大型构件装配中组合式测量的误差分离与消减方法研究

Aiming at the urgent demand for accurate and reliable measurement of key geometrical information of large components in major equipment assembly process, research on error separation and reduction methods of combined measurement technology for large component assembly will be carried out to solve the problems of interrelation of multi-source errors, unclear separation mechanism, and insufficient accuracy and reliability of measurement data in the field disturbance environment. The incidence relationship between dynamic datum errors and components, frocks’ geometric structures and material properties will be explored. And a four-dimensional dynamic reference error compensation model based on the correlation of temperature-coordinate will be established to ensure the unification of measurement datum and assembly model datum. A transfer error correction model based on deflection compensation and large rotation angle optimization will be proposed and an optimization strategy for single-source multi-station measurement will be developed to ensure the accuracy of single-source data acquisition. The mapping rule of “measurement area-size-ectopic constraint-measurement deviation” will be investigated and heterogeneous data fusion weight assignment criteria based on field standard information will be formulated to improve the accuracy of combined value measurement. Laboratory and field experiments will be conducted, and the uncertainty of measurement methods will be analyzed to achieve high-precision and high-reliability measurement of large-scale component assembly within 15 meters, providing technical basis for improving the assembly measurement capability and level of major assembly core components.

面向我国重大装备装配过程对大型零构件关键几何信息精准可靠测量的迫切需求，针对现场扰动环境下装配测量中多源误差相互关联、分离机制不明、测量数据精度和可靠性难以保证的问题，开展大型构件装配中组合式测量的误差分离与消减方法研究。探究现场环境下动态基准误差与构件、工装几何结构和材料属性等因素的关联关系，建立基于温差-坐标关联的四维动态基准误差修正模型，以保证测量基准与装配模型基准的统一；提出基于偏角补偿与大旋角优化的转站误差修正模型，制定单源多站测量误差的消减策略，保证单源数据的获取精度；探究“测量区域大小-异位约束-测量偏差”间的映射规律，制定基于现场标准信息的异源异构数据融合权重分配准则，提升组合式测量精度。开展实验室与现场试验，分析测量方法的不确定度，实现15米范围内大型构件装配的高精高可靠测量，为提升我国重大装备核心构件的装配测量能力和水平提供技术支撑。

大型构件是航空、航天、能源等领域重大装备的核心承力结构，其装配过程中大尺寸、数字化、高精度、高可靠的测量技术对提高大型构件装配质量、确保重大装备安全可靠服役至关重要。本项目围绕大型构件装配中组合式测量的误差分离与消减方法开展了理论、技术与实验研究，形成了集动态基准误差修正-静态误差分离校准-多源误差融合消减于一体的测量理论与技术。针对环境非均匀温度场引起测量基准动态偏移问题，提出了虑及非均匀环境温度的测量仪器精度基准在线修正方法，构建了基于热膨胀系数反求标定的基准偏差预测模型，开展了虑及环境温变的动态基准误差仿真，提高了现场长时域温变环境下测量数据的稳定性；面向大型构件长时域装配作业中连续稳定测量要求，阐明了激光跟踪仪单源测量中静态测量误差形成机制，提出了基于多边网络法的静态测量误差标定方法，实现了激光跟踪仪静态测量误差的现场快速校准；针对单源测量系统测量效率低、大范围测量时精度下降的问题，研究了激光跟踪仪多站组合测量与激光跟踪仪+工业摄影组合测量方法，建立了激光跟踪仪多站测量中误差均匀化模型和激光测距约束下光束法平差模型，实现了大范围多测站组合式测量的数据融合与误差消减，保障了大范围装配测量场内的测量精度；研发了大型构件集成测量分析软件，在上飞等企业制造现场开展了现场测量实验，有效提升了现场复杂条件下大型构件装配测量的精度和可靠性。项目执行期间共发表高水平论文11篇，其中SCI收录7篇，EI收录10篇，中文核心收录1篇；申请国家发明专利8项，其中授权5项；授权软件著作权4项；培养出站博士后1名，在读博士生2名，硕士生5名，其中毕业硕士生1名。项目负责人获评第八届中国科协中国科协青年人才。项目成果为提高工业现场环境下大尺寸构件数字化测量能力提供了重要的理论、方法与数据支撑，对提升我国航空航天、能源等领域的重大装备构件制造装配能力和水平具有重要的工程应用前景。