基于夹具主动定位补偿的飞机柔性件装配偏差优化方法

Assembly variation optimization method of aircraft compliant parts based on active locating compensation of fixture

柔性零件广泛用于航空、汽车等产品中,在柔性件的装配过程中,装配尺寸质量受零件制造、夹具和连接过程中多种偏差源的耦合影响,分析和控制难度大。提出了一种基于夹具主动定位补偿的装配偏差优化方法。首先,基于柔性件装配的受力变形分析,建立了考虑夹具法向定位误差的装配偏差模型。然后,根据上述模型,以夹具法向定位补偿量为优化变量,提出了夹具法向补偿量的优化模型和求解算法。以金属薄板装配和飞机壁板件装配为例,分别利用实验及有限元仿真分析了有无夹具主动定位补偿下的装配偏差。结果表明,夹具法向定位补偿对于减小柔性件的装配偏差具有显著效果,从而验证该优化算法的有效性和准确性。

Compliant parts are widely used in such products as aircrafts and automobiles.It is quite challenging to analyze and control the compliant assembly quality because the assembly is subject to the coupled effect of multiple error sources in part manufacturing,tooling and joining.A new methodology for assembly variation optimization is proposed based on the concept of active fixture locating compensation.First,an assembly variation model is developed by force-deformation analysis in compliant assembly considering fixture normal locating errors.Based on the assembly variation model,an optimization model is further developed to calculate the optimal fixture normal compensation,which takes the locating points of fixture as variables.Case studies on sheet metal assembly and fuselage panel assembly are conducted.Comparative studies are conducted on the two cases,i.e.,sheet metal assembly and fuselage panel assembly,in which the assembly variations with and without the proposed active fixture locating compensation are achieved and compared by experiment and Abaqus finite element analysis,respectively.The results show the proposed method can significantly decrease the predictive assembly variations.