CN114880796A - Tolerance analysis method for aircraft assembly process optimization - Google Patents
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Abstract
The invention relates to a tolerance analysis method for aircraft assembly process optimization. By calculating the assembly qualification rate, the process capability index and the sensitivity of the deviation source, the purpose of determining the optimized object of the assembler in consideration of multiple factors is achieved, the targeted optimized object determination is achieved, and therefore the efficiency and the accuracy of the assembly process optimization are improved. By means of tolerance optimization numerical calculation, quantitative calculation of the optimization quantity of the optimization object is achieved, the problem that the optimization quantity is determined through multiple times of simulation is solved, and the optimization efficiency of the assembly process is improved. The method for optimizing the aircraft assembly process based on tolerance analysis considers aircraft assembly requirements and field assembly capacity at the same time, and reduces the difficulty of field assembly in advance of meeting the assembly requirements.
Description
Technical Field
The invention belongs to the field of aviation manufacturing engineering/airplane assembly, and relates to a tolerance analysis method for optimizing an airplane assembly process.
Background
The optimization of the assembly process is a key means for improving the feasibility of the aircraft assembly process and ensuring the aircraft assembly quality. The main purpose of the optimization of the aircraft assembly process is to ensure that the process capability index is within a reasonable range, so as to achieve the balance between quality and cost. From the perspective of assembly tolerance analysis, the assembly process optimization mainly includes two aspects, namely, on one hand, the optimization of tolerance values, and on the other hand, the optimization of process parameters such as positioning reference, positioning method and assembly sequence in the assembly process. How to determine an object for optimizing the assembly process and give an optimization scheme according to the result of the analysis of the assembly tolerance, and ensure the balance between the assembly requirement of the airplane and the field assembly capability is the key point of the optimization of the assembly process.
The existing aircraft assembly process optimization is to adjust assembly processes and parameters for multiple times according to experience to give rough assembly process optimization measures aiming at different assembly process capability level and assembly target requirements, and needs to rely on the experience of engineers and a large amount of loop iteration to determine an optimized object and the optimization quantity of the optimized object. For example, in the aspect of assembly sequence optimization and planning, an intelligent optimization algorithm library for product assembly sequence planning (Jingshikao, Lissailai, Zenson) provides a method for solving the problem of assembly sequence planning by using the intelligent optimization algorithm library, wherein the algorithm library mainly comprises an algorithm consultant and an algorithm pool, and the algorithm pool comprises three intelligent optimization algorithms such as an improved ant colony algorithm, a simulated annealing algorithm and a genetic algorithm. A parallel assembly sequence planning method based on fuzzy rough sets is provided (Hu Xiao Mei, Zhu Wen Hua, Shu Tao). In the aspect of assembly path planning and optimization, a wizard model is constructed based on an assembly sequence based on a spatial scanning aircraft product assembly path planning technology-text (qiu 26206, weisheng, cheng), an assembly path is obtained by a spatial scanning method with the wizard model as a constraint, and the assembly path is optimized by a parametric analysis method, so that the assembly path planning efficiency is improved; a path feedback method (afterglow, afterglow and yadin) for evaluating the assembly sequence of a complex product provides an assembly path feedback method considering the influence of manufacturing resources, a swept volume closed-packet algorithm is used for solving an assembly process chain model to obtain an assembly path, the quality of the assembly sequence is evaluated through parametric analysis of the assembly path, and a reasonable assembly path is finally generated. In the aspect of assembly process optimization based on quality control, fuzzy optimization design of tolerance in CAD/CAPP integration (Liuyusheng, Yang Xin, Wu Zhao) provides a parallel tolerance fuzzy optimization mathematical model of CAD/CAPP integration, a tolerance optimization method based on artificial intelligence is provided in the research of the tolerance parallel design method in a virtual assembly environment (Jishuping), and finally, a genetic algorithm is used for carrying out repeated iteration solving on tolerance values. Designing a literary (frame, yellow hair beauty, charming) based on statistical tolerance and mass loss tolerance proposes a parallel tolerance design method which considers both processing cost and mass loss.
The optimization of the aircraft assembly process has a plurality of influence factors, the determination of an optimized object and an optimized quantity is difficult, and meanwhile, the assembly design requirement and the field assembly capacity need to be balanced in the optimization process, so the optimization of the aircraft assembly process still has the following problems:
1) the optimization of the assembly process for the problems of assembly out-of-tolerance and the like is not realized. The main work related to the optimization of the assembly process at the present stage focuses on how to shorten the assembly path, optimize the assembly sequence and the like, the assembly process is not optimized by taking the assembly quality control as a target, and the control of the final assembly precision at the preparation stage of the assembly process cannot be realized.
