CN112307562B - Method for assembling complex parts on large-scale airplane by combining thermal deformation and gravity deformation - Google Patents
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Abstract
The invention relates to an assembly method of complex parts on a large airplane with comprehensive thermal deformation and gravity deformation, belonging to the technical field of large airplane manufacturing. The method comprises the following steps of posture adjusting and positioning: (1) dispersing the complex part and key features on the three-dimensional model of the complex part into a key feature point set; (2) obtaining coordinate values of key feature points on the two key feature points; (3) calculating the coordinate deviation of the key characteristic points caused by the temperature and the gravity action by using a finite element analysis model based on the temperature of the assembly environment; (4) correcting the coordinate values of key feature points on the complex part based on the obtained coordinate deviation; (5) and calculating a pose coordination matrix T for adjusting and positioning the complex part to the target pose based on the corrected coordinate values of the key feature points on the complex part and the coordinate values of the key feature points on the three-dimensional model. The method can effectively improve the assembly efficiency and precision of the complex parts on the large-scale airplane, and can be widely applied to the technical field of manufacturing of large-scale airplanes.
Description
Technical Field
The invention relates to the technical field of assembly of large airplanes, in particular to a method for assembling complex parts on a large airplane, which integrates thermal deformation and gravity deformation in the assembly process.
Background
In the assembly process of a large aircraft, particularly in the assembly process of complex structural components on the large aircraft, repeated adjustment and repair are needed in the installation process due to the large size of the large aircraft, so that the installation precision requirement can be met. In order to solve the technical problem, the patent document with the publication number of CN107263044A discloses a design method of an assembly system of an outer wing box of a large aircraft considering the thermal deformation factor, and the patent document with the publication number of CN107052750A discloses a posture adjusting and positioning system of a leading edge assembly; in these prior arts, improvement is made on the structure of the installation tool, so as to solve the problem of thermal deformation coordination existing between a large-size component on an aircraft and a positioning tool thereof in the installation process, for example, positioning and installing the large-size component such as a wing box leading edge assembly, a trailing edge assembly, a wing root rib, and the like.
In the above solution, based on the improvement of the tool structure, although the problem of thermal deformation coordination between the component and the tool can be solved, in the process of field installation of the large aircraft, there is still a problem of deviation of measurement coordinate values produced by thermal deformation and gravity deformation, especially in the process of performing attitude adjustment and positioning on a single component or a first component (i.e. a reference component referred to in the subsequent component installation process) in coordination with the attitude, and in addition, the single component or the reference component on the large aircraft that needs to be subjected to attitude adjustment and positioning is usually a complex structural component, the thermal deformation and the gravity deformation will have a serious influence on the installation accuracy and efficiency thereof, for example, in the process of performing attitude adjustment and positioning on a large component such as a wall panel by using the numerical control attitude adjustment and positioning device disclosed in patent document No. CN107471171A, multiple adjustments and repairs are usually required.
Disclosure of Invention
The invention mainly aims to provide an assembly method of complex parts on a large airplane by combining thermal deformation and gravity deformation so as to improve the installation precision and the assembly efficiency of the complex structural parts on the large airplane.
In order to achieve the main purpose, the assembly method of the complex parts on the large-scale airplane integrating thermal deformation and gravity deformation, provided by the invention, comprises a posture adjusting and positioning step and a mounting and fixing step, wherein the posture adjusting and positioning step comprises the following steps:
a discrete processing step, namely, discretizing the complex part and key features on the three-dimensional model of the complex part into a key feature point set;
coordinate measurement, namely acquiring coordinate values of the complex component and key feature points on the three-dimensional model after being adjusted and positioned to the target pose;
a simulation solving step, namely calculating the coordinate deviation of the key characteristic points caused by the assembly environment temperature and the gravity action by using a finite element analysis model based on the three-dimensional model and the current assembly environment temperature;
a parameter correction step of correcting the coordinate values of the key feature points measured from the complex component based on the coordinate deviation obtained in the simulation solving step;
and a calculation step of calculating a pose coordination matrix T for adjusting and positioning the complex component to the target pose based on the corrected coordinate values of the key feature points on the complex component and the coordinate values of the key feature points on the three-dimensional model.
