CN116062198A - Virtual-real fusion ground test system and method for ultra-large aerospace structure - Google Patents
Virtual-real fusion ground test system and method for ultra-large aerospace structure Download PDFInfo
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Abstract
The invention discloses a virtual-real fusion ground test system and method for an ultra-large aerospace structure, and belongs to the field of aerospace dynamics tests. The test system comprises a virtual digital model, a physical module, a virtual-physical structure interface fusion device and four main parts of an assembly mechanical arm. The virtual digital model comprises a virtual structure, an interface force input port and an interface displacement output port. The physical module comprises a plurality of sub-modules to be assembled. The virtual-real structure interface fusion device comprises real-time control equipment, an interface loading actuator, a virtual-real connection interface structure and data acquisition equipment. The assembly mechanical arm comprises one or more of a crawling mechanical arm, a flying mechanical arm and a moving mechanical arm. The test system and the method solve the problem that the current ground assembly test equipment limits the geometric dimension and the weight of the tested object, and have the advantages of wide application range, high simulation precision and good consistency between the ground and the sky.
Description
Technical Field
The invention belongs to the field of aerospace dynamics, relates to a ground test system and a ground test method of aerospace dynamics, and particularly relates to a virtual-real fusion ground test system and a virtual-real fusion ground test method for an ultra-large aerospace structure.
Background
The ultra-large spacecraft will greatly enhance the ability of humans to perform spatial tasks, utilize spatial resources, and explore cosmic mystery. The ultra-large spacecraft cannot enter the orbit through single launching due to the limitation of rocket thrust and fairing envelopment, and is built in a modularized design, multiple launching and on-orbit assembly mode.
The on-orbit assembly and construction process of the ultra-large spacecraft is complex and has high risk, and the ground dynamics test is an important means for checking the rationality of the design of the complex spacecraft structure and the effectiveness of theoretical modeling, and is a key and necessary link for pushing the basic research results in the on-orbit assembly field of the spacecraft to the practical application of the aerospace engineering. In addition, the data result of the ground dynamics test is also an important basis for improving the design scheme of the ultra-large spacecraft and checking the reliability index of the assembly task.
On the one hand, the ground dynamics test verification technology of the conventional size space structure is mature. The gravity influence in the vertical direction of the spacecraft or the mechanical arm is usually counteracted by adopting modes such as an air floating platform, a porous air foot and the like so as to simulate the movements, creeping and the like of the multi-arm spacecraft system and the capturing and assembling processes of the space structure. However, the structural size of the ultra-large spacecraft is more than tens of meters and even reaches to the order of kilometers, which is far greater than the constraint of the current test equipment on the geometric size and weight of the tested object, and the ground test of the full-size structure is difficult to develop.
On the other hand, the virtual-real fusion technology is also developed in the field of reliability test, and loads of different working conditions are generated by using virtual scenes to load parts so as to evaluate indexes of reliability of the parts. However, in the field of aerospace dynamics test, not only complex dynamics loading is performed on an actual structure by a virtual scene, but also vibration and interface force/moment measured by the actual structure are required to be transmitted to the virtual scene in real time so as to achieve the conditions of interface displacement coordination and interface force balance of a virtual digital model-an entity physical module, and an ultra-large type aerospace structure virtual-real fusion combination body is formed, and how to achieve the above-mentioned objects is not disclosed in the literature or patent publication yet.
The search of the on-orbit assembly dynamics test technology of the ultra-large space structure finds that no mature research scheme exists in all countries of the world at present, and no published test system or method exists in academia and industry at home and abroad.
Disclosure of Invention
The invention provides a virtual-real fusion ground test system and a virtual-real fusion ground test method for an ultra-large space structure, which break through the difficult problem that the current space dynamics test equipment limits the geometry and the weight of a tested object and provide a new approach for the ground dynamics test of the assembly process of the ultra-large space structure.
In order to achieve the above purpose, the first aspect of the present invention provides a virtual-real fusion ground test system for an ultra-large aerospace structure, which has the following technical scheme:
a virtual-real fusion ground test system for an ultra-large aerospace structure comprises a virtual digital model, a physical module, a virtual-real structure interface fusion device and an assembly mechanical arm.
