大部件装配界面分体式互操作自适应精加工理论与应用基础

Adaptive finish machining the assembly interfaces of large-scale component is a significant research topics in the digital and smart manufacturing for large size products. There are several issues in the split-type layout finish machining system: (1) poor accuracy in global self-calibration and positioning; (2) difficulties in realizing high-level adaptive process execution when only considering on-line optimization of tool path and technological parameters; (3) low-level of interoperability and automation caused by insufficient dynamic-and-static fused semantic information. This project introduces the concept of “interoperable adaption”, and proposes a new theoretical framework and methods for adaptive finish machining the assembly interfaces. The proposed theory is based on semantic machining models and focuses on interoperable controlling and managing. Key technologies including the semantic machining modeling of dynamic-and-static semantic information, global self-calibration and positioning and the machining error modeling, adaptive process planning and execution for multiple processes will be researched. An MCS-based (Machine tool Coordinate System) method is presented to realize global self-calibration and machining error modeling. This method can solve the efficiency and accuracy problems in the calibration method based on foundation. An adaptive process control method which is event-driven and service-oriented is proposed to achieve dynamic reconfiguration and condition-based execution of the whole workplans, and this method is able to solve the problem in the high-level adaptive execution of multiple processes. The achievement of this project is a universal theory and methods for interoperable adaptive finish machining in the split-type machining layout of assembly interfaces of large-scale component, and will provide theoretical guidance and technical supports for the typical process system for large-scale component finishing.

大部件装配界面自适应精加工是大型产品数字化智能制造中一类重要论题，分体式布局精加工系统存在全局自标定与定位精度不高、仅考虑工艺参数和刀具路径在线优化而难以实现高层工艺自适应、缺乏静动态融合的语义信息所导致系统互操作性和自动化程度差等局限。本项目引入“互操作自适应”理念，提出基于语义加工模型以互操作管控为中心的装配界面自适应精加工理论框架及方法，开展静动态信息融合的语义加工模型、全局自标定与定位及其误差建模、多工艺自适应规划与执行方法研究。提出基于机床坐标系的全局自标定及加工误差建模方法，解决以地基为基准的标定效率不高和装配界面加工误差偏大问题；提出事件驱动面向服务的自适应工艺过程执行控制方法，实现工艺顺序的动态重构和视情执行，解决多工艺高层自适应执行难题。研究成果将形成具有普遍适用性的大部件装配界面分体式互操作自适应精加工理论方法，为大部件精加工这一类典型工艺系统提供理论指导和技术支持。

飞机、航天器、风电设备等大型产品制造中对大部件高精高效加工的需求日益增加，特别是大型产品最终装配前对其大部件装配界面的精加工工艺过程，成为制约大型产品最终装配质量和生产效率的瓶颈环节。本项目针对大部件装配界面精加工过程中亟需解决的若干科学问题，在分析装配界面精加工工艺特点的基础上，重点开展了支持大部件装配界面互操作自适应加工的静动态信息融合语义加工模型构建技术、考虑装配界面精加工精度约束条件的大部件自适应定位技术、基于空间统计分析的装配界面加工误差分析技术、基于功能块的装配界面精加工多工艺自适应工艺规划与执行控制技术、面向服务的大型薄壁件智能铣削技术等研究，实现了从装配界面精加工多工艺（如大尺寸测量、大部件定位、在机测量、装配界面加工等）的自适应规划、执行控制和工艺调整/优化，提高了装配界面的精加工质量和效率。此外，还深入拓展研究和解决了装配界面的加工稳定性问题，提出了基于电涡流阻尼效应的大部件装配界面加工振动抑制方法、基于优化STD法的大部件装配界面精加工过程模态参数辨识方法、实时振动数据驱动的大部件装配界面铣削工艺参数优化方法。通过以上研究实现了装配界面现有整体加工模式向分体式的测量—定位—加工一体化闭环自适应加工模式的转变，提高了应对加工工况和条件变化的能力，使之能够有效自适应大部件的实作状态、工艺系统的实际工作性能状态及装配界面的实际加工状态。总之，本项目瞄准大部件装配界面精加工高新技术的前沿，最终形成了一系列具有较好普适应性的大部件装配界面分体式互操作自适应精加工的基础理论和应用研究成果，丰富和完善了大型高端产品智能加工及智能制造系统的理论和方法体系，具有较强的学术和应用价值，并有力促进了机械、信息和控制学科知识的融合，也将为未来航空航天大部件加工的信息物理生产系统提供有效支撑。