Based on the technical scheme, the coordinate deviation caused by temperature and gravity is calculated through simulation, the coordinate deviation is utilized to correct the key characteristic point coordinate on the complex component, namely the influence deviation caused by gravity and temperature is eliminated from the existing coordinate measurement value, namely the coordinate deviation after the gravity influence and the temperature influence are roughly eliminated is utilized to solve the pose coordination matrix T, and the obtained pose coordination matrix T can be better matched with the target pose in the three-dimensional model, so that the nonlinearity between the key characteristic point coordinate measurement value and the three-dimensional model caused by thermal deformation and gravity deformation is effectively eliminated, and the accurate and efficient large-scale aircraft complex structure pose adjustment positioning is facilitated.
The specific scheme is that the step of calculating the pose coordination matrix T for adjusting and positioning the complex component to the target pose comprises the following steps:
(1) constructing a pose coordination optimization model J of the complex part and the feature point pairs of the parts on the three-dimensional model by adopting a least square method based on a three-dimensional point matching principle,
wherein n isThe number of the dispersed key characteristic point pairs, R and P are respectively the rotation component and the translation component of the pose coordination matrix T, KCsmeasuedFor the coordinate values, KCs, of key feature points on the complex part under the assembly coordinate system and after correctiondatumThe coordinate value of the key characteristic point coordinate on the three-dimensional model under the assembly coordinate system;
(2) and fusing a linear SVD algorithm and a nonlinear L-M algorithm, solving the pose coordination optimization model J, and acquiring an optimal pose coordination matrix T.
Based on the three-dimensional point matching principle, the pose coordination optimization model J of the feature point pairs of the complex part and the pipe fittings on the three-dimensional model is constructed by adopting the least square method, so that the influence of factors such as assembly deviation, measurement uncertainty and the like on the complex part can be effectively eliminated, and the assembly precision and efficiency are further improved.
In the function solving step, firstly, solving a pose coordination optimization model J by using a linear SVD algorithm to obtain an optimal pose coordination matrix T, and estimating a pre-estimated value of the pose coordination matrix T; and then, taking the estimated value as an initial value, fusing a linear SVD algorithm and a nonlinear L-M algorithm, and solving the attitude coordination optimization model J. The linear SVD is used for solving the initial value first, so that the convergence speed in the accurate solving process can be effectively improved.
The preferable scheme is that weights are given to different key feature point pairs according to preset importance, and a pose coordination optimization model J after correction is obtained:
wherein, six-element group S ═ X, Y, Z, A, B, C]X, Y and Z are parameters of a translation component P, and A, B and C are parameters of a rotation component R characterized by ZYX Euler angle parameters;
by six-membered group S and coordinate value KCsmeasuedAs a function of the parameter, ωiIs the weight of the ith key feature point pair.
Different weights are given to different key characteristic point pairs, namely higher weights are given to important positions, such as a transmitter suspension position and the like, so that the calculation structure is more consistent with the actual assembly situation, and the assembly efficiency and the assembly precision are further improved.
Preferably, in the parameter correction step, the coordinate values KCs of the key feature points on the complex part after correction are calculated based on the following formulameasured；
Wherein, KCs0 measuredFor direct measurement of key feature point coordinates on complex parts,
the coordinate value deviation caused by the temperature of the assembly environment is obtained for the simulation,
the coordinate value deviation caused by the weight is obtained for the simulation.
The preferred scheme is that the complex part is a wallboard, the adjustment is carried out based on a plurality of numerical control posture adjusting positioning devices which are arranged along the course interval of the wallboard at preset intervals, and each numerical control posture adjusting positioning device comprises a ball head locking mechanism which is used for forming ball head hinge joint with a supporting ball head arranged on the outer board surface of the wallboard.
The further scheme is that the posture adjusting and positioning step comprises the following steps: based on formula JPsdesired＝T*JPscurrentJPs sphere center coordinates of supporting ball heads on each numerical control adjusting and positioning device when the aircraft structure is adjusted to the target pose are calculateddesired，JPscurrentThe measured value of the spherical center coordinate of the supporting ball head on each numerical control adjusting and positioning device under the assembly coordinate system is obtained.
