基于四心误差累积量极小化的航空发动机核心机超精密测量与装配方法

Aeroengines are the most important equipment for our country. Because of the complexity of technology, the difficulty of research and development, and the blockade of foreign technology, Aeroengine has become a "neck jam" problem in the field of high-end equipment in China. In the field of aeroengine core-engine assembly and measurement, the lack of ultra-precision measurement and precision assembly means leads to "imprecise measurement, unclear mechanism, inaccurate assembly" problems, so it is urgent to study a cooperative adjustment control precise measurement and assembly method based on the space posture four-center error cumulative minimization mechanism. To break through the mechanism of multi-offset errors separation and compensation of large-diameter, narrow ring-band and short fit-stop rotating stators, the ultra-precision measurement of contact profile error and morphological filtering evaluation methods of aeroengine complex components are studied; To break through the error projection transmission mechanism of four-center of position and attitude in rotating subspace, a relevance theoretical modeling research on the micro-error stacking and macro-shape-performance is carried out. To break through the spatial matching cancellation mechanism of multilevel assembly error cumulants, the research on precision assembly method for macro-shape-performance coordinated control of geometric accuracy, dynamic balance, rotational inertia moment and dynamic vibration characteristics of aeroengine multi-stage rotor system is carried out. Core technical indicators include: the measuring accuracy of the micro-profile is improved by 20%, the prediction accuracy of macro-assembly performance is better than 90%, and the qualification rate of primary assembly is better than 96%. This study provides a strong theoretical and technical support for ultra-precision measurement and precision assembly of aeroengine.

航空发动机是国之重器。由于技术复杂，研制难度大，加上国外技术封锁，已成为我国高端装备领域中“卡脖子”问题。针对我国航空发动机核心机测量装配领域由于“测量不精密、机理不清晰、装配不精准”导致振动故障率高的技术瓶颈，提出基于四心误差累积量空间位姿匹配极小化的超精密测量和装配方法。突破大直径、窄环带、短止口多偏置误差分离与补偿机理，研究微观接触轮廓误差超精密测量形态学滤波评定方法；突破空间位姿四心误差投影传递机理，研究微观误差逐级堆叠与宏观形性关联理论；突破多级装配误差累积量空间位姿匹配极小化机理，研究多级转子系统几何精度、动平衡响应、转动惯量与动态振动宏观形性协同调控的精准装配方法。核心技术指标：微观轮廓测量精度提高20%，宏观装配性能预测精度优于90%，一次装配合格率优于96%，为航空发动机超精密测量与精准装配提供强有力的理论和技术支撑。

面向航空发动机核心机复杂构件超精密测量和精准装配需求，本项目突破了大直径、窄环带、短止口过盈配合的多偏置误差超精密测量方法和空间位姿误差矢量投影理论，构建了零件级微观轮廓接触误差与组件级宏观装配形状/性能的预测理论模型；突破了核心机形心、质心、重心和惯性中心四心误差累积量的空间传递机理，构建了零件级四心误差累积量与几何形状、质量特性、转动惯量、振动特性等装配性能的关联模型；突破了多级转静子四心误差协同调控的精准测量与装配方法，研究了超精密测量与装配一体化技术，提高了航空发动机核心机测量装配精度和效率。主要成果如下：.（1）突破了兼顾偏心误差、倾斜误差、传感器测头偏移误差、传感器测球半径和导轨倾斜误差的多项偏置误差分离与补偿模型，研究了航空发动机大直径、窄环带、短止口复杂构件轮廓超精密测量方法，建立了微观轮廓误差表面接触特性滤波与评定理论模型，提高了误差传递定向与定位特征向量的精度。.（2）突破了航空发动机多级复杂构件误差空间位姿投影传递理论模型，研究了多级转静子系统形心、质心、重心和惯性中心误差累积量传递、累积与放大机理与规律，构建了航空发动机单级构件微观轮廓表面接触误差与多级转静子系统宏观装配形状和力学/动态性能的关联预测理论模型，提高了航空发动机多级转静子系统宏观装配形状/性能的堆叠投影预测精度。.（3）突破了航空发动机核心机多级转静子构件堆叠四心误差累积量空间匹配极小化机理，研究了以每级转子定位/定向特征向量和装配相位为控制变量，以多级转子系统宏观形状误差、初始不平衡量、重力矩、转动惯量为测调目标的协同控制策略，实现了形心、质心、重心和惯性中心误差累积量匹配极小化对动态振动精准抑制与调控，提高了多级转静子系统四心误差累积量匹配测调堆叠装配的精度与效率。