摄影测量技术在飞机结构件修理中的应用研究

Application of Photogrammetry in Aircraft Components Repair

某型飞机修理时发现多个翼面存在严重损伤,且由于机翼整体产生了较大不可逆变形而无法按新品状态进行修理和更换。为解决再制造修理过程中的修理结构详细设计和装配定位及相邻翼面阶差等问题,借助摄影测量技术开展了逆向建模等相关研究;通过原位测量和离位测量相结合,采用激光跟踪仪建立一级测控网、工业摄影测量建立二级控制网、三维激光扫描仪进行“填充式”扫描的方式,快速高效获取了整体高精度扫描点云数据;综合考虑部件局部结构修补和损伤形变等实际工况,基于左右对称等原则利用点云数据进行型面重构,实现了变厚度双曲面等复杂外形翼面结构高精度实体逆向建模;基于数模完成了翼面结构再制造修理和机上模装验证等工作,提高了大部件修理精度和装配效率。

Several serious damages were detected on airfoils during the repair of a certain aircraft. And due to the large irreversible deformation of the wing as a whole, these airfoils could not be repaired and replaced as new state. In order to solve the problems during the repair process of remanufacturing, such as the detailed design of repair structure, assembly location and the step difference of adjacent airframes, the reverse modeling was carried out by means of photogrammetry. Through the combining of in-situ and ex-situ measurements, the first-level measurement and control network was established by laser tracker, the second-level control network was established by industrial photogrammetry, and a three-dimensional laser scanner was used for “filling” scanning. Finally, the overall high-precision scanning point cloud data was obtained quickly and efficiently. Considering the actual conditions such as local structural repair and damage deformation, the shape surface is reconstructed based on principles such as left-right symmetry, and the acquired point cloud data. And high-precision reverse modeling of complex shape wing structure, such as hyperboloid with variable thickness, is realized. Based on these mathematical models, the wing structure remanufacturing repair and in-flight model installation verification are completed, which improves the repair accuracy and assembly efficiency of large and complex shaped aircraft components.