The further proposal is that if the number of the supporting ball heads for coupling the wall plate with the same numerical control posture adjusting and positioning device is more than two, the connecting line of the fixed connecting positions of the more than two supporting ball heads and a plurality of points on the extension line thereof are taken as key characteristic points; if the number of the supporting ball heads for coupling the wall plate with the same numerical control posture adjusting positioning device is more than one, at least the central point of the fixed connection position of the supporting ball head is taken as a key characteristic point. On the premise of ensuring the accuracy of the calculation structure, the solving process is simplified as much as possible.
The preferred scheme is to arrange key feature points at mounting locations with high precision requirements relative to the peripheral area, according to assembly process specifications.
Drawings
FIG. 1 is a flowchart of the operation of the pose alignment step in the embodiment of the present invention;
fig. 2 is a schematic diagram of the positions of key feature points on a complex part of an aircraft according to an embodiment of the invention.
Detailed Description
The invention is further illustrated by the following examples and figures.
In the following embodiments, the process of adjusting the posture and positioning during the assembly of the wall panel of the large aircraft is taken as an example for explanation, and the assembly method can also be applied to the assembly of other reference components needing to be installed on the large aircraft, such as the fuselage section of which the posture and positioning is performed first in the butt-joint assembly of the fuselage.
Examples
In the embodiment, the assembly method of the invention is used for assembling the large-scale aircraft wall panel 01 as shown in fig. 1, wherein the device for adjusting and positioning the posture of the wall panel 01 in the assembly process is adjusted by using a numerical control posture adjusting and positioning device disclosed in patent document with the application of the applicant and the publication number of CN107471171A, in particular, a plurality of numerical control posture adjusting and positioning devices arranged at preset intervals along the spanwise direction of the wall panel 01 are used for adjusting; referring to the specific structure disclosed in the drawings of the patent document, the posture adjusting and positioning device specifically comprises a base, a sliding table pillar slidably mounted on the base through a guide rail slider mechanism, and more than one three-coordinate numerical control positioner mounted on the sliding table pillar with output ends arranged in parallel; the output end is fixedly provided with a ball head locker which is used for forming a ball head hinge mechanism with a supporting ball head arranged on the wall plate.
The assembly method comprises an attitude adjusting and positioning step and an installation and fixing step, as shown in fig. 2, the attitude adjusting and positioning step comprises a discrete processing step S1, a coordinate measuring step S2, a simulation solving step S3, a parameter correcting step S4, a calculating step S5 and an executing step S6, and the specific processes are as follows:
in the discretization step S1, the complex component and the key features on the three-dimensional model thereof are discretized into a key feature point set.
In this embodiment, the following rules are mainly referred to in the process of selecting key feature points on the complex component wall plate 01:
(1) if the number of the supporting ball heads of the wall plate 01 coupled with the same numerical control posture adjusting positioning device is more than two, taking a connecting line of fixed connection positions of the more than two supporting ball heads and a plurality of points on an extension line of the connecting line as key characteristic points; for example, in patent document CN107471171A, three numerically controlled attitude adjusting and positioning devices at the root end of the wing each have two support bulbs fixedly connected to the wall plate 01, and a central connecting line of the fixedly connected positions of the two support bulbs and the wall plate and a plurality of points on an extension line of the connecting line are used as key feature points, specifically, the three numerically controlled attitude adjusting and positioning devices are selected in a uniformly distributed manner.
(2) If the number of the supporting ball heads for coupling the wall plate with the same numerical control posture adjusting positioning device is more than one, at least the central point of the fixed connection position of the supporting ball head is taken as a key characteristic point. For example, in the patent document with publication number CN107471171A, only one support ball is fixedly connected to the wall plate 01 of each of two numerically controlled attitude adjusting and positioning devices at the wing tip end, and at least the connection center point of the support ball and the wall plate is required to be taken as a key feature point, or the connection direction of three key feature points at the wing root or the contour line direction of the wall plate holding tool may be parallel to the connection line direction, and multiple points on a straight line passing through the connection center point are taken as key feature points, specifically, the key feature points are selected in a uniform arrangement manner.
(3) According to the assembly process specification, compared with other positions, key feature points are also required to be set for positions with higher precision requirements, such as thermal deformation anchor points, engine installation positions and the like.
