theoretical appearance of the workpiece as a reference to design key characteristic points and a support structure. However, in the process of processing or assembling the aircraft wall plate, on one hand, processing errors can occur in the theoretical appearance; on the other hand, in the assembly work, the local processing generates a large acting force on the workpiece, and further causes deformation of the workpiece and changes in the positioning relationship, thereby causing stress concentration and assembly errors. These errors, if not adjusted during the machining or assembly process, will cause even greater deviations in subsequent assembly processes. In addition, manual adjustment is time-consuming and labor-consuming, and the working efficiency is greatly reduced.

Disclosure of Invention

The application aims at the deformation problem of the aircraft panel in the manufacturing process, combines the visual measurement technology and the flexible tool, and aims to provide a precision self-correction method for manufacturing the aircraft panel.

According to a first aspect of the present application, there is provided a method of precision self-correction for aircraft panel manufacturing, comprising:

arranging a vision measuring system according to the process information of the aircraft wall plate;

in the manufacturing process of the workpiece, the vision measuring system is used for carrying out real-time monitoring to obtain measuring data;

comparing the acquired measurement data with theoretical data of the workpiece to acquire a real-time error;

and adjusting the technological parameters of the flexible tool or the manufacturing equipment according to the real-time error.

According to some embodiments of the application, real-time monitoring using the vision measurement system comprises:

and using the structured light as a light source to irradiate the workpiece to be detected.

According to some embodiments of the application, a binocular measurement system is arranged according to process information of the aircraft panel, comprising:

the binocular measurement system is arranged according to the location of key features in the workpiece manufacturing process.

According to some embodiments of the application, a vision measurement system is arranged according to process information of the aircraft panel, comprising:

the vision measuring system is arranged according to the relative position of the process equipment and the workpiece and the motion position relation of the process equipment and the workpiece in the manufacturing process.

the vision measuring system is arranged according to the rigidity of the workpiece mounting position.

According to some embodiments of the present application, adjusting a process parameter of a flexible tool or manufacturing equipment according to the real-time error comprises:

and adjusting the supporting position of the flexible tool.

and adjusting the supporting rigidity of the flexible tool.

According to a second aspect of the present application, there is provided an accuracy self-correction system for aircraft panel manufacturing, comprising:

the vision measurement system is used for acquiring a real-time image of the workpiece;

and the flexible tool is used for providing support for the workpiece and fixing the workpiece.

Manufacturing equipment for manufacturing the workpiece;

the control device is used for presetting a precision correction strategy and is respectively connected with the binocular measurement system, the flexible tool and the manufacturing equipment; and acquiring real-time errors of the workpiece according to the real-time images, and feeding back a precision correction strategy to the flexible tool or the manufacturing equipment.

According to some embodiments of the application, the vision measurement system comprises: a binocular measurement system.

According to some embodiments of the application, the binocular measuring system comprises: at least two binocular measuring devices.

The precision self-correction method provided by the application monitors deformation by using a mode of visually measuring depth of field data, and is large in measurement range and quick in measurement response; the deformation data is fed back to the flexible tool, the flexibility of the flexible tool is fully utilized, the rigidity of the thin-wall part is improved, the machining vibration is reduced, and therefore the manufacturing precision is corrected.

Additional aspects and advantages of the present application will be set forth in part in the description which follows and, in part, will be obvious from the description, or may be learned by practice of the present application.

Drawings

In order to more clearly illustrate the technical solutions in the embodiments of the present application, the drawings needed to be used in the description of the embodiments will be briefly introduced below, and it is apparent that the drawings in the following description are only some embodiments of the present application.

Fig. 1 shows a flowchart of a precision self-correction method according to an example embodiment of the present application.

FIG. 2 illustrates an accuracy self-correction system according to an example embodiment of the present application.

Fig. 3 shows a perspective view of a binocular measuring apparatus according to an exemplary embodiment of the present application.

Fig. 4 shows a front view of a binocular measuring apparatus according to an exemplary embodiment of the present application.

Fig. 5 shows a right view of a binocular measuring apparatus according to an exemplary embodiment of the present application.

Detailed Description

Example embodiments will now be described more fully hereinafter with reference to the accompanying drawings. Example embodiments may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. These embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the concept of example embodiments to those skilled in the art. The same reference numerals denote the same or similar parts in the drawings, and thus, a repetitive description thereof will be omitted.

Furthermore, the described features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. In the following description, numerous specific details are provided to give a thorough understanding of embodiments of the application. One skilled in the relevant art will recognize, however, that the subject matter of the present application can be practiced without one or more of the specific details, or with other methods, components, devices, steps, and so forth. In other instances, well-known methods, devices, implementations, or operations have not been shown or described in detail to avoid obscuring aspects of the application.