In the virtual-real fusion ground test system, the virtual digital model comprises a virtual structure, an interface force input port and an interface displacement output port; the virtual structure is a dynamic model of an ultra-large space structure except for a physical module part of an entity; the interface force input port is used for receiving interface force and moment signals transmitted by the data acquisition equipment in the test process and transmitting the interface force and moment signals to the virtual structure to serve as external load input; and the interface displacement output port transmits displacement and rotation angle signals to the virtual-real structure interface fusion device according to the interface displacement and rotation angle response obtained by the virtual structure calculation.
In the virtual digital model, the virtual structure is described by adopting a high-dimensional linear or nonlinear dynamic equation and comprises mass, damping, rigidity distribution and geometric dimension information of the ultra-large space structure.
In the virtual digital model, the virtual structure uses a method for cutting off the fixed interface modes, namely cutting off the fixed interface modes of the virtual structure on the premise of keeping the freedom degree of the virtual-real connection interface structure.
In the virtual-real fusion ground test system, the physical module comprises a plurality of sub-modules to be assembled.
In the entity physical module, the sub-module is a local real structure of the ultra-large spacecraft, and is supported or suspended by a gravity unloading device so as to simulate an on-orbit zero gravity environment of the aerospace structure;
in the physical module, the supporting or hanging point of the sub-module can freely move in a horizontal plane; the submodules in the physical module are arranged according to an assembly sequence, wherein the first submodule is provided with an assembly interface with a virtual-real connection interface structure.
In the virtual-real fusion ground test system, the virtual-real structure interface fusion device comprises real-time control equipment, an interface loading actuator, a virtual-real connection interface structure and data acquisition equipment.
In the virtual-real structure interface fusion device, the real-time control equipment receives the interface displacement and the corner response signals provided by the virtual digital model, carries out real-time operation according to one of feedforward-feedback and hysteresis compensation control algorithms, and sends a signal instruction to an interface loading actuator, and the interface loading actuator drives the virtual-real connection interface structure to move to a designated position and corner; and the real-time control equipment receives interface sensor signals fed back by the data acquisition equipment at the same time.
In the virtual-real structure interface fusion device, the interface loading actuator comprises one or more combinations of a multi-degree-of-freedom mechanical arm, a hydraulic or pneumatic actuating rod/cylinder, an electromagnetic vibration exciter or a multi-degree-of-freedom vibration table.
In the interface fusion device with the virtual-real structure, one end of the virtual-real connection interface structure is connected with the interface loading actuator through a hinge, and the other end of the virtual-real connection interface structure is provided with one or more interfaces of a flange bolt, a multi-jaw chuck and a multi-point locking device.
In the interface fusion device of the virtual-real structure, the data acquisition equipment acquires the response of the sensor installed on the interface structure of the virtual-real connection at a high speed, wherein the response comprises the signals of the sensors of displacement, rotation angle, force and moment of the interface structure of the virtual-real connection, and possibly acceleration signals and speed signals.
In the virtual-real structure interface fusion device, the data acquisition equipment carries out analog-digital conversion on the interface force signal and then transmits the interface force signal to the virtual digital model.
In the virtual-real structure interface fusion device, the data acquisition equipment simultaneously acquires sensor signals installed on the physical module, and the sensor comprises one or more of position, vibration acceleration and attitude angle sensors of the sub-module of the physical module.
In the virtual-real structure interface fusion device, the data acquisition equipment simultaneously acquires sensor signals of the assembly mechanical arm, and the sensors comprise one or more of a spatial position sensor of a base of the assembly mechanical arm, a rotation angle sensor of each joint of the mechanical arm and a reaction force sensor of the tail end clamping jaw.
In the virtual-real fusion ground test system, the assembly mechanical arm comprises one or more of a crawling mechanical arm, a flying mechanical arm and a moving mechanical arm.
In the virtual-real fusion ground test system, the virtual digital model and the assembled submodule are linked through a virtual-real structure interface fusion device to form a combination body.
When the virtual digital model and the virtual-real connection interface structure are opened to realize real-time linkage, the virtual digital model and the assembled submodule meet the force balance condition and the displacement coordination condition on the degree of freedom of the virtual-real connection interface structure.
In the virtual-real fusion ground test system, the assembling mechanical arm captures, conveys and butts sub-modules so as to simulate the in-orbit assembling process of the ultra-large aerospace structure.