As shown in fig. 1, a total of 5 rows are selected in this embodiment, and there are 16 key feature points 1 in total.
And a coordinate measuring step S2, wherein coordinate values of the complex component and key feature points on the three-dimensional model after being adjusted and positioned to the target pose are obtained.
For obtaining the coordinate values of key characteristic points on the complex part wallboard 01, the coordinate values KCs are obtained for measurement by adopting a laser tracking measurement system0 measuredAnd obtaining coordinate value KCs for the three-dimensional model as the attitude adjusting reference obtained based on the design softwaredatum。
In this embodiment, the coordinate values of key feature points on the wall plate 01 obtained by measurement are measured values based on the local coordinate system of the component, and for the convenience of subsequent calculation, the coordinate values need to be converted to the measured values in the assembly coordinate system, specifically, the formula KCs is adopteddatum＝WTL*KCsL datumIs subjected to conversion, wherein, KCsL datumIs the coordinate value, KCs, of the structural wallboard of the airplane to be adjusted in the local coordinate systemdatumAre the coordinate values in the set-up coordinate system,WTLis a mathematical description of the local coordinate system of the structural panel of the aircraft in the assembly coordinate system.
And a simulation solving step S3, calculating the coordinate deviation of the key characteristic points caused by the assembly environment temperature and the gravity action by using the finite element analysis model based on the three-dimensional model and the current assembly environment temperature.
The assembly environment temperature is acquired by temperature sensors arranged at a plurality of points in an assembly workshop, and the temperature is measured by using the temperature sensors arranged at intervals along the spanwise direction of a wall plate.
And a parameter correction step S4 of correcting the coordinate values of the key feature points measured from the complex component based on the coordinate deviations obtained in the simulation solving step.
In this step, the coordinate values KCs of the key feature points on the complex part after correction are calculated based on the following formulameasured；
Wherein, KCs0 measuredFor direct measurement of key feature point coordinates on complex parts,
the coordinate value deviation caused by the temperature of the assembly environment is obtained for the simulation,
the coordinate value deviation caused by gravity is obtained for simulation, namely the coordinate value used for calculation is the coordinate measured value without the gravity and temperature influence, namely the corresponding influence is eliminated.
And a calculating step S5, calculating a pose coordination matrix T for adjusting and positioning the complex part to the target pose based on the coordinate values of the key feature points on the complex part and the coordinate values of the key feature points on the three-dimensional model after correction. The method specifically comprises the following steps:
(1) based on the three-dimensional point matching principle (Aren K S.left-square fitting of two 3-D point sets [ J ]. IEEE trans.pattern anal.machine Intell,1987,9.), a least square method is adopted to construct a pose coordination optimization model J of key feature point pairs on a complex component and a three-dimensional model:
wherein n is the number of the dispersed key feature point pairs, R and P are respectively the rotation component and the translation component of the pose coordination matrix T, and KCsmeasuedFor the coordinate values, KCs, of key feature points on the complex part under the assembly coordinate system and after correctiondatumThe coordinate values of the key characteristic point coordinates on the three-dimensional model under the assembly coordinate system.
In the step, after factors such as assembly deviation and measurement uncertainty of the complex component wall plate to be subjected to posture adjustment are considered, the posture coordination matrix is not accurate and consistent for all key feature point pairs, and the factors such as the assembly deviation and the measurement uncertainty are eliminated as much as possible based on the coordination optimization model J.
(2) Weighting different key feature point pairs according to preset importance, and acquiring a pose coordination optimization model J after correction:
wherein, six-element group S ═ X, Y, Z, A, B, C]X, Y and Z are parameters of a translation component P, and A, B and C are parameters of a rotation component R characterized by ZYX Euler angle parameters;
by six-membered group S and coordinate value KCsmeasuedAs a function of parameters for characterizing R & KCsmeasued+P，ωiIs the weight of the ith key feature point pair.
And manually assigning the weight of each key characteristic point pair according to a preset importance level to modify the attitude coordination optimization model, for example, according to the assembly process specification, the precision requirements of positions such as thermal deformation anchor points and engine installation positions are higher compared with other positions, namely the precision requirements of different areas are different, so that the weight assignment of the position with higher precision requirement is larger in the assignment process.