2) The optimization objective determines poor targeting. The aircraft assembly process is complex, factors influencing assembly quality are numerous, the determination of the optimized object at present mainly depends on experience of engineers and repeated simulation iteration, and the problems of low determination efficiency and poor pertinence of the optimized object exist.
3) And calculating the optimization quantity of the tolerance value. Research on quantitative optimization methods. The existing assembly process and quality optimization are mainly realized by controlling the manufacturing tolerance of the parts, so that the manufacturing cost of the parts is increased. However, the assembly tolerances are numerous and coupled with each other, and the determination of the tolerance optimization amount lacks a quantitative calculation method, so that the efficiency and the quality of the assembly process optimization are influenced.
In order to solve the problems, the patent provides an aircraft assembly process optimization method based on tolerance analysis, under the premise that assembly requirements and assembly site process capability balance are considered, an optimization object is determined quickly and pertinently, meanwhile, tolerance values can be calculated quantitatively, and efficiency and quality of aircraft assembly process optimization are improved.
Disclosure of Invention
In order to solve the problems that an optimized object of an aircraft assembly process is difficult to determine and the tolerance optimization quantity cannot be calculated quantitatively, the invention provides an aircraft assembly process optimization method based on tolerance analysis. The method utilizes the environment of the aircraft assembly tolerance simulation system to determine key characteristics, performs aircraft assembly tolerance simulation, assembly qualification rate analysis and process capability calculation, assembly process optimization content judgment, tolerance value optimization and assembly process parameter optimization, realizes quantitative calculation of assembly tolerance optimization values, quickly determines an optimization object, optimizes the aircraft assembly process based on tolerance analysis, and improves the efficiency and accuracy of aircraft assembly process optimization.
The purpose of the invention is realized by the following technical scheme:
a tolerance analysis method for aircraft assembly process optimization comprises the following steps:
step 1: determining key characteristics; based on the aircraft assembly requirements, key characteristics of the assembly requirements are determined.
Step 2: simulating assembly tolerance; and (3) importing the three-dimensional model of the airplane assembly into a tolerance simulation software environment, carrying out tolerance simulation modeling, and carrying out assembly tolerance simulation on the key characteristics determined in the step (1).
And step 3: assembly tolerance analysis, including the calculation of three parameters of assembly qualification rate, assembly process capability index and deviation source sensitivity;
and step 3 is to calculate three parameters of assembly qualification rate, assembly process capability index and deviation source sensitivity based on the simulation result of the aircraft assembly tolerance in the step 2. The assembly process capability index is shown in equation (1).
In the formula:
USL represents the design given the tolerance upper line;
LSL represents the design given the lower tolerance;
σ represents the overall standard deviation of the functional requirement.
The premise of estimating the assembling process capacity by using Cp is that the distribution center of the sample is coincident with the tolerance center, namely the overall average value of the sample is equal to the average value, and the influence of random deviation in the assembling process on the assembling precision is ignored. When random errors of an assembly system are considered, the distribution center of the statistical sample deviates from a tolerance center, and the estimation of the assembly process capability by using Cp can cause wrong results. Therefore, the process capability index Cpk is used at this time, and the calculation is shown in equation (2).
In the formula:
mu is the overall mean value of the functional requirements, and other parameters are the same as in the formula (1).
Wherein the assembly qualification rate is calculated by adopting a Monte Carlo method. And the sensitivity calculation of the deviation source adopts a method of solving the deviation of the assembly tolerance simulation model. The calculation methods of the two parameters are not included in the invention and are necessary steps for realizing the invention.
And 4, step 4: determining key out-of-tolerance characteristics;
and 5: determining an optimized object;
step 6: optimizing tolerance values based on CP;
and 7: optimizing parameters in the assembling process;
and 8: and (4) determining an assembly process scheme.
And 4, determining the key out-of-tolerance characteristic according to the calculation result of the step 3.
And the step 5 determines that the optimization object is to take the key characteristics of the out-of-tolerance as the optimization object of the assembly process. The optimized object comprises key characteristics of a process capability index larger than 1.0 and smaller than 1.67 and key characteristics of a process capability index range besides the key characteristics of the out-of-tolerance. When the optimization object is determined, the key characteristics with out-of-tolerance are higher in priority than the key characteristics with out-of-process capability index range.
