Approach to Interference Riveting Process Control of Aircraft Automatic Drilling and Riveting

Interference fit riveting is an effective way to improve the fatigue life of aircraft.The accurate control of riveting interference of aircraft automatic drilling and riveting equipment is achieved by process parameters including upsetting force and upset head height.It is valuable for aircraft manufacturing engineering.An approach to interference riveting process control based on the analysis of interference riveting stress field is proposed.According to assembly structure,the upsetting force is calculated by the material property and interference fit level,and the upset head height is deduced by the upsetting force.The experimental result shows that the interference fit level can be controlled accurately by the upsetting force and upset head height,and then,the quality of aircraft automatic riveting can be improved.The proposed approach is verified by the good match between the predicted result and the experimental result.

A Laser Line Scanner Based Hole Position Correction Mechanism for Automatic Drilling and Riveting in Aircraft Assembly

The low-stiffness of aircraft skins may results in the differences between aircraft actual parts and their theoretical models,which will consequently affect the accuracy of automatic drilling and riveting in aircraft assembly.In this paper,a novel approach of hole position correction using laser line scanner(LLS)is proposed to assign a single row of holes on the parts’surfaces.First,we adopt a space circle fitting method and the random sample consensus(RANSAC)to obtain the precise coordinates of center of the datum holes’coordinates.Second,LLS is calibrated by the laser tracker,and the relations between the LLS coordinate system and the tool coordinate system(TCS)can be calculated.Third,the kinematics model of the automatic riveting machine is established based on a two-point referencing strategy proposed in this paper.Thus,the positions of the holes to be drilled can be adjusted.Finally,the experimental results show that in TCS the measurement error of LLS is less than 0.1 mm,and the correction error of the hole position is less than 0.5 mm,which demonstrates the reliability of our method.

Automatic Modification of Local Drilling Holes via Double Pre-Assembly Holes

Manufacturing accuracy, especially position accuracy of fastener holes, directly affects service life and security of aircraft. The traditional modification has poor robustness, while the modification based on laser tracker costs too much. To improve the relative position accuracy of aircraft assembly drilling, and ensure the hole-edge distance requirement, a method was presented to modify the coordinates of drilling holes. Based on online inspecting two positions of pre-assembly holes and their theoretical coordinates, the spatial coordinate transformation matrix of modification could be calculated. Thus the straight drilling holes could be modified. The method improves relative position accuracy of drilling on simple structure effectively. And it reduces the requirement of absolute position accuracy and the cost of position modification. And the process technician also can use this method to decide the position accuracy of different pre-assembly holes based on the accuracy requirement of assembly holes.

Automatic de-noising and recognition algorithm for drilling fluid pulse signal

Wavelet forced de-noising algorithm is suitable for denoising of unsteady drilling fluid pulse signal, including baseline drift rectification and two-stage de-noising processing of frame synchronization signal and instruction signal. Two-stage de-noising processing can reduce the impact of baseline drift and determine automatic peak detection threshold range for signal recognition by distinguishing different features of frame synchronization pulse and instruction pulse. Rising and falling edge relative protruding threshold is defined for peak detection in signal recognition, which can make full use of the degree of the signal peak change and detect peaks flexibly with rising and falling edge relative protruding threshold combination. A synchronous decoding method was designed to reduce position uncertainty of the frame synchronization pulse and eliminate the accumulative error of time base drift, which determines the first instruction pulse position according to position of the frame synchronization pulse and decodes subsequent instruction pulse by taking current instruction pulse as new bit synchronization pulse. Special tool software was developed to tune algorithm parameters, which has a decoding success rate of about 95% for the universal coded signals. For the special coded signals with check byte, decoding success rate using the automatic threshold adjustment algorithm is as high as 99%.

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.

89钻杆自动排放机械手设计与研究

为了解决目前人工辅助完成陆地钻台立柱存取存在排放工作劳动强度大、安全性低等问题,以KV3000钻井平台为大环境、89钻杆组成的立柱为研究对象,设计了钻杆自动排杆机械手。首先,对钻井过程中存取立柱的动作及时序过程进行分析;其次,采用动力学仿真分析方法对自动排放机械手进行干涉检查和行程检验,并针对核心零部件进行有限元分析。结果表明:研究装置可顺利完成钻杆存取工作,实现立柱在立柱盒与井口之间的位置转换,加速度均为线性,变化比较平稳,整体无较大波动;核心零部件最大变形为0.15167 mm,最大应力为59.875 MPa,均在允许范围。设备结构合理、运动轨迹规划合理、核心受力部件满足使用要求,提高了钻井作业过程中的自动化程度和安全性,为钻井作业钻杆自动排放提供了解决方案。