The invention provides a virtual-real fusion ground test method for an ultra-large aerospace structure, which comprises the following steps of:
s1, constructing a virtual digital model and an entity physical module of an ultra-large space structure;
s2, constructing a virtual-real structure interface fusion device;
s3, starting a virtual digital model and a virtual-real connection interface structure to link in real time;
s4, sequentially assembling sub-modules in the physical modules by using an assembling mechanical arm according to the assembling sequence of the physical modules;
s5, closing the virtual digital model and the virtual-real connection interface structure to realize real-time linkage.
In the virtual-real fusion ground test method, the specific steps of the step S1 are as follows:
s1-1, modeling a virtual structure of an ultra-large space structure by adopting a dynamics equation, wherein the model comprises a structural dynamics model of the virtual structure and possibly one or more dynamics models of orbit dynamics and attitude dynamics;
s1-2, reducing the order of a dynamic model of the virtual structure, namely cutting off a fixed interface mode of the virtual structure on the premise of keeping the freedom degree of the virtual-real connection interface structure;
s1-3, constructing an entity physical module, and dividing the entity physical module into N sub-modules, wherein the value of N is more than or equal to 2. Determining an assembly sequence of the sub-modules, and arranging the sub-modules according to the assembly sequence, wherein the first sub-module is provided with an assembly interface with a virtual-real connection interface structure;
s1-4, mounting sensors on all sub-modules, wherein the sensors on the sub-modules comprise one or more of a position sensor, a vibration acceleration sensor and an attitude angle sensor;
s1-5, hanging or supporting each sub-module by using a gravity unloading device.
In the virtual-real fusion ground test method, the specific steps of the step S2 are as follows:
s2-1, constructing real-time control equipment, an interface loading actuator, a virtual-real connection interface structure and data acquisition equipment, and connecting a signal cable in the interface fusion device of the virtual-real structure;
s2-2, connecting the virtual-real structure interface fusion device with the virtual-real digital model, the physical module and the signal cable of the assembly mechanical arm.
In the virtual-real fusion ground test method, the specific steps of the step S3 are as follows:
s3-1, setting a zero initial condition for the dynamic equation of the virtual structure after the order reduction, and recording the time integral step length of the set dynamic equation as fatt.
Taking a time step between 0.1 millisecond and 1 second, and enabling the initial time t to be 0;
s3-2, at the time t, interface force and moment signals are obtained through an interface force input port, and displacement and rotation angle of the virtual-real connection interface structure at the time t are calculated through a dynamic equation of the virtual structure; transmitting the calculated displacement and rotation angle instructions of the virtual-real connection interface structure to real-time control equipment, and enabling the real-time control equipment to give control signals according to a control algorithm and drive an interface loading actuator; the interface loading actuator is connected to the virtual-real connection interface structure through a hinge and drives the connection interface structure to move to a designated position and a designated corner; meanwhile, the force and moment at the interface are measured in real time by a sensor arranged on the virtual-real connection interface structure, and are transmitted to an interface force input port after being subjected to analog-digital conversion by data acquisition equipment;
s3-3, calculating the next time step, and enabling t=t+fatter;
s3-4, circulating the step S3-2 and the step S3-3, wherein the virtual digital model and the virtual-real connection interface structure are linked in real time at the moment, so that the interface force balance condition and the interface displacement coordination condition are met, and a virtual-real fusion assembly is formed.
In the virtual-real fusion ground test method, when the step S4 is finished, the sub-modules in all the physical modules are assembled, and the virtual digital structure and the physical modules are linked to form a complete ultra-large space structure assembly;
in the virtual-real fusion ground test method, after the virtual-real structure interface fusion device is closed, in step S5, the real-time control equipment and the interface loading actuator do not work any more, and the virtual digital model does not read port data or perform time integral calculation any more.
Compared with the prior art, the invention has the advantages that:
1. the invention discloses a virtual-real fusion ground test system for an ultra-large aerospace structure, which consists of four main parts, namely a virtual digital model, a physical module, a virtual-real structure interface fusion device and an assembly mechanical arm, wherein the virtual digital model and an assembled submodule are linked through the virtual-real structure interface fusion device to form a combination body of the ultra-large aerospace structure. The test system can better ensure the consistency of the dynamic characteristics of the ultra-large structure and solves the problem that the current space dynamics ground test device limits the geometric size and the weight of a tested object.
2. The invention has wide application range, can simulate on-orbit assembly scenes of various aerospace structures, can simulate multiple stages of the assembly process of the ultra-large aerospace structures, and is compatible with the operation of various assembly mechanical arms.
