CN113204851B - Tolerance optimization method for all-welded assembly - Google Patents
Tolerance optimization method for all-welded assembly Download PDFInfo
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Abstract
The invention discloses a tolerance optimization method for an all-welded assembly, relates to the welding deformation accumulated error prediction and tolerance optimization of multiple assemblies, and solves the problem of requirement on tolerance design optimization of the all-welded assembly. Collecting original design information of an all-welded assembly, and summarizing various tolerance information; establishing a three-dimensional tolerance analysis model, carrying out simulation analysis on virtual assembly, and predicting the deviation of the total deflection of the all-welded assembly; and establishing a weighted calculation value based on the contribution factor and the sensitivity factor of each deviation and the control difficulty factor of the welding deformation, and continuously iterating according to the simulation analysis result until a tolerance optimization scheme meeting the optimization target is obtained and output. The method can effectively predict the welding deformation accumulated error, realize tolerance optimization and improve the efficiency of tolerance secondary design.
Description
Technical Field
The invention relates to a method for predicting welding deformation accumulated errors and optimizing tolerance of a multi-component, in particular to a method for optimizing tolerance of an all-welded component.
Background
In the fields of nuclear industry, ship industry, energy industry and the like, a plurality of large key components are composed of a large number of components, multiple types of components and complex components, all the components are connected by welding, and global prediction and reasonable tolerance optimization of welding deformation influence are important factors influencing product quality. Particularly, the method is represented by a part of key parts in the nuclear industry, and the method is formed by welding and assembling a large number of parts through multiple processes, so that the manufacturing process is complex, the number of welding steps is large, and the requirement on precision control is high. The method is characterized in that a large complex structural part is taken as a representative, because each link has design errors, welding deformation and other deviations, and the deviations are continuously accumulated and transmitted along with the welding process, the overall deviation of a finished product is finally caused, the quality of the finished product of the product and the processing and assembly of subsequent processes are influenced, and a method and a means for error accumulation prediction are lacked in the actual manufacturing process. In quality control, in order to reduce the fraction defective, it is generally necessary to strictly control the welding precision of each process step, but excessively controlling the welding deformation greatly increases the manufacturing cost. Therefore, the accumulated error of welding deformation is predicted in the design stage, the tolerance variable with large influence on the quality of the finished product is found out, the targeted tolerance optimization is carried out according to the analysis result of the deviation source, and the secondary design of the tolerance is realized, so that the process difficulty is reduced, the tolerance is reasonably distributed, the welding process is optimized, and the manufacturing cost is saved.
The chinese patent "an optimized design method for assembly tolerance" discloses an optimized design method for assembly tolerance, which aims at minimum processing cost to establish an objective function for assembly tolerance optimization, thereby satisfying the assembly functional requirements of products, but the application range and method thereof are greatly different from the present patent. The Chinese patent 'a car body assembly tolerance distribution method' discloses a tolerance distribution method which comprises the steps of establishing a car body three-dimensional assembly tolerance analysis model, carrying out simulation, determining an optimization target and a scheme, and compensating welding deformation, and the application object and the specific implementation method of the method are greatly different from the method. The Chinese patent 'an assembly tolerance optimization design method based on genetic algorithm' relates to an assembly tolerance optimization design method, but the application object and the implementation mode of the method are greatly different from the method. Therefore, no published reports about the core removing device of the electric heating element of the voltage stabilizer related to the patent are found at home and abroad.
Disclosure of Invention
The technical problem to be solved by the invention is as follows: the invention provides a tolerance optimization method for an all-welded assembly, which solves the problem.
The invention discloses a welding deformation accumulated error prediction and tolerance optimization method for an all-welded assembly, which is used for predicting the welding deformation error accumulation of the all-welded assembly, carrying out tolerance optimization aiming at a welding process to obtain a reasonable tolerance distribution scheme and providing an important method for the tolerance design of the all-welded assembly. Aiming at the optimization requirement of tolerance design of the all-welded assembly, a welding deformation accumulated error prediction and tolerance optimization method for the all-welded assembly is provided, virtual assembly, simulation calculation and tolerance optimization are carried out on the welding process of the all-welded assembly, the error accumulated prediction of the welding deformation of the all-welded assembly is realized, tolerance optimization is carried out on the welding process, the secondary design of the tolerance is finally completed, a reasonable tolerance distribution scheme is obtained, and important guidance is provided for the optimization analysis of the all-welded assembly in the design stage.
