基于局部刚度加强的大型飞机壁板装配变形控制及安全恢复技术研究

Panel is one of the major components of large modern aircraft, and its assembly accuracy directly influences the coordination of aircraft components and accuracy of the aircraft's overall shape. How to effectively control the distortion of panel is one of the key technical difficulties in aviation industry which urgently need to be overcomed. In this project, we will intensively investigate how to predict the panel distortion during assembly, as well as how to control and recover the distortion. The mechanization in the generating, accumulating and evolving process of assembly distortion will be discovered by a novel and advanced method of physical modeling and simulation, which result in quantitative prediction of assembly quality and scientific optimization of assembly process. Additionally, the irregular assembly distortion of panel will be well regulated under scientific control by the modeling and simulating the process of local stiffness enhancement. Furthermore, by modeling and simulating the process of moving and pulling of numerical control positioners, an inverting model is created to calculate distortion-correcting displacement. An online-measurement and feedback-control strategy based on measuring-correcting process integration is produced for recovering assembly distortion. Research findings will promote the development of new principles and methods in digital aircraft assembly, and provide theoretical guidance and technician support for high-accuracy, high-efficiency and high-quality panel assembly of civil large airplane.

壁板作为现代大型飞机的重要组件之一，它的装配精度直接影响飞机部件间的相互协调性和整机的外形准确度，如何有效控制壁板装配变形是目前我国航空工业亟需解决和攻克的技术难题之一。本项目从壁板装配变形预测、调控和恢复三个层面开展系统深入的研究，通过壁板装配过程物理建模与仿真，揭示壁板装配变形产生、累积和演变的内在机理，实现壁板装配质量的定量预测和装配工艺的科学优化；通过壁板局部刚度加强工艺仿真与优化，诱导装配变形从无序化到有序化，实现装配变形的科学调控；通过数控定位器移动牵引壁板过程建模与仿真，建立定位器校形位移反演计算模型，进而形成一整套基于测量-校形一体化的壁板装配变形恢复过程在线检测与反馈控制策略，实现装配变形的数字化恢复。研究成果将进一步发展飞机数字化装配新原理与新方法，为我国大型飞机壁板高精度、高效率和高品质装配提供理论指导和技术支持。

壁板作为现代大型飞机的重要组件之一，它的装配精度直接影响飞机部件间的相互协调性和整机的外形准确度。本项目从壁板装配变形预测、调控和恢复三个层面开展系统深入的研究，发展飞机数字化装配新原理与新方法，为实现壁板高精度、高效率和高品质装配提供理论指导和技术支撑。. 在壁板装配变形预测方面，综合考虑壁板装配过程中影响装配精度的关键影响因素，研究了基于隔框定位误差的壁板装配偏差；为提高预连接质量，有效控制壁板装配变形，建立了一种避免强迫装配和提升效率的预连接工艺规划模型和一种预连接工艺快速优化模型；通过对壁板装配残余应力场及装配连接质量进行针对性的精确调控，揭示了壁板装配物理场形成和演变规律，实现对壁板装配工艺的全局优化。. 在壁板装配变形调控方面，面向壁板装配变形检测和数字化调姿对接装配精度评价的需求，提出了检测点优化布置方法；分析壁板装配变形有序化特征及其变形规律，提出了壁板校形判据及其数学表达方法，以保证壁板的装配精度和质量；建立了基于工艺接头工装的壁板局部刚度强化有限元模型，探索局部刚度加强对壁板装配变形有序化调控的内在机理，建立壁板应变能与工艺接头支撑参数之间的数学关系，取得了最优工艺接头支撑布局。. 在壁板装配变形恢复方面，建立了数控定位器位移数据与检测点位置误差数据之间的反演计算模型，实现对机身壁板装配变形的正确预测和校正；研究基于“测量-校形”一体化的壁板装配变形恢复过程数字化在线检测与反馈控制原理和方法，开发了基于数控定位器的大型飞机壁板安全恢复及准确定位软件系统，实现了装配变形表达、变形有序化判别和数控定位器校形位移计算实现壁板装配变形安全恢复。. 本项目主要研究成果包括：培养博士生2名，硕士生5名，发表SCI、EI论文18篇，获得授权国家发明专利3项，多项研究成果已经在我国大型飞机数字化装配领域得到了成功应用。