大型壁板自动钻铆定位误差分析与优化

Analysis and optimization for locating errors of large wing panel during automatic drilling and riveting

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 for large-sized wing panels,the mapping relationship between their practical poses and theoretical poses could not be established accurately due to the large locating errors.Nevertheless,the error compensation process is complicated,which leads to low efficiency in aircraft assembly.Focusing on compensation method through fixture design,locating errors tracing analysis and optimization approach for the layout of locating points are studied aiming to control the locating errors during locating of large-sized wing panels.First,locating errors tracing analysis is carried out according to the process flow of automatic drilling and riveting.The sources of the errors and the propagation mechanism are analyzed.Second,the locating variation propagation process is divided in two sub-process,rigid part and flexible part.For the rigid part,the Monte-Carlo method and the homogeneous transformation method are applied to analyzing the produce and propagation of the errors respectively.As to flexible part,the deformation error of each key feature points on the wing panel is calculated utilizing the finite-element method.Third,combing the rigid part and flexible part,the locating error distributing law is analyzed based on the confidence degree.Fourth,parameterized models are developed using Abaqus scripting language,and the layout of locating points is optimized based on NSGA-II by the means of backstage calling and assignment planning using Isight.Finally,a wing panel of X-type aircraft is used to validate the methodology proposed,which demonstrates the technical feasibility of the methodology.