精密机电系统精准数字装配基础理论与方法研究

The trend towards severe and extreme service environment in precision electromechanical systems is more remarkable, and it makes customer to have more demands for the system performance, especially in high service performance, high reliability, and high performance stability. With the significantly improved consistency of the design and manufacture precision in parts and components, the key point of performance guarantees in precision electromechanical systems has been transferred from “design phase”, which is the most front-end in the development process, to “manufacturing phase”, and continually been moved to “assembly phase” of the end. The aim of this project is to improve the assembly accuracy and service performance of precision electromechanical systems. The polymorphic nature of geometric accuracy in the domain of “space” and “time” is studied. The description model of “shape” and “state” is built. The evolution mechanism of geometric accuracy in the domain of “space” and “time” is derived for different assembly topology structure. The mechanism of transfer and accumulation in the space domain is explored, and the rule of evolution and decline in time domain also is analyzed. Based on this, the real physical behavior during the assembly accuracy(geometry) inducing the work performance(physical) is presented. Moreover, this project studied on the active design and control methods of geometric accuracy, and the inversion design, testing and manufacturing methods of topology shape and surface topography of assembly interface. The research above will achieve the accurate digital assembly, and provide the fundamental theory and technical support to guarantee the high service performance, high reliability, and high performance stability for precision electromechanical systems.

随着精密机电系统工作环境的恶劣化与极限化趋势越来越显著，客户对于系统的性能表现提出了越来越高的要求，特别是高服役性能、高可靠性、高性能保持性。随着零部件设计制造精度的一致性显著提高，精密机电系统的性能保障重心已由开发过程最前端的“设计环节”向“制造环节”再向末端“装配环节”转移。本项目以提高精密机电系统装配精度与整机服役性能为目标，研究几何精度的空间与时间多态性本质，构建“形、态”描述模型，阐明不同装配拓扑下几何精度在时间与空间衍生与演变机理。探索装配精度在空间域传递与积累、在时间域演变与衰退的机理与规律，并据此揭示装配精度（几何量）诱发服役性能（物理量）的真实物理行为。研究不同拓扑装配结构几何精度的主动设计与调控方法，研究装配结合面拓扑形状与表面形貌的反演设计、检测与制造方法，实现精准数字装配，为保障精密机电系统高服役性能、高可靠性、高性能保持性，提供基础理论与技术支撑。

随着服役环境的恶劣化与极限化趋势越来越显著，精密机电系统对高服役性能、高可靠性、高性能保持性的追求和保障越来越迫切。由于当前零部件设计制造精度一致性显著提高，精密机电系统的性能保障重心已由开发过程前端的“设计环节”向“制造环节”再向末端“装配环节”转移。为此，本项目系统地建立了面向精准装配的精度设计、连接工艺与测量系统理论体系，具体进展如下：（1）提出了精密装备几何精度统一建模理论体系，建立了误差不确定性的解析传递法则，构建了考虑装调能力的公差优化设计模型，实现精密装备几何精度精准预测与控制。（2）构建了考虑真实形貌和微凸体非线性变形的装配接触分析模型，提出了装配界面表面形貌和表面硬度优化设计方法，实现了装配连接性能的精确预测、量化控制与精准设计，形成了装配界面主动设计理论与方法。（3）建立了装配连接扭矩-载荷动态关联模型，提出了载荷弹性交互作用力学建模理论，形成了装配连接工艺优化设计方法，突破了高温高压高频振动等高参数环境下装配性能的退化机理，实现了精密装备的精准装配与性能保障。（4）构建了应用于装配特征几何测量的光频扫描干涉（FSI）测量系统，提出了动态目标高速跟踪测量方法，构建了面向精密运动部件和大尺寸空间的光学测量系统，实现了装配特征多目标、多自由度同时测量。（5）研制了精密机电系统精准装配分析软件和工艺装备，在精密卧式坐标镗床、大型星载SAR天线、航空发动机、大推力运载火箭及助推器发动机、主战坦克等高端装备中得到重要应用。项目团队发表论文81篇，其中SCI收录56篇、EI收录24篇。签署专著出版合同1项。申请国家发明专利41项（其中授权33项），申请并授权PCT专利1项，登记软件著作权6项。组织学术会议5次，作大会特邀报告9人次。获得省部级科研奖励2项。培养国家优青2人、博士研究生6人（其中1名博士生毕业论文被评为省级优秀博士学位论文）、硕士研究生12人。