The invention is realized by the following technical scheme:
a method of tolerance optimization of an all-welded assembly comprising the steps of:
s1, collecting original design information of all structural members of the all-welded assembly, and summarizing various tolerance information, wherein the original design information of all structural members, namely design input, comprises but is not limited to: the sizes and design tolerances of the parts of each structural part, the assembly process and the statistical error of the tool clamp; obtaining a statistical result of welding deformation in the welding process step through experience; and (4) counting error sources, control modes and control difficulties of all the tolerances.
Between S1 and S2, the method further comprises the following steps: determining a tolerance optimization target, specifically comprising: and performing tolerance optimization to expect the achieved technical indexes, wherein the technical indexes comprise but are not limited to the qualified rate of meeting the quality requirement of a finished product through tolerance optimization analysis and the size requirement to be met by the subsequent process.
S2, establishing a three-dimensional tolerance analysis model, establishing geometric characteristics required by tolerance analysis, performing virtual assembly, converting welding deformation parameters into size deviation of corresponding parts according to specific deformation shapes, inputting the size deviation into the tolerance analysis model by combining with the distribution type of the welding deformation deviation, performing simulation analysis, and S2, establishing a space assembly size chain for the three-dimensional tolerance analysis model, determining a closed ring, establishing a measurement target, and describing the constraint relation between the closed ring and other tolerances in the size chain, wherein the perfect model tolerance information of the three-dimensional tolerance analysis model comprises the added design tolerance and the assembly tolerance, and the welding deformation parameters are converted into the size deviation of the parts and are added to the model based on the statistical result of the design input.
And describing the constraint relation in the size chain by adopting an extreme value method or a probability method.
The specific operation of performing simulation analysis in S2 is performing monte carlo simulation calculation analysis on the three-dimensional tolerance analysis model.
S3, predicting the deviation of the total deflection of the all-welded assembly according to the simulation analysis result obtained in the S2;
step S3 includes a prediction error accumulation result, which specifically includes: analyzing an error accumulation value of a measurement target under the existing assembly scheme according to the calculation result; comparing with the optimized target, and analyzing the over-tolerance rate of the measured target;
and analyzing the deviation source, which specifically comprises the following steps: and calculating the sensitivity and contribution degree analysis results of each tolerance, obtaining the amplification factor and the influence factor of each tolerance on the measurement target, and finding out the tolerance which has larger influence on the measurement target, wherein the amplification factor is the sensitivity, and the influence factor is the contribution degree.
S4, establishing a weighted calculation value based on the contribution factor, the sensitivity factor and the control difficulty factor of welding deformation of each deviation, guiding size optimization by the weighted calculation value, calculating a weighted average coefficient after each tolerance is weighted, setting the adjustment proportion of each tolerance to obtain a first optimization scheme, simulating the first optimization scheme, and continuously iterating according to the simulation analysis result until a tolerance optimization scheme meeting the optimization target is obtained and output.
Determining a tolerance optimization scheme according to the influence factor of S3 in S4, specifically comprising: analyzing the contribution degree of each tolerance to the measurement target, performing weighted calculation and analysis according to the sensitivity factor, the contribution factor and the control difficulty factor of the tolerance, and determining a preliminary tolerance optimization scheme, wherein the weighted calculation is performed by adopting two weighted values for analysis, the weighted value A is obtained by multiplying the sensitivity result and the contribution result, and the weighted value B is adjusted by the control difficulty of the actual welding deformation.
And judging the Euclidean distance between the weighted analysis result value and the tolerance optimization target value, and when the weighted analysis result does not meet the tolerance optimization target, adjusting and correcting the tolerance optimization scheme, and iterating until the tolerance optimization target is met.
The invention has the following advantages and beneficial effects:
the method can effectively predict the welding deformation accumulated error, realize tolerance optimization and improve the efficiency of tolerance secondary design. The method can be applied to welding deformation accumulated error prediction and tolerance optimization of various all-welded assemblies.
Drawings
The accompanying drawings, which are included to provide a further understanding of the embodiments of the invention and are incorporated in and constitute a part of this application, illustrate embodiment(s) of the invention and together with the description serve to explain the principles of the invention. In the drawings:
FIG. 1 is a flow chart of the present invention.
Fig. 2 is a structural view of embodiment 2 of the present invention.
Reference numbers and corresponding part names in the drawings:
1. a joint assembly; 2. a left box cover; 3. a left tube sheet; 4. a tube bundle; 5. a right tube sheet; 6. and a right box cover.
