面向工艺的飞机线束精准设计技术探索

Process Oriented Precision Design Technology for Aircraft Harness

针对飞机线束敷设过程中因长度/分叉不合理导致多次返工、线束敷设质量不能满足工艺规范要求等装配过程中的瓶颈问题,分析现阶段线束设计、制造、装配各环节存在的问题,参考国外线束设计方法,探索适应于国内飞机的线束设计阶段分工模式,以及该模式下工艺设计具体内容,提出一种面向工艺的飞机线束精准设计方法。方法以飞机设计电路原理图、线缆通道图、线缆支架图等三维设计数模为依据,在线束三维设计中融入导线材料、弯曲半径、松弛度、间距、维护性等电气线路互联系统(Electrical Wiring Interconnection Systems,EWIS)相关工艺要素,并通过柔性仿真对线束受力情况进行分析优化,实现线束敷设路径、线束长度的精准设计及应用。

Aiming at the bottleneck problems in the assembly process such as repeated rework due to unreasonable length/bifurcation in the laying process of aircraft wiring harnesses,and the quality of wiring harness laying cannot meet the requirements of process specifications,the existing problems in the current stage of wiring harness design,manufacturing,and assembly are analyzed.Referring to foreign wiring harness design methods,the division of labor mode wiring harness design stage suitable for domestic aircraft is explored,as well as the specific content of process design under this mode,and a process-oriented precise design method for aircraft harness is presented.Based on the three-dimensional design models such as aircraft design circuit schematic diagram,cable channel diagram and cable bracket diagram,the method incorporates the related process elements of the electrical line interconnection system(EWIS),such as traverse material,bending radius,relaxation,spacing,maintenance,etc.into the three-dimensional design of the wire harness,and analyses and optimizes the force on the wire harness through flexible simulation to achieve the route of wire harness laying,and precise design and application of harness length.