Design of Drilling and Riveting Multi-functional End Effector for CFRP and Aluminum Components in Robotic Aircraft Assembly

To fulfill the demands for higher quality,efficiency and flexibility in aviation industry,a multi-functional end effector is designed to automate the drilling and riveting processes in assembling carbon fiber reinforced polymer(CFRP)and aluminum components for a robotic aircraft assembly system.To meet the specific functional requirements for blind rivet installation on CFRP and aluminum materials,additional modules are incorporated on the end effector aside of the basic processing modules for drilling.And all of these processing modules allow for a onestep-drilling-countersinking process,hole inspection,automatic rivet feed,rivet geometry check,sealant application,rivet insertion and installation.Besides,to guarantee the better quality of the hole drilled and joints riveted,several online detection and adjustment measures are applied to this end effector,including the reference detection and perpendicular calibration,which could effectively ensure the positioning precision and perpendicular accuracy as demanded.Finally,the test result shows that this end effector is capable of producing each hole to a positioning precision within ±0.5 mm,aperpendicular accuracy within 0.3°,a diameter tolerance of H8,and a countersink depth tolerance of±0.01 mm.Moreover,it could drill and rivet up to three joints per minute,with acceptable shearing and tensile strength.

A new principle and device for large aircraft components gaining accurate support by ball joint

How to obtain an accurate support for large components by ball joint is a key process in aircraft digital assembly. A novel principle and device is developed to solve the problem. Firstly, the working principle of the device is introduced. When three or four displacement sensors installed in the localizer are touched by the ball-head, the spatial relation is calculated between the large aircraft component's ball-head and the localizer's ball-socket. The localizer is driven to achieve a new position by compensation. Relatively, a support revising algorithm is proposed. The localizer's ball-socket approaches the ball-head based on the displacement sensors. According to the points selected from its spherical surface, the coordinates of ball-head spherical center are computed by geometry. Finally, as a typical application, the device is used to conduct a test-fuselage's ball-head into a localizer's ball-socket. Positional deviations of the spherical centers between the ball-head and the ball-socket in the x, y, and z directions are all controlled within ±0.05 mm under various working conditions. The results of the experiments show that the device has the characteristics of high precision, excellent stability, strong operability, and great potential to be applied widely in the modern aircraft industry.

大型飞机自动化装配技术

简述了大型飞机及其结构特点,通过比较人与机器两种装配系统的特性,及分析装配自动化水平与装配成本等诸因素的关系曲线,指出了自动化装配技术在保证大型飞机结构长寿命、高效率、低成本研制和生产等方面的意义;对国外大型飞机的装配自动化发展状况进行了综述,简要分析了国外发展的几种主要自动化装配系统,总结了国外大型飞机的自动化装配水平;对西方国家在大型飞机自动化装配中采用的先进的装配理念和方法,如决定性装配方法等进行了概述。最后针对国内自动化装配水平低的现状和大型飞机研制和生产的需求,提出了发展模块化结构的自动化装配系统、贯彻并行工程理念、实现面向制造和面向装配的设计等发展建议。

柔性工装及自动化装配设备在大型飞机装配中的运用

大型飞机的大尺寸、高要求的特点为其装配过程带来了不少的困难,国外大型飞机装配多采用柔性装配工装与自动化装配设备完成其装配过程。本文分析了国外大型飞机装配中所运用的先进技术手段与国内飞机制造业的现有基础,并为国内大型飞机的装配提出切实可行的建议。

飞机大部件自动对接同步调姿方法

提出了飞机大部件自动对接同步调姿方法,实现了大部件调姿基准点的连续自动跟踪测量和位姿连续调整。在此基础上开发了集测量场构建、大部件位姿解算和调整等功能于一体的大部件自动对接集成控制软件,并在ARJ21飞机翼身自动对接现场进行了应用试验,结果证明该方法能有效完成飞机翼身自动对接过程,提高测量和对接效率。

Research on uncertainty in measurement assisted alignment in aircraft assembly

Operations in assembling and joining large size aircraft components are changed to novel digital and flexible ways by digital measurement assisted alignment.Positions and orientations（P＆O）of aligned components are critical characters which assure geometrical positions and relationships of those components.Therefore,evaluating the P＆O of a component is considered necessary and critical for ensuring accuracy in aircraft assembly.Uncertainty of position and orientation（U-P＆O）,as a part of the evaluating result of P＆O,needs to be given for ensuring the integrity and credibility of the result;furthermore,U-P＆O is necessary for error tracing and quality evaluating of measurement assisted aircraft assembly.However,current research mainly focuses on the process integration of measurement with assembly,and usually ignores the uncertainty of measured result and its influence on quality evaluation.This paper focuses on the expression,analysis,and application of U-P＆O in measurement assisted alignment.The geometrical and algebraical connotations of U-P＆O are presented.Then,an analytical algorithm for evaluating the multi-dimensional U-P＆O is given,and the effect factors and characteristics of U-P＆O are discussed.Finally,U-P＆O is used to evaluate alignment in aircraft assembly for quality evaluating and improving.Cases are introduced with the methodology.

飞机大部件装配能力测算方法研究

针对具有典型离散型制造特征的飞机大部件结构装配能力测算问题,以其下级部段件为研究单位,分析了部段装配能力随工艺方案、操作熟练度、倒班模式、制造资源以及一般能力社会化等因素的动态变化关系,提出了基于部段装配能力数据集并综合考虑飞机装配流程时序关系以及各部段装配能力匹配关系的飞机大部件实际装配能力测算方法,通过举例计算,验证了该方法的可行性和有效性。

基于WinCC的飞机大部件自动对接系统开发

针对飞机大部件对接装测控一体化需求开展相关装备研究,结合大部件对接实际工艺需求,突破了定位器布局优化、上下位机通信、自动化测量、多轴同步运动控制、调姿路径规划、对接软件集成等多项关键技术,开发了基于WinCC的飞机大部件自动对接系统,包括定位器系统、自动测量系统和集成控制系统等。该系统集自动化和过程控制于一体,以数据库为桥梁,依靠可靠稳定的上下位机实时通信技术,集成了装测控一体化控制软件,实现了飞机大部件的自动测量和自动调姿,进一步提高了飞机大部件对接的自动化程度和效率。

基于机械手的飞机部件铆接系统设计

飞机上的部件数量众多且多为薄壁连接结构,存在形状材料复杂、加工难度高、精度要求严格等特性。目前,机械手不断融合多种技术,正越来越多地应用于制造业。在此背景下,设计并搭建基于机械手的飞机部件铆接系统,设计末端执行器、机械手移动装置、顶铁移动装置以及待加工件夹具等,分析并探究保障制孔精度的控制方案。利用系统对飞机蒙皮模型进行铆接实验验证,结果表明该系统达到了精度要求,同时提高了铆接效率。

飞机大部件对接机构驱动分析与优选

飞机大部件对接装配一般通过多个定位器协调运动来实现,由于支撑需求,定位器存在驱动冗余,驱动方式存在多个方案,需要对不同方案进行分析和优选。文章分析定位器的空间布置和驱动方式对装配对接精度和效率的影响,将对接系统抽象为对接并联机构,采用螺旋理论分析了不同定位器布置和驱动方式的运动自由度,计算了不同驱动方式对位姿调整误差的影响。分析和比较了冗余驱动度小于2的几种典型驱动方式,得出了最优方案,为飞机大部件对接装配定位器的设计和控制提供了理论基础。