大型飞机壁板装配变形控制与校正技术研究

发布时间：2019-03-16 19:16

【摘要】：飞机装配作为飞机制造过程中最重要、最复杂的环节之一,直接决定了飞机产品的最终性能、质量和寿命,而壁板作为飞机的重要组件之一,其装配精度将直接影响飞机各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。论文从壁板支撑布局优化、检测点布置优化、壁板变形预测与校正等层面展开系统深入研究,从而为实现壁板装配变形的科学有效调控提供行之有效的解决方法。主要研究内容包括：阐述了论文的研究背景及意义,介绍了国内外飞机数字化装配技术的发展现状,指出大型飞机壁板变形控制与校正技术是当前飞机数字化装配中的重点和难点之一。为提高飞机壁板在数字化装配中的刚度,提出了一种基于多工艺接头的壁板支撑布局优化方法,通过建立壁板与工艺接头的有限元模型,利用混合均匀试验设计法,得到在不同工艺接头支撑布局下的壁板应变能,同时根据偏最小二乘回归分析法,建立了壁板应变能与工艺接头支撑参数之间的数学模型,从而实现工艺接头支撑布局优化,并分析比较了壁板在全保形工装支撑和工艺接头支撑下的变形情况。在数字化装配中,飞机壁板的位置和姿态精度通过检测点的理论和实际位置进行匹配计算得到,而其变形也可由检测点的位置误差进行描述。因此,合理布置壁板上的检测点就尤为重要。为能更全面地描述壁板变形,更多地涵盖壁板变形信息,提出了一种基于D-Optimality和自适应模拟退火遗传算法的飞机壁板检测点优化布置方法,通过最小化壁板变形的估计误差,实现从一系列初始待选点中优选出指定数量的检测点。在大型飞机机身部件的数字化装配过程中,数控定位器被广泛应用于机身壁板的定位、支撑,但机身壁板的弱刚度和低强度容易造成自身装配变形过大、装配精度超差。为控制壁板变形,首先构建了飞机壁板的有限元模型,同时利用正交仿真试验研究了壁板在数控定位器移动牵引过程中产生的变形特性,并获取了描述壁板变形的检测点位置误差数据,然后应用偏最小二乘回归分析方法,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,并利用该模型实现对壁板变形的准确预测和校正。为验证飞机壁板支撑布局优化、装配变形校正等方法的正确性,设计并搭建了相应的壁板定位调姿试验系统,并在此基础上安排了一系列试验研究,进一步验证了相关方法的可靠性。最后,总结了全文的研究内容,并对有待进一步研究的内容进行了展望。
[Abstract]:Aircraft assembly, as one of the most important and complicated links in the aircraft manufacturing process, directly determines the final performance, quality and life of the aircraft product, and the wallboard is one of the important components of the aircraft. The assembly accuracy will directly affect the compatibility of the aircraft components and the shape accuracy of the whole machine. How to effectively control the panel assembly deformation is one of the technical problems urgently needed to be solved and solved in the aviation industry of our country at present. In this paper, a systematic and in-depth study is carried out from the aspects of panel support layout optimization, detection point layout optimization, panel deformation prediction and correction, and so on, so as to provide an effective solution for the scientific and effective regulation and control of panel assembly deformation. The main research contents are as follows: the research background and significance of this paper are expounded, and the development status of aircraft digital assembly technology at home and abroad is introduced. It is pointed out that the deformation control and correction technology of large aircraft panels is one of the key points and difficulties in the digital assembly of aircraft. In order to improve the stiffness of aircraft panel in digital assembly, an optimization method of panel support layout based on multi-process joints is proposed. The finite element model of panel and process joint is established, and the mixed uniform test design method is used. At the same time, according to the partial least square regression analysis, the mathematical model between the wall strain energy and the supporting parameters of the process joint is established, so as to realize the optimization of the supporting layout of the process joint. The deformation of wall plate under full conformal tool support and process joint support is analyzed and compared. In digital assembly, the position and attitude accuracy of the plane wall panel is calculated by matching the theory and actual position of the detection point, and the deformation can also be described by the position error of the detection point. Therefore, it is particularly important to arrange the detection points on the panel reasonably. In order to describe the panel deformation more comprehensively and to cover more information of panel deformation, an optimal placement method of aircraft panel detection points based on D-Optimality and adaptive simulated annealing genetic algorithm is proposed, which minimizes the estimation error of panel deformation. Select a specified number of detection points from a series of initial points to be selected. In the process of digital assembly of large aircraft fuselage parts, NC locators are widely used to locate and support the fuselage panels. However, the weak stiffness and low strength of the fuselage panels can easily lead to excessive assembly deformation and poor assembly accuracy. In order to control the deformation of the panel, the finite element model of the aircraft panel is constructed firstly. At the same time, the deformation characteristics of the panel during the moving traction of the NC locator are studied by the orthogonal simulation experiment. The position error data of the detection point describing the deformation of the panel are obtained, and then the inverse calculation model between the displacement data of the NC locator and the position error data of the detection point is established by using the partial least square regression analysis method. The model is used to predict and correct the wall plate deformation accurately. In order to verify the correctness of aircraft panel support layout optimization, assembly deformation correction and other methods, the corresponding panel positioning attitude adjustment test system is designed and built, and a series of experimental studies are arranged on this basis. The reliability of the related methods is further verified. Finally, the research contents of this paper are summarized, and the further research contents are prospected.
【学位授予单位】：浙江大学
【学位级别】：博士
【学位授予年份】：2015
【分类号】：V262.4

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