3. The virtual-real fusion test method disclosed by the invention has high simulation precision, and firstly, the virtual structure and the physical module of the ultra-large spacecraft are divided. The virtual structure part is a part which is easy to model and has higher modeling precision in the whole structure of the ultra-large spacecraft, and a high-precision dynamic model of the virtual structure is established; the physical module part is a part with large modeling difficulty, and the sub-module with actual size is developed to truly reflect the dynamics characteristic of the aerospace structure. On the basis, the virtual-real structure interface fusion device is adopted to link the high-precision virtual digital model and the assembled submodule to form a virtual-real fusion assembly, so that the dynamics characteristic of the on-orbit assembly process of the ultra-large aerospace structure is accurately simulated.
Drawings
FIG. 1 is a diagram of a first embodiment of a virtual-real fusion ground test system for in-orbit assembly of a very large aerospace structure according to the present invention;
FIG. 2 is a diagram of a second embodiment of a virtual-real fusion ground test system for in-orbit assembly of a very large aerospace structure according to the present invention;
FIG. 3 is a diagram of one embodiment of a method of dynamic testing of an on-orbit assembly process for a very large aerospace structure in accordance with the present invention.
Detailed Description
In order to make the objects, technical solutions, advantages and advantageous effects of the present invention clearer, the present invention will be described in detail with reference to the accompanying drawings and detailed embodiments.
Example 1
Referring to fig. 1, a virtual-real fusion ground test system for on-orbit assembly dynamics of an ultra-large space solar power station includes a virtual digital model 101, a physical module 102, a virtual-real structure interface fusion device 103 and an assembly mechanical arm 104.
In the virtual-real fusion ground test system, the virtual digital model 101 comprises a virtual structure 112, an interface force input port 113 and an interface displacement output port 111; wherein the virtual structure 112 is a kinetic model of a main truss of an ultra-large space solar power station; the interface force input port 113 is configured to receive interface force and moment signals transmitted by the data acquisition device 134 during the test process, and transmit the interface force and moment signals to the virtual structure 112 as external load input; the interface displacement output port 111 transmits displacement and rotation angle signals to the virtual-real structure interface fusion device 103 according to the interface displacement and rotation angle response obtained by calculating the virtual structure 112.
In the virtual digital model 101, the virtual structure 112 is modeled by adopting a finite element method, a high-dimensional linear dynamics differential equation set is obtained, the high-dimensional linear dynamics differential equation set comprises a mass matrix and a stiffness matrix of a main truss of the ultra-large space solar power station, and the modal damping ratio of each stage of the structure is 0.5%.
In the above-mentioned virtual digital model 101, the virtual structure 112 uses a method of cutting off the fixed interface modes to reduce the order, that is, the fixed interface modes of the virtual structure 112 are cut off on the premise of keeping the degree of freedom of the virtual-real connection interface structure 133, the cutting order is 12, and the method includes 6 rigid body modes and 6 low-order flexible modes of the main truss of the ultra-large space solar power station.
In the virtual-real fusion ground test system, the physical module 102 includes a plurality of sub-modules to be assembled, namely a first sub-module 121, a second sub-module 122 and a third sub-module 123.
In the above-mentioned physical-physical module 102, the first sub-module 121 is an expansion truss module of the ultra-large space solar power station, the second sub-module 122 is a solar sailboard module, and the third sub-module 123 is another solar sailboard module. The submodules are suspended by a gravity unloading device to simulate an on-orbit zero gravity environment of the aerospace structure;
in the physical entity module 102, suspension points of the first sub-module 121, the second sub-module 122 and the third sub-module 123 can all freely move in a horizontal plane; the submodules in the physical module 102 are arranged according to an assembly sequence, and the assembly sequence of the submodules is determined as follows: the first sub-module 121 is assembled with the virtual-real connection interface structure 133, the second sub-module 122 is assembled with the first sub-module 121, and the third sub-module 123 is also assembled with the first sub-module 121.
In the virtual-real fusion ground test system, the virtual-real structure interface fusion device 103 comprises a real-time control device 131, an interface loading actuator 132, a virtual-real connection interface structure 133 and a data acquisition device 134.
In the virtual-real structure interface fusion device 103, the real-time control apparatus 131 receives the interface displacement and the rotation angle response signals provided by the virtual digital model 101, performs real-time operation according to a feedforward-feedback control algorithm, and sends a signal instruction to the interface loading actuator 132, where the interface loading actuator 132 drives the virtual-real connection interface structure 133 to move to a specified position and rotation angle. The real-time control device 131 receives the interface sensor signals fed back by the data acquisition device 134.