(3) And fusing a linear SVD algorithm and a nonlinear L-M algorithm, solving the pose coordination optimization model J, and acquiring an optimal pose coordination matrix T.
Wherein the pose coordination matrix T is used to adjust the wallboard to be pose from the current pose to the target pose, i.e., the pose designed in the three-dimensional model, i.e., KCsdatum＝T*KCsmeasued。
In the function solving step, firstly, solving the pose coordination optimization model J by using a linear SVD algorithm, acquiring a pose coordination matrix T, and estimating a pre-estimated value of the pose coordination matrix T; and then, taking the estimated value as an initial value, fusing a linear SVD algorithm and a nonlinear L-M algorithm, and solving the attitude coordination optimization model J. The specific process is as follows:
(1) based on non-iterationPose coordination parameter S calculated by SVD algorithm0＝[X0,Y0,Z0,A0,B0,C0]。
(2) The coordinates of the key characteristic points in the attitude adjusting reference and the centroid of the coordinate measurement value of the key characteristic points of the structure of the airplane to be adjusted can be respectively expressed as
And order
If the obtained pose coordination parameters R and P are least square solutions, the coordinates of key characteristic points in the pose adjustment reference
And
having the same centre of mass in Cartesian space, i.e.
Based on the above representation, the pose coordination model J can be simplified as follows:
solving the formula to obtain:
therefore, minimizing the objective function J is equivalent to maximizing the function Q.
Wherein,
performing SVD on Q:
Q＝UDVT
where D is a diagonal matrix and U, V are orthonormal matrices, based on which the rotation component R can be calculated according to:
R＝VUT
and based on formulas
Calculating a translation component:
the rigid kinematic transformation matrix T, consisting of the rotation matrix R and the translation vector P, can be represented as a six-membered set S.
(3) Pose coordination parameter S calculated by non-iterative SVD algorithm0＝[X0,Y0,Z0,A0,B0,C0]As an initial value of a nonlinear least square Levenberg-Marquard (L-M) algorithm, solving the optimal pose coordination parameter S [ X, Y, Z, A, B, C ] which minimizes the objective function J]。
The L-M algorithm is a fusion of the gradient descent method and the Gauss-Newton (G-N) algorithm, and is more robust than the G-N algorithm. In the L-M algorithm, a modified Hessian matrix is used:
H(S,λ)＝2JTJ+λI
where J is the Jacobian matrix, I is the identity matrix, and λ is the damping factor, which is adjusted at each iteration. If λ is small, H approximates a G-N Hessian matrix. Otherwise, H is close to the identity matrix, and the L-M algorithm degenerates to a gradient descent method.
The steps of the L-M algorithm can be briefly described as follows:
let λ be 0.001.
2 calculation ofδS＝-H(S,λ)-1g, where δ S is the increment of the estimated pose coordination parameter six-tuple S. In the G-N algorithm, G ═ 2JTJ δ S, while in the gradient descent method, g ═ λ δ S.
(S)n+δS)＞f(Sn) λ ═ 10 λ, and then return to step @.
If not, λ is 0.1 λ, Sn+1＝Sn+ δ S and then go to step (ii).
And S6, controlling the pose adjusting and positioning device to adjust the pose of the wallboard based on the obtained pose coordination matrix T.
In the present embodiment, it is specifically based on formula JPsdesired＝T*JPscurrentJPs sphere center coordinates of supporting ball heads on each numerical control adjusting and positioning device when the aircraft structure is adjusted to the target pose are calculateddesired，JPscurrentThe method is used for measuring the sphere center coordinates of the supporting ball heads on the numerical control posture adjusting and positioning devices under the assembly coordinate system, namely, the obtained posture coordination matrix is endowed for the posture adjustment of the supporting ball heads on the numerical control posture adjusting and positioning devices, so that the calculation process is effectively simplified.