钻井液漏斗黏度和密度自动检测仪的研制与应用

近年来,国内外对钻井液性能自动检测技术的研究取得了长足进步。针对现有钻井液自动检测仪器成本高、结构复杂和工作环境受限等问题,研制了钻井液漏斗黏度和密度自动在线检测仪。使用可编程逻辑控制器、物联网模组、压力传感器、超声传感器、蠕动泥浆泵、电动球阀和隔膜泵等,搭建取浆模块、检测模块、清洗模块和控制模块,实现了对钻井液漏斗黏度和密度的自动检测、移动端设备数据查看和操作等功能。采用传感器数据融合和滤波算法等方法提高仪器精度和稳定性,对不同钻井液体系性能测试验证,漏斗黏度误差控制在±1 s,密度误差控制在±0.01 g/cm^(3),且可连续地对钻井液性能进行自动测试。室内测试和现场试验结果表明,该仪器具有操作方便、测试结果准确、可重复性高、人为测量误差小和节约人工等优点,能满足实际钻井施工过程中对钻井液性能检测的要求,具有较强的普适性和广泛的应用前景。

煤矿井下三段式自动封孔器结构设计

针对传统封孔器自动化程度低和现有自动封孔器安全性低、封孔器下放与注料不连续等问题,分析了自动封孔器的功能需求与安全需求,提出三段式自动封孔器方案。设计了封孔器同轴接扣机构、钻孔封堵机构、自动注料流道和动密封机构等关键机构。制作样机并开展了室内封孔实验。实验显示,钻孔封堵机构可自动封堵模拟钻孔,封孔料可自动注入模拟钻孔中完成封孔,三段式自动封孔器方案合理,具有可行性。

煤矿井下自动钻机集控系统设计

针对煤矿井下多台自动钻机工作状态,实现一控多模式,提出了一种自动钻机集控系统。通过从硬件搭建、控制方法、网络连接三方面对煤矿井下自动钻机集中控制系统进行设计研究,最终采用井下控制站对多自动钻机进行集中控制。现场试验表明,该方案可达到减人提效的安全生产目标。

煤矿用钻机钻杆自动更换机构分析

煤矿用钻机在钻进过程中,钻杆的上杆与下杆都需要人工进行操作。在操作过程中劳动强度大、效率低且存在很大的安全隐患。针对此问题,提出一种自动换杆机构的思路,并对换杆机构的运动学进行可行性分析。

TGQ-200RC型多工艺自动化钻机的研制与应用

新一轮找矿突破战略行动对钻探技术提出更高要求,利用浅钻技术在浅覆盖区进行快速查证是重要的技术手段。多工艺钻探可以为复杂地层钻探施工提供绿色高效的钻探技术支撑。围绕这一需求研制了TGQ-200RC型多工艺自动化钻机,制定了钻机的总体方案,研制了多工艺动力头、夹持拧卸装置、6自由度移摆管机构、车装集成式液压储杆库、电液控制及参数监测系统等钻机主要部件,规划了自动加减钻杆过程中多机构协同动作控制流程。实钻试验表明,TGQ-200RC型钻机钻进效率高,取样质量好,具有多工艺、机动化、自动化、数字化等特点,单次自动加减钻杆平均用时约90 s,配合无线遥控可实现孔口无人操作,有效降低劳动强度,提高施工安全性。TGQ-200RC型多工艺自动化钻机可以为构建绿色、高效、经济的快速查证钻探技术体系提供坚实支撑,为推动国内浅层钻探装备自动化升级提供有益借鉴。

自动垂直钻井工具纠斜液压系统的研究

对一种用于石油自动垂直钻井工具的纠斜液压系统展开研究,以实现钻具的纠斜力稳定、可变及钻具矢量纠斜效果。针对油缸压力无法调节及液压泵引起油缸压力不易稳定的问题,研究一种新型纠斜液压系统。在建立纠斜液压系统数学模型的基础上,进行了系统和油缸压力的动态响应分析。仿真结果表明,新型纠斜液压系统提供的导向推力较传统系统稳定性更高,压力波动幅度更低;调节比例溢流阀的输入电流55~85 mA,并保持比例溢流阀输入电流增量不变,钻杆转速越大,油缸压力在单位时间内的开环调节精度就越高。

基于激光测距的标贯自动记录系统研究

随着现代工程技术的发展,地质勘探和钻探作业在土木工程、矿业开采等领域中扮演着至关重要的角色。然而,传统的地质钻探作业存在着效率低下、安全隐患较多、数据采集不准确等问题,亟待解决。为了提高地质钻探作业的效率和安全性,笔者旨在探讨基于激光测距技术的标贯自动记录系统的设计与应用,以期为地质勘探行业的现代化和智能化发展提供有益的借鉴。

碎软煤层中自动化钻机关键技术研究与应用

为解决碎软煤层中瓦斯抽采钻孔作业常出现的喷孔、塌孔、堵孔及埋钻等情况,研发出一款适用于碎软煤层的ZDY4500LFK型自动化钻机;围绕碎软煤层自动化施工难点,介绍了该钻机的机械结构及控制原理,研究分析了钻机在碎软煤层中运用自适应钻进、钻杆自动定位修正、协同式钻杆加卸路径规划等技术原理。现场试验验证结果表明:该钻机高成孔率、高人均效率、高安全性、高携杆量等作业优势,为碎软煤层安全高效生产提供了技术保障。