In the virtual-real structure interface fusion device 103, the interface loading actuator 132 is composed of 6 electromagnetic exciters into a Stewart configuration.
In the virtual-real structure interface fusion device 103, one end of the virtual-real connection interface structure 133 is connected to the interface loading actuator 132 through a hinge, and the other end is provided with a multi-point locking interface, so that the virtual-real connection interface structure can be assembled with the first sub-module 121.
In the virtual-real structure interface fusion device 103, the data acquisition device 134 acquires the response of the sensor installed on the virtual-real connection interface structure 133 at a high speed, and the sensor includes displacement, rotation angle, force and moment sensors.
In the above-mentioned virtual-real structure interface fusion device 103, the data acquisition device 134 performs analog-to-digital conversion on the interface force signal and then transmits the interface force signal to the virtual digital model 101.
In the virtual-real structure interface fusion device 103, the data acquisition device 134 simultaneously acquires sensor signals installed on the physical module 102, including the position, vibration acceleration and attitude angle sensor signals of the sub-modules.
In the interface fusion device 103 with the virtual-real structure, the data acquisition device 134 simultaneously acquires sensor signals of the assembly mechanical arm 104, and the sensors include a spatial position sensor of a base of the assembly mechanical arm 104, a rotation angle sensor of each joint of the mechanical arm, and a reaction force sensor of the terminal clamping jaw.
In the virtual-real fusion ground test system, the assembly robot 104 is a mobile robot.
In the virtual-real fusion ground test system, the virtual digital model 101 and the assembled submodule are linked to form a combination body through a virtual-real structure interface fusion device 103.
When the virtual digital model 101 and the virtual-real connection interface structure 133 are opened to link in real time, the virtual digital model 101 and the assembled sub-modules satisfy the force balance condition and the displacement coordination condition in the degree of freedom of the virtual-real connection interface structure 133.
In the virtual-real fusion ground test system, the assembly mechanical arm 104 sequentially captures, transports and butts the first sub-module 121, the second sub-module 122 and the third sub-module 123 so as to simulate the in-orbit assembly process of the ultra-large aerospace structure.
Example 2
FIG. 2 is another embodiment of the virtual-real fusion ground test system for in-orbit assembly of a very large aerospace structure of the invention. This embodiment differs from embodiment 1 in that:
the embodiment builds a virtual-real fusion ground test system for on-orbit assembly of an ultra-large stretching whole stretching arm, and the virtual-real fusion ground test system comprises a virtual digital model 201, a physical module 202, a virtual-real structure interface fusion device 203 and an assembly mechanical arm 204.
In the virtual-real fusion ground test system, the virtual digital model 201 comprises a virtual structure 212 and a multifunctional input/output port 211 for inputting interface force and outputting interface displacement; wherein the virtual structure 212 is a structural dynamics model of an oversized tensegrity extension arm except for portions of the physical module 202.
In the virtual-real fusion ground test system, the physical module 202 includes a sub-module 221, a sub-module 222 and a sub-module 223. Wherein the sub-module 221 is suspended from one carriage on the support 227 by a soft spring 224, the sub-module 222 is suspended from a second carriage on the support 227 by a soft spring 225, and the sub-module 223 is suspended from a third carriage on the support 227 by a soft spring 226. The three pulleys on the support 227 are all free to move in a horizontal plane.
In the physical module 202, the sub-modules 221, 222, 223 are three stretching units, each of which is a foldable prism structure with a length of 5 m, a width of 0.5 m, and a height of 0.5 m. The assembly sequence of the submodules is determined as follows: the sub-module 221 is assembled with the virtual-real connection interface structure 233, the sub-module 222 is assembled with the sub-module 221, and the sub-module 223 is assembled with the sub-module 222.
In the virtual-real fusion ground test system, the virtual-real structure interface fusion device 203 comprises a real-time industrial personal computer 231, an interface loading actuator 232 and a virtual-real connection interface structure 233; the real-time industrial personal computer 231 is an integrated machine comprising real-time control equipment and data acquisition equipment.
In the virtual-real fusion ground test system, the assembly robot 204 is a seven-degree-of-freedom robot with a mobile chassis.