The optimization of the tolerance value based on CP in step 6 is calculated according to equation (3).
In the formula:
T j representing the design given jth source tolerance;
T j ' is the optimized tolerance;
Cp min for the lower limit of the process capability index at economic accuracy, Cp min ＝1.0；
Cp max For the upper limit of the process capability index at economic accuracy, Cp max ＝1.67；
In the step 7, the parameter optimization of the assembly process is the assembly process optimization which takes the assembly sequence, the positioning mode and the like as optimization objects;
and 8, determining an assembly process scheme after the calculated values of the optimized assembly qualification rate, the optimized process capability index and the like meet the design and manufacturing requirements.
The invention has the beneficial effects that:
the invention provides an aircraft assembly process optimization method based on tolerance analysis, which has the following realization effects: 1) by calculating the assembly qualification rate, the process capability index and the sensitivity of the deviation source, the purpose of determining the optimized object of an assembler in consideration of multiple factors is achieved, the targeted optimized object determination is achieved, and therefore the efficiency and the accuracy of the assembly process optimization are improved. 2) By means of tolerance optimization numerical calculation, quantitative calculation of the optimization quantity of the optimization object is achieved, the problem that the optimization quantity is determined through multiple times of simulation is solved, and the optimization efficiency of the assembly process is improved. 3) The method for optimizing the aircraft assembly process based on tolerance analysis considers aircraft assembly requirements and field assembly capacity at the same time, and reduces the difficulty of field assembly in advance of meeting the assembly requirements.
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FIG. 1 is a flow chart of aircraft assembly process optimization based on tolerance analysis.
Detailed Description
Reference will now be made in detail to the embodiments of the present invention, examples of which are illustrated in the accompanying drawings, wherein like or similar reference numerals refer to the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are illustrative only for the purpose of explaining the present invention, and are not to be construed as limiting the present invention.
The invention is a method which is established on a tool with an aircraft assembly tolerance simulation system and realizes tolerance optimization numerical calculation and aircraft assembly process optimization based on tolerance analysis (as shown in figure 1).
The following describes the implementation of the present invention in detail with reference to fig. 1, the embodiment is implemented on the premise of the technical solution of the invention, and the detailed implementation and the specific implementation process of the invention are given, but the protection scope of the present invention is not limited to the following implementation examples.
Step 1: a key characteristic is determined. According to design requirements, key characteristics including key product characteristics and key control characteristics are determined by combining an assembly process and are used as targets and optimized objects of assembly precision analysis.
And 2, step: and carrying out simulation analysis on assembly tolerance. And according to the determined key characteristics, performing assembly tolerance simulation in an aircraft assembly tolerance simulation system environment by adopting a Monte Carlo method based on an assembly tolerance simulation model to obtain statistical parameters such as the assembly qualification rate of the key characteristics.
And step 3: the assembly process capability and bias source sensitivity are calculated. And (3) respectively calculating the technological capacity indexes according to the assembling tolerance simulation result of the step (2) and the formula (1) or (2).
And 4, step 4: determining out-of-tolerance key characteristics. And judging whether the assembling precision of the key characteristics is out of tolerance or not according to the process capability index, if the assembling precision meets the design requirement and Cp is more than 1.0 and less than or equal to 1.67, judging that the key characteristics are not out of tolerance, outputting an assembling process scheme, and finishing the optimization of the assembling process. Otherwise, jumping to the step 5 to continue the assembly process optimization.
And 5: an optimization object is determined. The key characteristics that the assembly precision does not meet the design requirement or Cp is more than 1.0 and less than or equal to 1.67 are taken as optimization objects. Wherein, the key characteristic that the assembly precision can not meet the design requirement is used as the primary and necessary optimization object, and the key characteristic that Cp is more than 1.0 and less than or equal to 1.67 is used as the optimization object of the secondary priority.
Step 6: and determining the assembly process optimization content of the optimization object. Based on the optimization objective determined in step 5, it is further determined whether to optimize the tolerance values of the key control features or their associated assembly process parameters. And judging whether the sensitivity of the deviation source of the optimized object is far greater than 1, if so, indicating that the deviation of the deviation source is sharply amplified in deviation transmission, and optimizing the tolerance value of the deviation source has no influence on the assembly precision of the key characteristics basically, so that the assembly process parameters such as an optimized assembly sequence, a positioning scheme or a connection process are selected at the moment.