It will be understood that, although the terms first, second, etc. may be used herein to describe various components, these components should not be limited by these terms. These terms are used to distinguish one element from another. Thus, a first component discussed below may be termed a second component without departing from the teachings of the present concepts. As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed items.

Those skilled in the art will appreciate that the drawings are merely schematic representations of exemplary embodiments, which may not be to scale. The blocks or flows in the drawings are not necessarily required to practice the present application and therefore should not be used to limit the scope of the present application.

The use of flexible tooling in the manufacture of aircraft panels makes it possible to adjust the support solution during the manufacturing process. By adjusting the supporting scheme of the flexible tool in the manufacturing process, stress concentration and deformation caused by clamping can be better avoided. In addition, the development and application of visual measurement technology enables on-line measurement during the process of aircraft panel support.

Therefore, the inventor provides a precision self-correction method for manufacturing an aircraft panel by combining a visual measurement technology and a flexible tool aiming at the deformation problem of the aircraft panel such as the aircraft panel in the manufacturing process.

As shown in fig. 1, the present application provides a precision self-correction method for aircraft panel manufacturing, comprising:

in step S110, a vision measuring system is arranged according to the aircraft panel process information.

The vision measuring system is used for imaging the workpiece in real time in the manufacturing process of the aircraft panel. According to an example embodiment of the present application, the vision measurement system may be a binocular measurement system. Because the aircraft wallboard has the characteristics of large size and easy deformation, the key parts needing real-time monitoring are relatively dispersed. Therefore, a binocular measuring system composed of a plurality of binocular measuring devices is required to measure the entire workpiece in real time. The positions of the binocular measuring devices directly influence the result of real-time monitoring and finally influence the accuracy of precision correction. Therefore, a reasonable layout of the positions of the plurality of binocular measuring apparatuses is required.

In the accuracy self-correcting method provided by the application, the layout of a plurality of binocular measuring devices is mainly determined by the following factors:

the location of critical features in the fabrication of a workpiece. Taking the assembly of an aircraft panel as an example, in the assembly process, the stress concentration part caused by the processing of the connecting hole is easy to deform. Therefore, real-time monitoring is required as a key feature.

The relative position of the process equipment and the workpiece and the motion position relation of the process equipment and the workpiece in the manufacturing process. Taking the assembly of an airplane wallboard as an example, the process assembly can be a flexible tool and a robot hole making system. The positions of the binocular measuring devices are required to avoid interference with the movement track of the robot hole making system and the flexible tool.

Rigidity of the mounting position. A plurality of binocular measuring device mounted position need possess sufficient rigidity, just can guarantee real-time measurement result's accuracy.

By considering the factors and carrying out accessibility analysis of the measuring space through a simulation means, the position of the binocular measuring device can be determined. The whole wallboard is detected by a plurality of binocular cameras, at least one binocular camera in each wallboard area is guaranteed to monitor, and excessive inclined visual angles do not exist

In step S120, during the manufacturing process of the workpiece, the vision measuring system is used for real-time monitoring and obtaining the measurement data.

The use of vision measurement systems requires a corresponding illumination source. According to some embodiments of the present application, structured light may be used as illumination to provide a light source for a vision measurement system during real-time monitoring. Compared with a common white light source, the light reflection problem cannot be caused when the structured light irradiates the metal wall plate, so that a large number of identification marks do not need to be pasted on the surface of a measured object, and the workload can be greatly reduced.

The vision measurement system uses an optical camera for image acquisition. Because the optical lens of the optical camera has distortion, before measurement, the optical camera needs to be subjected to distortion correction to obtain the focal length and the imaging origin. In addition, because the binocular measuring system is composed of at least two binocular measuring devices, the positions of the optical cameras of the binocular measuring devices need to be calibrated, so that the relative positions of the optical cameras are obtained, and the coordinates of the imaging origin among the binocular measuring devices are consistent.

And the vision measuring system which completes the correction and calibration monitors the processing process of the workpiece in real time and obtains a real-time image. The plurality of binocular measuring devices can respectively acquire real-time images of a certain workpiece area. And performing feature matching on the real-time image and the original image of the workpiece to obtain corresponding depth data. And after the depth of field data matched with the binocular measuring devices are subjected to image fusion, the three-dimensional coordinates of all points of the whole workpiece can be obtained.

In step S130, the acquired measurement data is compared with theoretical data of the workpiece to obtain a real-time error.

Discrete point coordinates for each key feature may be obtained by a vision measurement system. The three-dimensional measurement model can be reconstructed from the point coordinates. And (3) carrying out translation and rotation coordinate transformation on the measurement model and the theoretical model of each key characteristic to obtain deformation errors, including position deviation and rotation deviation, of each key characteristic.