In the virtual-real fusion ground test system, the virtual digital model 201 and the currently assembled sub-module 221 and sub-module 222 are linked to form a combination body through the virtual-real structure interface fusion device 203, and the force balance condition and the displacement coordination condition are satisfied on 6 degrees of freedom of the virtual-real connection interface structure 233.
In the virtual-real fusion ground test system, the assembly robot 204 is capturing, transporting and docking the sub-modules 223 to simulate the in-orbit assembly process of the ultra-large stretching whole stretching arm.
Example 3
Referring to fig. 1 and 3, an on-orbit assembly dynamics virtual-real fusion ground test method for a solar power station in an ultra-large space comprises the following steps:
s1, constructing a virtual digital model 101 and an entity physical module 102 of an ultra-large space solar power station; the specific steps of the step S1 are as follows:
s1-1, selecting an ultra-large space solar power station as a research object, and dividing the space solar power station to remove one expansion truss and the rest of two solar sailboards to form a virtual structure 112. The dynamic equation of the virtual structure 112 is modeled by adopting a finite element method, and the modal damping ratio of each order in the dynamic equation is taken to be 0.5%.
S1-2, reducing the order of a dynamic model of the virtual structure 112 by adopting a fixed interface substructure method, and cutting off the fixed interface mode of the virtual structure on the premise of reserving 6 degrees of freedom of the virtual-real connection interface structure, wherein the cut-off order is selected as 12;
s1-3, constructing an entity physical module 102 of the ultra-large space solar power station, and dividing the entity physical module 102 into three sub-modules. The first sub-module 121 is an expansion truss of the space solar power station, the second sub-module 122 is a first solar panel, and the third sub-module 123 is a second solar panel. The assembly sequence of the submodules is determined as follows: the first sub-module 121 is assembled with the virtual-real connection interface structure 133, the second sub-module 122 is assembled with the first sub-module 121, and the third sub-module 123 is also assembled with the first sub-module 121. The sub-modules are arranged in an assembly sequence of the first sub-module 121, the second sub-module 122, and the third sub-module 123.
S1-4, installing mark points of the motion capture system on each sub-module;
s1-5, suspending each sub-module by using a gravity unloading device, and simulating an on-orbit zero gravity environment of the aerospace structure.
S2, constructing a virtual-real structure interface fusion device 103, wherein the specific steps of the step S2 are as follows:
s2-1, selecting a real-time control device 131, selecting a six-degree-of-freedom Stewart platform as an interface loading actuator 132, selecting a truss interface as a virtual-real connection interface structure 133, selecting a 64-channel data acquisition device 134, and connecting a signal cable in the virtual-real structure interface fusion device 103;
s2-2, connecting the virtual-real structure interface fusion device 103 with the virtual-real digital model 101, the physical module 102 and the signal cable of the assembly mechanical arm 104.
S3, starting the virtual digital model 101 and the virtual-real connection interface structure 133 to link in real time; the specific steps of the step S3 are as follows:
s3-1, setting a zero initial condition for the dynamic equation of the reduced virtual structure 112, and recording the set dynamic equation time integral step length as father t=1 ms, so that the initial time t=0;
s3-2, at the time t, interface force and moment signals are taken through the interface force input port 113, and the displacement and the rotation angle of the virtual-real connection interface structure 133 at the time t are calculated through the virtual structure 112; transmitting the displacement and rotation angle instructions of the virtual-real connection interface structure 133 to the real-time control device 131, and the real-time control device 131 gives control signals according to a control algorithm and drives the interface loading actuator 132; the interface loading actuator 132 is connected to the virtual-real connection interface structure 133 through a hinge, and drives the connection interface structure 133 to move to a designated position and a designated corner; meanwhile, the force and moment at the interface are measured in real time by the sensor installed on the virtual-real connection interface structure 133, and are transmitted to the interface force input port 113 after analog-to-digital conversion by the data acquisition device 134;
s3-3, calculating the next time step, and enabling t=t+fatter;
s3-4, the steps S3-2 and S3-3 are cycled, and at this time, the virtual digital model 101 and the virtual-real connection interface structure 133 are linked in real time to form a virtual-real fusion assembly.
S4, sequentially assembling three sub-modules in the physical module 102 by using an assembling mechanical arm according to the assembling sequence of the physical module;
in the virtual-real fusion ground test method, when step S4 is finished, sub-modules in all the physical modules 102 are assembled, and the virtual digital structure 101 and the physical modules 102 are linked to form a complete ultra-large space structure assembly;
s5, closing the virtual digital model 101 and the virtual-real connection interface structure 133 to link in real time.
