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在机翼大型壁板自动钻铆工艺中,由于定位误差较大,壁板实际位姿和理论数模位姿之间难以建立精确的映射关系,而现有补偿工艺流程复杂,导致装配效率较低。着眼于工装设计补偿,针对大型壁板自动钻铆定位误差控制问题展开定位误差溯源分析和定位点布局优化。首先,根据自动钻铆工艺流程进行定位误差溯源,分析其误差的来源及传递机理;其次,将定位误差分为刚性误差和柔性误差两部分,采用Monte-Carlo法模拟刚性定位误差的分布,通过齐次坐标变换分析刚性误差的传递过程,利用有限元虚拟仿真计算关键特征点的柔性变形误差;再次,集成刚性误差与柔性误差,基于统计学思想讨论特定置信度下的定位误差分布规律;然后,基于脚本语言开发Abaqus参数化模型,通过Isight进行后台调用及赋值规划,实现基于带精英策略的非支配解排序遗传算法(NSGA-II)的定位点布局多目标优化;最后,以某型飞机机翼上侧壁板的一号组件为实例,验证了该方法的可行性。
In the process of automatic drilling and riveting of the large wings, it is difficult to establish an accurate mapping relationship between the actual pose of the wall plate and the theoretical pose of the digital model due to the large positioning error. However, the existing compensation process is complicated, resulting in a higher assembly efficiency low. Focusing on the design of tooling design compensation, aiming at the positioning error control of large-scale siding automatic drilling riveting, the localization error tracking analysis and the positioning point layout optimization are carried out. First of all, according to the automatic drilling riveting process flow to locate the error source, analyze the source of error and transmission mechanism; Secondly, the positioning error is divided into two parts of rigid error and flexible error, using Monte-Carlo simulation rigid positioning error distribution, Homogeneous coordinate transformation is used to analyze the transmission process of rigid errors. The finite element virtual simulation is used to calculate the flexible deformation errors of key feature points. Thirdly, the rigid and flexible errors are integrated. Based on the statistical theory, the distribution of positioning error under certain confidence is discussed. , The Abaqus parameterization model is developed based on the scripting language, background calling and assignment programming are performed by Isight, and the multi-objective optimization of the anchor placement based on non-dominated destructuring genetic algorithm (NSGA-II) with elitist strategy is implemented. Finally, The first component on the upper wing of the wing is an example to verify the feasibility of this method.