Detailed Description
Hereinafter, the term "comprising" or "may include" used in various embodiments of the present invention indicates the presence of the invented function, operation or element, and does not limit the addition of one or more functions, operations or elements. Furthermore, as used in various embodiments of the present invention, the terms "comprises," "comprising," "includes," "including," "has," "having" and their derivatives are intended to mean that the specified features, numbers, steps, operations, elements, components, or combinations of the foregoing, are only meant to indicate that a particular feature, number, step, operation, element, component, or combination of the foregoing, and should not be construed as first excluding the existence of, or adding to the possibility of, one or more other features, numbers, steps, operations, elements, components, or combinations of the foregoing.
In various embodiments of the invention, the expression "or" at least one of a or/and B "includes any or all combinations of the words listed simultaneously. For example, the expression "a or B" or "at least one of a or/and B" may include a, may include B, or may include both a and B.
Expressions (such as "first", "second", and the like) used in various embodiments of the present invention may modify various constituent elements in various embodiments, but may not limit the respective constituent elements. For example, the above description does not limit the order and/or importance of the elements described. The foregoing description is for the purpose of distinguishing one element from another. For example, the first user device and the second user device indicate different user devices, although both are user devices. For example, a first element could be termed a second element, and, similarly, a second element could be termed a first element, without departing from the scope of various embodiments of the present invention.
It should be noted that: if it is described that one constituent element is "connected" to another constituent element, the first constituent element may be directly connected to the second constituent element, and a third constituent element may be "connected" between the first constituent element and the second constituent element. In contrast, when one constituent element is "directly connected" to another constituent element, it is understood that there is no third constituent element between the first constituent element and the second constituent element.
The terminology used in the various embodiments of the invention is for the purpose of describing particular embodiments only and is not intended to be limiting of the various embodiments of the invention. As used herein, the singular forms are intended to include the plural forms as well, unless the context clearly indicates otherwise. Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which various embodiments of the present invention belong. The terms (such as those defined in commonly used dictionaries) should be interpreted as having a meaning that is consistent with their contextual meaning in the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein in various embodiments of the present invention.
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is further described in detail below with reference to examples and accompanying drawings, and the exemplary embodiments and descriptions thereof are only used for explaining the present invention and are not meant to limit the present invention.
Example 1:
as shown in fig. 1, the steps are as follows:
step A, finishing design input required by tolerance analysis, and specifically comprising the following steps: part dimensions, design tolerances, etc. of the parts; counting errors of an assembly process and a tool clamp; obtaining a statistical result of welding deformation in the welding process step through experience; and emphasizes on counting error sources, control modes, control difficulties and the like of all tolerances.
Step B, determining a tolerance optimization target, specifically comprising: at present, tolerance optimization is carried out to expect the achieved technical indexes, such as the qualified rate of the finished product quality requirement, which is met by the subsequent process, is achieved through tolerance optimization analysis.
Step C, establishing an all-welded assembly three-dimensional tolerance analysis model, which specifically comprises the following steps: building a three-dimensional model of the part; importing three-dimensional tolerance calculation software; geometric features are created and the components are assembled.
Step D, perfecting model tolerance information, and specifically comprising: adding tolerance information such as design tolerance, assembly tolerance and the like; converting the welding deformation parameters into the size deviation of the parts based on the statistical result and adding the size deviation to the model; establishing a spatial assembly dimension chain, determining a closed ring and establishing a measurement target, and describing the constraint relation between the closed ring and other tolerances in the dimension chain by adopting an extreme value method or a probability method.
Step E, carrying out simulation calculation and result analysis, and specifically comprising the following steps: determining the virtual assembly calculation times according to requirements; carrying out Monte Carlo simulation calculation analysis on the three-dimensional tolerance analysis model;
step F: the prediction error accumulation result specifically includes: analyzing an error accumulation value of a measurement target under the existing assembly scheme according to the calculation result; and comparing with an optimized target, and analyzing the over-tolerance rate of the measured target and the like.
Step G: analyzing a deviation source, specifically comprising: and calculating the sensitivity and contribution analysis results of each tolerance to obtain the amplification coefficient (sensitivity) and the influence factor (contribution) of each tolerance to the measurement target, and finding out the tolerance which has larger influence on the measurement target.
Step H: determining a tolerance optimization scheme according to the influence factors, specifically comprising: analyzing the contribution degree of each tolerance to the measurement target, performing weighted calculation and analysis according to the sensitivity factor, the contribution factor and the control difficulty factor of the tolerance, and determining a preliminary tolerance optimization scheme; wherein, the weighted value A is obtained by multiplying the sensitivity result and the contribution degree result, and the weighted value B is adjusted by the control difficulty of the actual welding deformation.
