复杂机电产品中的柔性线缆装配过程仿真技术

Assembly Process Simulation for Flexible Cable Harness in Complex Electromechanical Products

针对复杂机电产品中柔性线缆结构复杂且在装配操作中发生变形而导致的装配过程仿真难的问题,系统地提出了柔性线缆装配过程仿真的解决方案及其关键技术的实现方法.首先提出一种基于元素包含关系和无向图的线缆数字化表达模型,实现了复杂线缆拓扑、几何和属性信息的统一表达,为装配过程仿真奠定了基础;然后提出一种改进的层次链装配过程模型,统一处理针对不同对象的装配任务和装配操作等,实现了装配过程中线缆和结构件交叉装配任务和装配操作的表达和存储;最后建立一种改进的线缆质点-弹簧模型,通过添加长度变化约束并设定典型装配操作中的约束条件,实现了线缆在装配仿真中柔性形变的实时仿真.在开发的原型系统中实现了柔性线缆的装配过程仿真,并通过实例验证了文中方法的可行性.

Assembly process simulation for cable harness in complex electromechanical products is challenging due to the complex structure of the cable harness and its deformation in assembly operations. This paper presents a solution for flexible cable harness assembly process simulation and its key techniques. A digital representation model for complex cable harness is proposed, in which primitive elements are defined and the model is constructed based on the containing relationship and joint relationship between the elements. A hierarchy-chain-based assembly process model which uniformly organizes all the assembly objects, tasks and operations is proposed to represent and store the assembly process, in which assembly tasks and operations may be performed alternatively on rigid part and flexible cable harness. A refined mass-spring model of cable harness with length reservation is built and utilized to calculate the deformation of cable harnesses in typical assembly operations. A prototype system is developed, in which an industrial application is carried out and the proposed solution and key techniques are validated.