基于机器人建模的航空装配测控仿真分析方法

Aerial assembly measurement and control analysis method based on robot modeling

在航空飞机数字化装配过程中,需要对装配环境中的运动调姿机构的运动能力和靶标测量机构的测量能力进行仿真,以确保调姿机构实现给定运动空间的灵活调姿及测量机构实现对目标测量点的无遮挡、高精度测量,从而测控结合完成装配。而航空领域常用的仿真平台如DELMIA、CATIA和SA等,目前无法实现结合设备位置规划、运动控制评估和测量场分析的综合仿真。为了在同一体系下实现航空装配数字化测控系统的综合仿真,该文提出一种基于机器人建模的航空装配测控仿真分析方法。将数字化装配环境中的零部件及工装、调姿机构、测量机构、环境干扰物体等关键要素在机器人仿真平台中分别建模为不同的机器人,进而按照装配需求编写控制程序,使系统按照需求控制各个机器人联合运动执行仿真分析,以完成测控算法验证,并可进一步设置动态优化问题对测调参数、测量设备站位等现有仿真平台难仿信息进行优化。以高遮挡环境下的多个激光跟踪仪对大量测量点的联合测量可达性仿真分析和多激光跟踪仪站位仿真规划为例,阐述了测量机构的机器人建模方法、仿真系统的搭建方法、仿真激光测量系统的原理和站位规划的实施方式,验证了所提方法的可行性。该方法简单、高效,当环境改变时可快速重规划。

[Objective]To ensure successful assembly in the digital process of aviation aircraft,it is necessary to simulate the motion and measurement capabilities of the adjustment and measurement mechanisms,respectively,for flexible posture adjustment and high-precision target point measurement.However,commonly used simulation platforms in the aviation field,such as DELMIA,CATIA,and SA,cannot achieve comprehensive simulation that combines location planning,motion control evaluation,and measurement field analysis of the equipment.To achieve a comprehensive simulation of aviation assembly digital measurement and control under a uniform system,a simulation analysis method for aviation assembly measurement and control based on robot modeling was proposed.[Methods]The proposed method first models essential elements,such as components and tooling,motion adjustment mechanisms,measurement mechanisms,and environmental interference objects,in a digital assembly environment into different robots in a robot simulation platform and subsequently compiles control programs according to assembly requirements to enable the system to control the joint motion of each robot to perform simulation analysis according to the requirements,complete the verification of measurement and control algorithms,and further set dynamic optimization issues for measuring and adjusting parameters where existing simulation platforms,such as measurement equipment stations,cannot easily emulate information for optimization.To better illustrate the specific implementation and practical effects of this method,the simulation analysis of the measurement accessibility of multiple laser trackers to a large number of measurement points under high occlusion environments and the simulation planning of the stations of multiple laser trackers are taken as examples,and the robot modeling method of the measurement mechanism,the construction method of the simulation system,the principle of the simulation laser measurement system,and the implementation method of station planning are described in detail.[Results]The proposed method is applied to location planning of laser trackers in aircraft measurement fields,where a total of 25 measurement points distributed on the surface of the aircraft need to be accurately measured by four laser trackers.Approximately 1 s is needed to achieve measurement accessibility analysis for a single measurement point,and 1401.5 s is needed to determine the optimal combination location of four laser trackers,which are efficient and have excellent visibility compared with other methods based on modeling software.How the parameters(e.g.,grid density)can affect planning efficiency is discussed by executing multiple simulations with different parameters,and the measurement robustness of the optimal combination location is verified by applying random perturbation errors to the base position of the four laser trackers.[Conclusions]A simulation analysis method for aviation assembly measurement and control based on robot modeling,which can achieve comprehensive simulation of planning,control,and measurement,is proposed.Based on this method,a detailed application case is proposed for the analysis of the measurement accessibility of multiple laser trackers in complex environments and the combined location planning of multiple laser trackers to achieve higher measurement accuracy.The feasibility of the proposed method is verified,and the method is simple,efficient,and can be quickly replanned when the environment changes.