And repeating the steps D-G, if the result meets the optimization target, obtaining a reasonable tolerance optimization scheme, and if the result does not meet the optimization target, correcting the tolerance optimization scheme, and continuously iterating until the optimization target is met.
Step I: the output tolerance optimization scheme specifically comprises the following steps: and summarizing the main steps of tolerance optimization calculation, writing a report, outputting an optimized tolerance distribution scheme, and finishing tolerance secondary design.
Example 2:
on the basis of the embodiment 1, the technical characteristics and the advantages of the method are explained in more detail through a tolerance optimization example of a large-scale complex structural part.
A certain large-scale complex structural part is formed by welding and connecting components, the quality of a finished product of the large-scale complex structural part has a close relation with the deflection of a joint component, if the deflection is too large, subsequent process machining is directly influenced, therefore, the accumulated error of welding deformation of each process step needs to be predicted, and tolerance optimization is carried out to ensure that the final deflection meets the machining requirement of subsequent design procedures.
Taking a certain large-scale complex structural part as an example, the large-scale complex structural part comprises a joint assembly, a left box cover, a right box cover, a left tube plate, a right tube plate and a tube bundle (parts 1-6 are sequentially arranged from left to right, the parts 1-6 are respectively 1, the joint assembly, 2, the left box cover, 3, the left tube plate, 4, the tube bundle, 5, the right tube plate, 6 and the right box cover, the horizontal direction is the X direction, the vertical direction is the Y direction, and the inner direction and the outer direction are the Z direction).
The method is characterized in that original design information such as dimension information and design tolerance of a structural component is collected before tolerance analysis, possible assembly process errors are counted according to a clamping tool, an assembly process and the like on the basis of the past assembly experience, and most importantly, welding deformation after welding of each process step needs to be counted and analyzed on the basis of the past similar welding operation so as to determine the distribution type, and the welding precision of each process step, the control means of the welding deformation and the control difficulty are arranged. Finally, various tolerance information, control means and control difficulty are summarized, and design input is provided for tolerance analysis.
A second part: and establishing a three-dimensional tolerance analysis model of a certain large complex structural part and calculating.
Modeling is generally carried out by CAD software, three-dimensional tolerance analysis software is introduced, and geometric features required by tolerance analysis are created in the software and are virtually assembled; secondly, adding tolerance information into the model according to design input, wherein the method adopts a mode that welding deformation parameters are converted into size deviation of corresponding parts according to specific deformation shapes, and the size deviation is input into a tolerance analysis model by combining with the distribution type of the welding deformation deviation; and then establishing the measurement of the pre-welding assembly clearance and the deflection of the joint tail end in each direction in each step, and then carrying out Monte Carlo simulation calculation to respectively obtain the simulation results of the pre-welding assembly clearance and the deflection in each direction.
And a third part: simulation result analysis and deviation source analysis
According to simulation analysis results, the deviation of the total deflection quantity of the joint tail end is predicted to be distributed in a positive mode, the mean value is 1.59mm, the range of 6 sigma is 0.35-2.85 mm, and the out-of-tolerance rate exceeding the specified range (less than or equal to 2.2mm) is 21.0%.
Because the optimization target is not met, deviation source analysis is needed, and the sensitivity and contribution degree of each tolerance are calculated, wherein the contribution degree of Z-direction deviation caused by welding deformation between the part 1 and the part 2 to the result is 25.4%, the sensitivity factor is greater than 2, the contribution degree of X, Z-direction deviation caused by welding deformation between the part 2 and the part 3 is 23.7% and 6.6%, the sensitivity factor is greater than 2, the contribution degree of deviation caused by shrinkage after welding of the part 2 is 25.1%, and the sensitivity is less than 2.
And fourthly, determining a tolerance optimization scheme.
And establishing a weighted calculation value based on the contribution factor and the sensitivity factor of each deviation and the control difficulty factor of the welding deformation so as to guide size optimization. Wherein the weighted value A is obtained by multiplying the sensitivity result and the contribution degree result, the weighted value B is adjusted by the control difficulty of the actual welding deformation, and the calculation method is obtained by counting by an expert scoring method. And weighting each tolerance, then calculating a weighted average coefficient, setting respective adjustment proportion, thus determining a preliminary optimization scheme, repeating the steps, and continuing iteration according to the simulation analysis result until obtaining the tolerance optimization scheme meeting the optimization target. Finally outputting a reasonable tolerance distribution scheme.