煤矿用自动化钻机远程控制系统的研制

针对钻机在复杂施工环境下所面临的劳动强度大以及安全风险高等问题,采用电子电路技术、测量传感技术、远程控制技术、视频监测技术以及大数据技术,研制出一套适用于煤矿自动化钻机的远程监控系统。该系统以ZDY4500LFK型煤矿用钻机为主体,实现了视距内控制、井下集控以及地面远程监控3种控制模式,并构建了云端自动化钻机管控平台。具体而言,视距内监控模式通过遥控器、控制器及配套传感器,实现了对井下视觉范围内钻机的精确操作;井下集控模式则集成了集控舱、隔爆兼本安型计算机、本安显示器、隔爆兼本安型交换机、本安摄像头以及本安操控箱等设备,实现了对井下危险钻场的钻机远距离安全监控;地面监控模式则通过地面操控台、地面服务器、显示器、交换机以及AI智能分析盒子等设备,为自动化钻机的地面远程监控提供了有力支持。此外,云端自动化钻机管控平台则主要用于自动化钻机群运行状态和施工状态的数据统计与分析。研制的远程控制系统应用于ZDY4500LFK、ZDY6500LDK型钻机,并实现了视距内遥控、井下集控以及地面远距离控制等多种控制方式的稳定运行。现场试验和测试研究结果表明:(1)钻机视距内遥控系统遥控器按键丰富、控制器具有CAN、RS485等丰富的接口,手机升级便捷方便,可广泛应用于钻机电控化升级和改造。(2)远程集中控制系统可以实现10km距离的远程控制,控制响应时间小于200ms。视频、参数采集数据响应及时无卡滞,可以满足井下钻机远程监控的需求。(3)地面远程监控系统可以实现地面钻机远程监控并具有AI识别功能,可实现人员闯入预警和停机功能。(4)自动化钻机管控平台经过功能、压力、并行、访问测试,功能正常,响应及时,系统无崩溃,可用于自动化钻机数据和工况的统计分析。该控制系统的应用在保证钻孔施工安全的同时也为煤矿钻机实现少人化、智能化、信息化提供了借鉴。

膨胀夹头式自动进给钻应用技术分析

随着航空装备的快速发展,传统手工制孔方式已经不能满足现代化飞机装配制孔需求,根据飞机装配典型应用工况,在保证孔径、锪窝精度前提下,先进高效的半自动制孔技术成为急需突破的关键技术。本文从自动进给钻的实际应用出发,研究了最新膨胀夹头式自动进给钻配套刀具、进给量与转速和叠层厚度等因素对制孔精度的影响,为膨胀夹头式自动进给钻在航空装配制孔的推广应用提供一定参考。

复合材料半自动制孔刀具结构设计与试验研究

采用传统硬质合金刀具对碳纤维复合材料进行半自动制孔时容易产生烧伤、分层、撕裂等质量缺陷,本文对刀具材料和结构进行优化设计,提出一种PCD钻头和台阶式PCD扩孔钻,通过开展PCD和硬质合金刀具半自动制孔试验,分析孔壁温度、刀具磨损及出孔面质量,得出该刀具具有切削热量低、轴向力和径向力小的特点,能够减少碳纤维过热、烧伤和出孔面分层、撕裂的风险。

瓦斯抽采钻孔自动防喷系统研究及应用

瓦斯抽采是解决突出矿井瓦斯喷出问题的主要方法,在钻孔施工时容易因瓦斯喷出而造成瓦斯超限。针对现有防喷装备依赖人工操作、安全性较差的问题,研发了一种与钻机集成安装且具有自动断电、封堵功能的瓦斯抽采自动防喷系统。在其主要功能的基础上,对主要部件和电液联合控制系统展开研究。现场试验结果表明:该系统完成自动断电封堵的全流程工作时间不超过5 s;密封性能良好;对钻孔过程中产生的瓦斯喷出起到了有效的防护作用,在一定程度上杜绝了瓦斯超限。

管道定向钻穿越等级公路套管全自动解锁装置设计

根据JTG D20—2017《公路路线设计规范》规定“油气输送管道与各级公路相交叉且采用下穿方式时,应设置地下通道(涵)或套管”,定向钻穿越等级公路传统工艺有全套管和半套管2种,施工成本高、难度大,尤其在大口径厚壁管中更是明显。为有效降低施工成本和难度,结合天然气工程实践,设计一种管道定向钻穿越等级公路套管全自动解锁装置,套管长度仅延伸至道路外缘2~5 m,这尚属首创,不仅适用于油气管道工程,也适用于其他市政管道工程,具有较高的经济效益和推广价值。

万米科学特深井防斜纠斜技术方案及研究建议

根据科学钻探特点和我国特深井井身结构情况,论文首先设定了我国万米科学特深井基本井身结构和取心井段,结合前苏联SG-3井、德国KTB主井和我国内地科钻一井、松科2井等内地科学钻探工程项目,阐述了特深井井斜预测方法、测量方法、全面钻进和取心钻进的防斜纠斜技术方法。给出我国万米科学特深井上部井段井斜控制方法和控制指标以及连续取心井段防斜纠斜工艺、器具等总体方案,并提出了进一步研究的建议。