In the virtual-real fusion ground test method, in step S5, after the virtual-real structure interface fusion device 103 is turned off, the real-time control device 131 and the interface loading actuator 132 do not work any more, and the virtual digital model 101 does not read port data or perform time integral calculation.
Example 4
Referring to fig. 2 and 3, another embodiment of a virtual-real fusion ground test method for on-orbit assembly dynamics of a very large-scale stretching arm is shown. Compared with embodiment 3, this embodiment is different in that:
in sub-step S1-1, the oversized tensegrity boom is selected as the test object, and the remainder of the oversized tensegrity boom from which the three tensegrity boom units are removed is divided into virtual structures 212. The dynamic equation of the virtual structure 212 is modeled by adopting a finite element method, and the modal damping ratio of each order in the dynamic equation is taken to be 0.5%.
In the S1-3 substep, a physical module of the ultra-large stretching arm of the stretching whole is constructed, and the physical module is divided into three submodules. Wherein sub-module 221 is a first extension arm, sub-module 222 is a second extension arm, and sub-module 223 is a third extension arm. The assembly sequence of the submodules is determined as follows: the sub-module 221 is assembled with the virtual-real connection interface structure 233, the sub-module 222 is assembled with the sub-module 221, and the sub-module 223 is assembled with the sub-module 222 to form a series assembly sequence. The sub-modules are arranged in the order of sub-module 221, sub-module 222, sub-module 223.
Other steps and parameter selections in this example are consistent with those in example 3.
The above examples illustrate only a few embodiments of the invention, which are more specific and detailed, but are not to be construed as limiting the scope of the invention. It should be noted that it will be apparent to those skilled in the art that several variations and modifications can be made without departing from the spirit of the invention, which are all within the scope of the invention. Accordingly, the scope of protection of the present invention is to be determined by the appended claims.
Claims (10)
1. The virtual-real fusion ground test system for the ultra-large aerospace structure is characterized by comprising a virtual digital model, a physical module, a virtual-real structure interface fusion device and an assembly mechanical arm; the virtual digital model comprises a virtual structure, an interface force input port and an interface displacement output port; the entity physical module comprises a plurality of sub-modules to be assembled; the virtual-real structure interface fusion device comprises real-time control equipment, an interface loading actuator, a virtual-real connection interface structure and data acquisition equipment; the assembly mechanical arm comprises one or more of a crawling mechanical arm, a flying mechanical arm and a moving mechanical arm; the virtual digital model and the assembled submodule are linked through a virtual-real structure interface fusion device to form a combination body; the assembling mechanical arm captures, conveys and butts the submodules to be assembled so as to simulate the in-orbit assembling process of the ultra-large aerospace structure.
2. The virtual-real fusion ground test system of claim 1, wherein the virtual structure is a kinetic model of an oversized aerospace structure with a physical module portion removed; the interface force input port is used for receiving interface force and moment signals transmitted by the data acquisition equipment in the test process and transmitting the interface force and moment signals to the virtual structure to serve as external load input; and the interface displacement output port transmits displacement and rotation angle signals to the virtual-real structure interface fusion device according to the interface displacement and rotation angle response obtained by the virtual structure calculation.
3. The virtual-real fusion ground test system of claim 1, wherein the sub-modules of the physical module are local real structures of the oversized spacecraft, and the sub-modules are supported or suspended by a gravity unloading device to simulate an in-orbit "zero gravity" environment of the aerospace structure.
4. The virtual-real fusion ground test system of claim 1, wherein,
the real-time control equipment receives interface displacement and corner response instructions provided by the virtual digital model, and drives an interface loading actuator according to a real-time control algorithm; the interface loading actuator drives the virtual-real connection interface structure to move to a designated position and corner;
the interface loading actuator comprises one or more of a multi-degree-of-freedom mechanical arm, a hydraulic or pneumatic action rod/actuator cylinder, an electromagnetic vibration exciter and a multi-degree-of-freedom vibration table; the data acquisition equipment synchronously acquires signals of sensors arranged on the virtual-real connection interface structure, wherein the signals comprise signals of displacement, rotation angle, force and moment sensors of the virtual-real connection interface structure and/or signals of acceleration and speed sensors.