Claims (7)
1. The method for assembling the complex parts on the large-scale airplane integrating thermal deformation and gravity deformation comprises a posture adjusting and positioning step and an installation and fixing step, and is characterized in that the posture adjusting and positioning step comprises the following steps: a discrete processing step, namely, discretizing the complex part and key features on the three-dimensional model of the complex part into a key feature point set; coordinate measurement, namely acquiring coordinate values of the complex component and key feature points on the three-dimensional model to be adjusted and positioned to reach a target pose state; a simulation solving step, namely calculating the coordinate deviation of the key characteristic points caused by the assembly environment temperature and the gravity action by utilizing a finite element analysis model based on the three-dimensional model and the current assembly environment temperature; a parameter correction step of correcting the coordinate values of the key feature points measured from the complex component based on the coordinate deviation obtained in the simulation solving step; calculating a pose adjusting matrix T for adjusting and positioning the complex component to the target pose based on the coordinate values of the key feature points on the complex component and the coordinate values of the key feature points on the three-dimensional model after correction;
the step of calculating a pose adjustment matrix T for pose positioning of the complex component to the target pose comprises the steps of: (1) constructing a pose adjustment optimization model J of the complex component and key feature point pairs on the three-dimensional model by adopting a least square method based on a three-dimensional point matching principle,
wherein n is the number of the dispersed key feature point pairs, R and P are respectively the rotation component and the translation component of the pose adjustment matrix T, and KCsmeasuedFor the coordinate values, KCs, of key feature points on the complex part under the assembly coordinate system and after correctiondatumThe coordinate value of the key characteristic point coordinate on the three-dimensional model under the assembly coordinate system; (2) and fusing a linear SVD algorithm and a nonlinear L-M algorithm, solving the pose adjustment optimization model J, and acquiring an optimal pose adjustment matrix T.
2. The assembly method of claim 1, wherein: in the simulation solving step, firstly, solving the pose adjustment optimization model J by using a linear SVD algorithm to obtain an optimal pose adjustment matrix T, and estimating a pre-estimated value of the pose adjustment matrix T; and then, the estimated value is used as an initial value, a linear SVD algorithm and a nonlinear L-M algorithm are fused, and the pose adjustment optimization model J is solved.
3. The assembly method of claim 1, wherein: weighting different key feature point pairs according to preset importance, and acquiring a pose adjustment optimization model J1 after correction:
wherein, six-membered group S ═ X, Y, Z, A, B, C]X, Y, Z are parameters of the translational component P, A, B, C are characterized by ZYX Euler angle parametersThe parameter of the rotational component R of (a);
by six-membered group S and coordinate value KCsmeasuedAs a function of the parameter, ωiIs the weight of the ith key feature point pair.
4. An assembly method according to any one of claims 1 to 3, characterized in that: in the parameter correction step, the coordinate values KCs of the key feature points on the complex part after correction are calculated based on the following formulameasured；
Wherein, KCs0 measuredFor direct measurement of the coordinates of key feature points on the complex part,
the coordinate value deviation caused by the temperature of the assembly environment is obtained for the simulation,
the coordinate value deviation caused by gravity is obtained for simulation.
5. An assembly method according to any one of claims 1 to 3, characterized in that: the complex part is a wallboard and is adjusted based on a plurality of numerical control posture adjusting positioning devices arranged at preset intervals along the spanwise direction of the wallboard, and each numerical control posture adjusting positioning device comprises a ball head locking mechanism which is used for forming ball head hinge joint with a supporting ball head arranged on the outer board surface of the wallboard.
6. The assembly method of claim 5, wherein the step of adjusting the position comprises the steps of: based on formula JPsdesired＝T*JPscurrentEach numerical control adjusting and positioning device for calculating and adjusting airplane structure to the target poseCenter of sphere coordinates JPs for supporting ball headdesired，JPscurrentThe measured value of the spherical center coordinate of the supporting ball head on each numerical control adjusting and positioning device under the assembly coordinate system is obtained.
7. The assembly method of claim 6, wherein: if the number of the supporting ball heads for coupling the wall plate with the same numerical control posture adjusting positioning device is more than two, taking a connecting line of fixed connection positions of the more than two supporting ball heads and a plurality of points on an extension line thereof as the key characteristic points; if the number of the supporting ball heads for coupling the wall plate with the same numerical control posture adjusting positioning device is more than one, at least the central point of the fixed connection position of the supporting ball head is used as the key characteristic point.
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