飞机装配协调尺寸一致性主动控制方法研究

Interchangeability and coordination is one of the difficult challenges in aircraft manufacturing. Aiming at the problems of the discontinuity of digital transmission, and the lack of controlling of accumulated assembly error in the current period of "analog entity and digital model ", the active controlling method for the coordination accuracy between aircraft assemblies is to be studied combining with the turning point of aviation intelligent manufacturing transformation. Firstly, by calculating the real physical deformation and measuring the actual precision state, with the modification of the geometric topological relationship and the reconstruction of the assembly deformation, the digital coordination model is constructed to accurately reflect the assembly coordination state and to provide accurate data source for coordinated control in real time. Secondly, through the combination of "assembly", "measurement" and "control", on the basis of digital coordination model, with the guidance of product assembly error propagation, according to measured data, the controlling system is built for the coordination consistency. Continuous improvement actions, such as quantitative identification of coordination characteristics, nonlinear cumulative prediction of assembly and coordination error, hierarchical cooperative diagnosis and accurate optimal allocation of coordination error sources, are adopted to adjust the coordination error links with active feedback. Thirdly, experimental verification is carried out to ensure the design requirements of the gap and flush between different components. Finally, the change from passive iterative adjustment for final assembly quality to the real-time active control of assembly coordination process is realized, which would provide a new idea and method for accurate assembly control of large scale and complex equipment in intelligent manufacturing mode.

互换协调是飞机制造的难点工作之一，针对“混合协调”过程中存在的数字量传递不连续以及协调尺寸误差累积控制欠缺等问题，结合航空智能制造转型契机，研究装配协调尺寸一致性主动控制方法。首先，融合真实物理状态，考虑几何拓扑关系修正与变形重构，动态构建面向现场的协调工艺模型，准确反映装配协调状态，为协调性的控制实时提供精准数据源；其次，通过“装”、“测”、“控”相结合的误差控制手段，以协调工艺模型为基础、以装配误差传递为导向、以测量数据为依据，构建协调一致性控制体系，并采取协调特征定量识别、协调误差非线性累积预测、协调误差源的分级协同诊断与精准优化分配等持续改进行动，主动反馈调整协调误差环节，闭环控制协调一致性；最后，开展试验验证保证部件外形间阶差与间隙的设计要求。最终实现装配质量事后被动迭代调整向装配协调过程实时主动控制的模式转变，为智能制造模式下大尺寸复杂装备的精准装配控制提供新的途径和方法。

对于飞机产品，协调准确度要求往往比制造准确度要求更高，即使单个零部件的制造准确度与装配准确度达到要求，零部件之间的协调准确度仍难以保证，因此飞机的制造需要非常复杂而完善的互换协调理论支持。由于实物协调控制技术自身的缺陷，已无法满足现代飞机研制需求。在国内，虽然数字化制造技术与大量数控设备应用在主力机型的制造中，但仍处于模拟量与数字量的“混合协调”时期，存在数字量传递的不连续以及协调尺寸误差累积控制的欠缺问题。.为满足新一代飞机的装配协调质量，避免或减少修配工作量，本课题以智能制造为背景，通过“装”、“测”、“控”相结合的误差控制手段，对装配协调尺寸一致性主动控制方法进行研究。首先，研究考虑真实拓扑关系的协调工艺模型动态构建方法，为装配协调控制提供精准而唯一的协调依据，建立数字量连续传递的基本模式；其次，根据数字量协调特点，基于多层次的现场装配过程，构建协调尺寸一致性的主动控制技术体系，包括：（1）适用于数字量装配环境下的协调特征定量识别方法；（2）基于实测几何量与装配现场物理量融合的协调误差非线性接力传递规律；（3）小样本数据量下协调状态与误差源间的分级映射方法；（4）面向装配协调过程的容差优化分配机制，通过误差溯源、追踪及持续改进等行动，主动反馈调整协调误差环节，解决协调尺寸误差累积控制欠缺的现状；最后，以某试验件为验证对象，实现其组成部件外形间阶差与间隙的精准装配。.经过三年时间已完成项目研究目标，发表与项目紧密相关且标准本项目资助的SCI论文7篇、EI论文6篇、中文核心论文4篇，中文会议论文1篇，学术会议报告PPT宣讲4次（含国外交流1次），申请国家发明专利2项，报批行业标准1项，取得软件著作权1项，培养研究生5名，在读1名。