After the deformation error data of all key features are calculated, the deformation data of the whole workpiece can be obtained by adopting a calculation method from local deformation to overall deformation. For example, the deformation data of the key features can be converted into the displacement load information of the key features at different positions, and then the displacement load is applied to the constructed theoretical wall plate and the key feature assembly finite element model, so that the overall deformation error of the workpiece can be solved.

In step S140, adjusting and adjusting the process parameters of the flexible tooling or the manufacturing equipment according to the real-time error. Large thin-walled workpieces may be distorted, bent, and slipped during machining. From the results of the real-time measurements, these unexpected operating conditions may be identified during the manufacturing process.

According to different real-time error situations, the reason and the solution can be searched in a preset strategy library. The real-time error caused by the machining process can be corrected by adjusting the machining parameters. For example, for real-time errors caused by drilling, process parameters such as the rotating speed and the feeding amount of the machining equipment can be adjusted. For real-time errors generated by the clamping force of the tool, the manufacturing precision can be corrected by adjusting the supporting position and/or the supporting rigidity of the flexible tool.

Taking an aircraft wallboard assembly process as an example, the analyzed deformation of the processed wallboard is decomposed into a support lattice of the flexible tool according to a preset strategy, so that the follow-up quantity of each movable support point can be obtained. Each supporting motor is finely adjusted according to the follow-up momentum of the movable supporting points, the rigidity characteristic of the supporting points of the wall plate is changed, and the purposes of relieving deformation, avoiding vibration and the like can be achieved.

Fig. 2 illustrates an accuracy self-correcting system according to an example embodiment of the present application.

According to a second aspect of the present application, there is provided an accuracy self-correction system 1000 for large panel processing. As shown in fig. 2, the accuracy self-correction system 1000 includes: flexible tooling 200, manufacturing equipment 300 and vision measuring system 400, and a control device (not shown).

The flexible tooling 200 is attached to the workpiece 100 to provide support and hold to the workpiece. The flexible tool 200 is further connected with a control device, a precision correction strategy of the control device is obtained, and a scheme of a supporting point or supporting rigidity is adjusted.

The manufacturing equipment 300 is connected to a control device, and during the process of machining the workpiece 100, a precision correction strategy is obtained from the control device and corresponding machining parameters are adjusted.

The vision measurement system 400 may be a binocular measurement system including a plurality of binocular measurement devices 410 respectively disposed around the workpiece 100 such that the measurement area covers key feature points of the workpiece 100. The vision measuring system 400 is connected to the control device, and transmits the acquired real-time image to the control device for error determination.

The control device, which may be an upper computer, receives the real-time image acquired by the vision measurement system 400, and performs feature matching on the real-time image and the original image to obtain depth data. And carrying out image fusion on the depth of field data matched with the plurality of binocular measuring devices to obtain three-dimensional measuring coordinates of each point of the whole workpiece. And comparing the three-dimensional measurement coordinate with theoretical data to obtain the real-time deformation error of the workpiece.

And the control device is internally preset with a precision strategy library. And inquiring the precision correction strategy from the precision strategy library according to the obtained real-time deformation error. For example, the processing parameters of the manufacturing equipment can be adjusted, and the supporting position or rigidity of the flexible tool can also be adjusted.

According to some embodiments of the present application, the binocular measuring device 410 used by the precision self-correction system provided by the present application may be a binocular camera shown in fig. 3 to 5.

As shown in fig. 3, the binocular measuring apparatus 410 includes a main body 411, two optical cameras 412, two light sources 413, a set of calibration lamps 414, a pitch driving apparatus 415, a rotation driving apparatus 416, and a base 417.

Two optical cameras 412, two light sources 413 and a set of calibration lamps 414 are arranged on the main body 411. One to the left and one to the right of the two optical cameras 412 for acquiring real-time grating images. According to some embodiments of the present application, optical camera 412 may employ a CCD camera. The light sources 413 are arranged in one-to-one correspondence with the optical cameras, and emit speckle-encoded light sources with phase differences. A set of calibration lights 414 is disposed around the optical camera 412 and the light source 413 to provide calibration references for the machine-to-machine calibration of the binocular measuring apparatus 410.

The pitch drive 415 and the rotation drive 416 are disposed on a base 417 and are connected to the main body 411. The pitching driving device 415 can drive the optical camera to pitch up and down, and the rotating driving device 416 can drive the optical camera to rotate left and right, so that automatic calibration between the binocular cameras is realized.

The precision self-correction method provided by the application applies a three-dimensional real-time imaging technology to the manufacturing process of the aircraft panel to obtain real-time measurement data of a workpiece; comparing the real-time measurement data with theoretical data to obtain real-time errors in the manufacturing process; and executing a corresponding precision correction strategy according to the real-time error, feeding back the precision correction strategy to the flexible tool or the manufacturing equipment, and performing self-correction on the manufacturing precision by adjusting the supporting scheme of the flexible tool or the processing parameters of manufacturing and assembling. Therefore, the deformation is relieved, the vibration is avoided, and the manufacturing precision of the aircraft wall plate is corrected.

