卧式双机联合自动钻铆系统压铆精度保障技术研究

As one of high-end technological equipments in aviation manufacturing, automatic drilling and riveting system has long been a bottleneck restricting the assembly quality and efficiency of large aircraft panel of our country. Regarding the new automatic horizontal dual-machine cooperative drilling and riveting system as the study object, this project make extensively research of equipment positioning, pressure riveting process and riveting control. By constrained kinematics modeling, unified parameter calibration and posture error compensation of the two cooperative machines, the precise positioning is realized in the system’s cooperative work space. By physical modeling and simulation of pressure riveting process, the inner mechanism of the production, accumulation and evolution of the riveting deformation is revealed, the geometric accuracy and physical properties are quantitative predicted, and the riveting processes are optimized scientifically. By designing the movement/pressure controller of presser foot in the process of preloading, the synchronous positioning and clamping operation of the bilateral presser foots is realized. By designing force/position hybrid controller in the process of pressure riveting, the accurate position and balanced force control are realized. Research findings will further enhance the ability of independent research and development of the automatic drilling and riveting system, and provide theoretical guidance and technical support for the high precision, high efficiency and high quality assembly of large aircraft panel in our country.

自动钻铆系统作为航空制造高端工艺装备之一，长期以来一直是制约我国大型飞机壁板装配质量和效率提升的瓶颈。本项目以新型卧式双机联合自动钻铆系统为对象，从设备定位、压铆工艺和压铆控制三个层面开展系统深入的研究，通过双机末端位姿协调运动学建模、参数统一标定和位姿误差补偿，实现钻铆系统工作空间精准定位；通过压铆过程物理建模与仿真，揭示壁板叠层结构压铆变形产生、积累和演变的内在机理，实现压铆几何精度和物理性能的定量预测与压铆工艺的科学优化；通过设计预压过程压脚同步运动/压力控制器，实现双侧压脚的同步定位和夹紧；通过设计压铆过程力/位混合控制器，实现压铆位置精确和压铆力平衡控制。研究成果将进一步提升我国自动钻铆系统的自主研发能力，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。

自动钻铆系统作为航空制造高端工艺装备之一，长期以来一直是制约我国飞机壁板装配质量和效率提升的瓶颈。本项目以新型卧式双机联合自动钻铆系统为对象，从设备定位、压铆工艺和压铆控制三个层面开展系统深入的研究。在设备工作空间定位方面，提出了位姿约束运动学建模、运动学参数联合标定和位姿误差降维空间网格化补偿方法，实现了双机双五轴联动钻铆系统全作业空间精准定位，双机末端位置跟随精度达到0.08mm，姿态跟随精度达到0.02°。在压铆工艺优化方面，建立了自动压铆系统多体闭链耦合压铆过程数值仿真模型，完整揭示了压铆过程中钻铆机、铆钉和壁板的多体耦合瞬态压铆形变规律；提出了一种基于双侧协同进给（顺序和同步性）的铆钉钉头齐平度误差补偿控制方法，提升了钉头齐平度精度；提出了一种基于自适应遗传算法(AGA)优化径向基神经网络（RBF）的自动钻铆机全作业空间压铆变形预测方法，并通过施铆侧铆头进给在线补偿压铆设备变形，保障了铆钉墩头成形精度。在压铆精度控制方面，建立了双机压铆系统等效柔性轴动力学模型，并设计了以自适应扰动观测器为内环、H_∞控制器为外环的压铆力控制器，进而提出了一种力/位置混合控制压铆方法，内侧执行器采用位置控制作为主轴，外侧执行器采用力控制作为从轴，解决了双机末端铆接力动态平衡控制难题，实现了铆钉压铆精确成型，钉头齐平度≤0.02mm，镦头高度误差±0.03mm，达到国际领先水平。项目共发表SCI论文19篇、EI论文1篇，授权国家发明专利4项。项目成果提升了我国自动钻铆系统的自主研发能力，并成功应用于歼-15等我国重点型号飞机壁板自动化装配，大幅提升了飞机壁板装配精度和质量。