And 7, calculating a tolerance optimization value. Calculating a tolerance optimization value according to the formula (3);
and 8, re-simulating the optimized assembly tolerance. Substituting the optimized parameters into the assembly tolerance simulation model, jumping to the step 2, performing re-simulation on the optimized assembly tolerance, and analyzing whether the simulation value of the assembly key characteristics meets the design requirements and the manufacturing process capability. If the requirements are met, an assembly process optimization scheme is formed, and the process is ended. If the critical characteristic is out of tolerance, go to step 6.
Claims (4)
1. An aircraft assembly process optimization method based on tolerance analysis is characterized by comprising the following steps:
step 1: determining key characteristics; determining key characteristics of assembly requirements based on aircraft assembly requirements;
step 2: simulating assembly tolerance; importing the three-dimensional model of the airplane assembly into a tolerance simulation software environment, carrying out tolerance simulation modeling, and carrying out assembly tolerance simulation on the key characteristics determined in the step 1;
and 3, step 3: assembly tolerance analysis, including the calculation of three parameters of assembly qualification rate, assembly process capability index and deviation source sensitivity;
step 3 is based on the simulation result of the assembly tolerance of the airplane in step 2, and three parameters of assembly qualification rate, assembly process capability index and deviation source sensitivity are calculated; the assembly process capability index is shown in formula (1);
in the formula:
USL represents the design given the tolerance upper line;
LSL represents the design given the lower tolerance;
σ represents the total standard deviation of the functional requirement;
calculating by adopting a process capability index Cpk as shown in a formula (2);
in the formula:
mu is the overall mean value of the functional requirement, and other parameters are the same as the formula (1);
and 4, step 4: determining key out-of-tolerance characteristics;
and 5: determining an optimized object;
step 6: optimizing tolerance values based on CP;
the step 6 is calculated according to the formula (3) based on the tolerance value optimization of the CP;
in the formula:
T j representing the design given jth source tolerance;
T j ' is the optimized tolerance;
Cp min the lower limit of the process capability index under economic precision；
Cp max The upper limit of the process capability index under the economic precision;
and 7: optimizing parameters in the assembling process;
the step 7 of optimizing the parameters of the assembly process is to optimize the assembly process by taking the assembly sequence and the positioning mode as optimization objects;
and 8: determining an assembly process scheme;
and 8, determining an assembly process scheme after the optimized assembly qualified rate and the optimized calculated value of the process capability index meet the design and manufacturing requirements.
2. An aircraft assembly process optimization method based on tolerance analysis according to claim 1, wherein the step 5 determines the optimization object as follows: taking key characteristics of the out-of-tolerance as an assembly process optimization object; the optimization object comprises key characteristics of a process capability index larger than 1.0 and smaller than 1.67 and key characteristics of an ultra-process capability index range besides the key characteristics of ultra-difference; when the optimization object is determined, the key characteristics with out-of-tolerance are higher in priority than the key characteristics with out-of-process capability index range.
3. The method for optimizing an aircraft assembly process based on tolerance analysis according to claim 1, wherein in the step 3, the monte carlo method is adopted for the assembly yield calculation.
4. The method for optimizing the aircraft assembly process based on the tolerance analysis as claimed in claim 1, wherein in the step 3, the deviation source sensitivity calculation adopts a method of calculating the deviation of the assembly tolerance simulation model.
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| CN103164584A (en) * | 2013-03-29 | 2013-06-19 | 江西洪都航空工业集团有限责任公司 | Calculation method of coordination accuracy based on key characteristics |
| CN108629114A (en) * | 2018-05-04 | 2018-10-09 | 西北工业大学 | A kind of fabrication tolerance simulating analysis towards the deformation of aircraft assembly connection |
| CN113779885A (en) * | 2021-09-16 | 2021-12-10 | 南京航空航天大学 | Tolerance optimization method based on genetic algorithm |
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| CN103164584A (en) * | 2013-03-29 | 2013-06-19 | 江西洪都航空工业集团有限责任公司 | Calculation method of coordination accuracy based on key characteristics |
| CN108629114A (en) * | 2018-05-04 | 2018-10-09 | 西北工业大学 | A kind of fabrication tolerance simulating analysis towards the deformation of aircraft assembly connection |
| CN113779885A (en) * | 2021-09-16 | 2021-12-10 | 南京航空航天大学 | Tolerance optimization method based on genetic algorithm |
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