5. The virtual-real fusion ground test system of claim 1, wherein,
the data acquisition equipment acquires signals of a sensor installed on the physical module at the same time, wherein the sensor comprises one or more of a position sensor, a vibration acceleration sensor and an attitude angle sensor of a sub-module of the physical module;
the data acquisition equipment is used for simultaneously acquiring signals of sensors on the assembled mechanical arm, wherein the sensors comprise one or more of a spatial position sensor of a mechanical arm base, a rotation angle sensor of each joint of the mechanical arm, a reaction moment sensor of each joint of the mechanical arm and a reaction force sensor of a tail end clamping jaw.
6. A virtual-real fusion ground test method for an ultra-large aerospace structure is characterized by comprising the following steps of:
s1, constructing a virtual digital model and an entity physical module of an ultra-large space structure;
s2, constructing a virtual-real structure interface fusion device;
s3, starting a virtual digital model and a virtual-real connection interface structure to link in real time;
s4, sequentially assembling sub-modules in the physical modules by using an assembling mechanical arm according to the assembling sequence of the physical modules;
s5, closing the virtual digital model and the virtual-real connection interface structure to realize real-time linkage.
7. The virtual-real fusion ground test method according to claim 6, wherein the specific steps of step S1 are as follows:
s1-1, modeling a virtual structure of an ultra-large space structure by adopting a dynamics equation, wherein the model comprises one or more of a structural dynamics model, an orbit dynamics model and a posture dynamics model of the virtual structure;
s1-2, reducing the order of a dynamic model of the virtual structure, and cutting off a fixed interface mode of the virtual structure on the premise of keeping the freedom degree of the virtual-real connection interface structure;
s1-3, constructing an entity physical module, dividing the entity physical module into N sub-modules, wherein the value of N is more than or equal to 2; determining an assembly sequence of the submodules, and arranging the submodules according to the assembly sequence, wherein the first submodule is provided with an assembly interface with a virtual-real connection interface structure;
s1-4, mounting sensors on all sub-modules, wherein the sensors on the sub-modules comprise one or more of a position sensor, a vibration acceleration sensor and an attitude angle sensor;
s1-5, hanging or supporting each sub-module by using a gravity unloading device.
8. The virtual-real fusion ground test method according to claim 6, wherein the specific steps of step S2 are as follows:
s2-1, constructing real-time control equipment, an interface loading actuator, a virtual-real connection interface structure and data acquisition equipment, and connecting a signal cable in the interface fusion device of the virtual-real structure;
s2-2, connecting the virtual-real structure interface fusion device with the virtual-real digital model, the physical module and the signal cable of the assembly mechanical arm.
9. The virtual-real fusion ground test method according to claim 6, wherein the specific steps of step S3 are as follows:
s3-1, setting a zero initial condition for a dynamic equation of the reduced virtual structure, and recording the time integral step length of the dynamic equation as fatter, wherein the initial time t=0;
s3-2, at the time t, interface force and moment signals are obtained through an interface force input port, and displacement and rotation angle of the virtual-real connection interface structure at the time t are calculated through a dynamic equation of the virtual structure; transmitting the calculated displacement and rotation angle instructions of the virtual-real connection interface structure to real-time control equipment, and enabling the real-time control equipment to give control signals according to a control algorithm and drive an interface loading actuator; the interface loading actuator is connected to the virtual-real connection interface structure through a hinge and drives the virtual-real connection interface structure to move to a designated position and a designated corner; meanwhile, the force and moment at the interface are measured in real time by a sensor arranged on the virtual-real connection interface structure, and are transmitted to an interface force input port after being subjected to analog-digital conversion by data acquisition equipment;
s3-3, calculating the next time step, and enabling t=t+fatter;
s3-4, circulating the step S3-2 and the step S3-3, wherein the virtual digital model and the virtual-real connection interface structure are linked in real time at the moment, so that the interface force balance condition and the interface displacement coordination condition are met, and a virtual-real fusion combination is formed.
10. The method of claim 6, wherein,
when the step S4 is finished, the sub-modules in all the entity physical modules are assembled, and the virtual digital structure and the entity physical modules are linked to form a complete combination of the ultra-large type aerospace structure;
and S5, after the virtual-real structure interface fusion device is closed, the real-time control equipment and the interface loading actuator do not work any more, and the virtual digital model does not read port data or perform time integral calculation any more.
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