In the precision self-correction method provided by the application, deformation is monitored by using a mode of measuring depth of field data by using a binocular camera, the measurement range is large, and the measurement response is quick; the deformation data is fed back to the flexible tool, the flexibility of the flexible tool is fully utilized, the rigidity of the thin-wall part is improved, the machining vibration is reduced, and therefore the manufacturing precision is corrected.

It should be understood that the above examples are only for clearly illustrating the present application and are not intended to limit the embodiments. Other variations and modifications will be apparent to persons skilled in the art in light of the above description. And are neither required nor exhaustive of all embodiments. And obvious variations or modifications of this invention may be made without departing from the spirit or scope of the invention.

Claims

1. A method of real-time morphing self-correction for aircraft panel manufacturing, comprising:

arranging a vision measurement system according to the position of a key feature in the manufacturing process of the aircraft panel so as to monitor the key feature in real time;

in the manufacturing process of the aircraft panel, the vision measurement system is used for acquiring the discrete point coordinates of the key features in real time, and then the real-time deformation errors of the key features are acquired through reconstruction and transformation;

in the manufacturing process of the aircraft panel, converting the data of the real-time deformation error of the key features into displacement loads, and applying the displacement loads to the reconstructed finite element model of the aircraft panel so as to calculate the integral real-time deformation error of the aircraft panel;

in the manufacturing process of the aircraft panel, adjusting the follow-up quantity of a movable supporting point of a flexible tool for supporting the aircraft panel in real time according to the integral real-time deformation error and a preset strategy, so as to relieve deformation and avoid vibration; and/or

And in the manufacturing process of the aircraft panel, adjusting the processing parameters for processing the aircraft panel in real time according to the integral real-time deformation error and a preset strategy, thereby correcting the processing precision.

2. The method of real-time morphing self-correcting of claim 1, wherein acquiring discrete point coordinates of the key feature in real-time using the vision measurement system comprises:

3. The method of real-time morphing self-correcting of claim 1, wherein the deploying a vision measurement system further comprises:

the vision measuring system is arranged according to the relative position of the process equipment and the aircraft wall plate and the motion position relation of the process equipment and the aircraft wall plate in the manufacturing process, so that interference is avoided.

4. The method of real-time morphing self-correcting of claim 1, wherein the deploying a vision measurement system further comprises:

and arranging the vision measuring system according to the rigidity of the installation position of the aircraft wallboard, thereby ensuring the accuracy of a real-time measuring result.

5. The method of real-time morphing self-correcting of claim 1, wherein the real-time adjusting of the amount of follow-up of the movable support point of the flexible tooling supporting the aircraft panel further comprises:

and adjusting the supporting position of the flexible tool in real time.

6. The method of real-time morphing self-correcting of claim 1, wherein the real-time adjusting of the amount of follow-up of the movable support point of the flexible tooling supporting the aircraft panel further comprises:

and adjusting the supporting rigidity of the flexible tool in real time.

7. A real-time morphing self-correction system for aircraft panel manufacturing, comprising:

the vision measurement system is used for monitoring key features in the manufacturing process of the aircraft panel in real time and acquiring discrete point coordinates of the key features in real time;

the flexible tool is used for supporting and fixing the aircraft wallboard;

manufacturing equipment, wherein the aircraft wall plate is manufactured;

the control device is respectively connected with the vision measuring system, the flexible tool and the manufacturing equipment; wherein the content of the first and second substances,

the control device acquires real-time deformation errors of the key features through reconstruction and transformation according to the discrete point coordinates of the key features acquired in real time in the manufacturing process of the aircraft panel;

the control device converts the data of the real-time deformation error of the key features into displacement loads in the manufacturing process of the aircraft panel, and applies the displacement loads to the reconstructed finite element model of the aircraft panel so as to calculate the integral real-time deformation error of the aircraft panel;

the control device adjusts the follow-up quantity of a movable supporting point of a flexible tool for supporting the aircraft panel in real time according to the integral real-time deformation error and a preset strategy in the aircraft panel manufacturing process, so that deformation is relieved, and vibration is avoided; and/or

And the control device adjusts the processing parameters of the manufacturing equipment in real time according to the integral real-time deformation error and a preset strategy in the manufacturing process of the aircraft panel, so as to correct the processing precision.

8. The real-time morphing self-correcting system of claim 7, wherein the vision measuring system comprises:

a binocular measurement system.

9. The real-time morphing self-correcting system of claim 8, wherein the binocular measuring system comprises:

at least two binocular measuring devices.