The above-mentioned embodiments are intended to illustrate the objects, technical solutions and advantages of the present invention in further detail, and it should be understood that the above-mentioned embodiments are merely exemplary embodiments of the present invention, and are not intended to limit the scope of the present invention, and any modifications, equivalent substitutions, improvements and the like made within the spirit and principle of the present invention should be included in the scope of the present invention.
Claims (10)
1. A method of tolerance optimization of an all-welded assembly, comprising the steps of:
s1, collecting original design information of all structural members of the all-welded assembly, and summarizing all kinds of tolerance information;
s2, establishing a three-dimensional tolerance analysis model, creating geometric characteristics required by tolerance analysis, performing virtual assembly, converting welding deformation parameters into size deviation of corresponding parts according to specific deformation shapes, inputting the size deviation into the tolerance analysis model by combining with the distribution type of the welding deformation deviation, and performing simulation analysis;
s3, predicting the deviation of the total deflection of the all-welded assembly according to the simulation analysis result obtained in the S2;
s4, establishing a weighted calculation value based on the contribution factor, the sensitivity factor and the control difficulty factor of welding deformation of each deviation, guiding size optimization by the weighted calculation value, calculating a weighted average coefficient after each tolerance is weighted, setting the adjustment proportion of each tolerance to obtain a first optimization scheme, simulating the first optimization scheme, and continuously iterating according to the simulation analysis result until a tolerance optimization scheme meeting the optimization target is obtained and output.
2. The method of claim 1, wherein the raw design information or design inputs for each structural component include, but are not limited to: the sizes and design tolerances of the parts of each structural part, the assembly process and the statistical error of the tool clamp; obtaining a statistical result of welding deformation in the welding process step through experience; and (4) counting error sources, control modes and control difficulties of all the tolerances.
3. The method of optimizing tolerances for an all-welded assembly according to claim 2, further comprising the step between S1 and S2 of: determining a tolerance optimization target, specifically comprising: and performing tolerance optimization to expect the achieved technical indexes, wherein the technical indexes comprise but are not limited to the qualified rate of meeting the quality requirement of a finished product through tolerance optimization analysis and the size requirement to be met by the subsequent process.
4. The method for optimizing tolerance of an all-welded assembly according to claim 3, wherein the step S2 includes adding design tolerance, assembling tolerance, converting welding deformation parameters into dimensional deviation of the parts based on statistical results of design input and adding the dimensional deviation to the model.
5. The method for optimizing the tolerance of the all-welded assembly according to claim 4, further comprising establishing a spatial assembly dimension chain for the three-dimensional tolerance analysis model, determining closed loops and creating measurement targets, and describing the constraint relationship between the closed loops and other tolerances in the dimension chain.
6. The method for optimizing the tolerance of the all-welded assembly according to claim 5, wherein the constraint relation in the dimension chain is described by an extreme value method or a probability method.
7. The method for optimizing the tolerance of the all-welded assembly according to claim 5, wherein the specific operation of performing the simulation analysis in the step S2 is performing Monte Carlo simulation calculation analysis on the three-dimensional tolerance analysis model.
8. The method for optimizing the tolerance of the all-welded assembly according to claim 3, wherein the step S3 further comprises predicting an error accumulation result, specifically comprising: analyzing an error accumulation value of a measurement target under the existing assembly scheme according to the calculation result; comparing with the optimized target, and analyzing the over-tolerance rate of the measured target; and analyzing the deviation source, which specifically comprises the following steps: and calculating the sensitivity and contribution degree analysis results of each tolerance, obtaining the amplification factor and the influence factor of each tolerance on the measurement target, and finding out the tolerance which has larger influence on the measurement target, wherein the amplification factor is the sensitivity, and the influence factor is the contribution degree.
9. The method for optimizing the tolerance of an all-welded assembly according to claim 8, wherein the step of determining the tolerance optimization scheme according to the influence factor of S3 in S4 specifically comprises the steps of: analyzing the contribution degree of each tolerance to the measurement target, performing weighted calculation and analysis according to the sensitivity factor, the contribution factor and the control difficulty factor of the tolerance, and determining a preliminary tolerance optimization scheme, wherein the weighted calculation is performed by adopting two weighted values for analysis, the weighted value A is obtained by multiplying the sensitivity result and the contribution result, and the weighted value B is adjusted by the control difficulty of the actual welding deformation.
10. The method of claim 9, wherein the euclidean distance between the weighted analysis result value and the tolerance optimization target value is determined, and when the weighted analysis result does not satisfy the tolerance optimization target, the tolerance optimization scheme is adjusted, modified, and iterated until the tolerance optimization target is satisfied.
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