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2022 Vol. 65, No. 12
Published: 2022-06-15
FEATURE
FORUM
RESEARCH
C0NTENTS
COVER STORY
 
       FEATURE
1 COVER
2022 Vol. 65 (12): 1-1 [Abstract] ( 63 ) HTMLNew PDF (7262 KB)  ( 72 )
       C0NTENTS
6 CONTENTS
2022 Vol. 65 (12): 6-10 [Abstract] ( 82 ) HTMLNew PDF (345 KB)  ( 86 )
       FEATURE
14 Improvement and Implementation of Aircraft System Zonal Safety Analysis Process in Digital Environment
LI Tao, YE Bo, LI Benjun
DOI: 10.16080/j.issn1671-833x.2022.12.014
The large number of new functions equipped with modern aircraft are performed together by many airframe systems arranged in different aircraft bays. Compared with aircraft structure, airframe systems have more complicated functional integration from interactions and interdependencies than physical integration. Since airframe systems are normally arranged and allocated in limited rooms, a good assembly design and reliable installations are crucial for the correct performing of aircraft overall functionalities. In SAE Aerospace Recommend Practice 4761, it introduces how a zonal safety analysis (ZSA) be used to identify and analyze the influence between airframe systems, including improper installations between system to system, system to structure, and the possible consequence of functions failure caused by those improper installations. Although SAE ARP4761 recommends that ZSA should cover the entire development process, current industrial practice mainly focuses on the application at design stage, with less application in aircraft assembly. It is also found that current ZSA process not well worked and supported in digitalization environment. This research improves ZSA process towards current digital manufacturing background by following the continuous model transmission principles, which integrates virtual reality (VR) and augmented reality (AR) together to cover conceptual design stage to manufacturing and assembly. Thanks to the digital mock-ups (DMU) used in the overall development process, it expands the application scope of ZSA method. Finally, an aircraft test-structural section is built in laboratory, and typical case studies of aircraft electrical wiring interconnect system (EWIS) integration are selected based on it to verify the feasibility of the ZSA process in virtual reality and augmented reality environment.
2022 Vol. 65 (12): 14-23 [Abstract] ( 150 ) HTMLNew PDF (27561 KB)  ( 294 )
       COVER STORY
24 Posture Optimization of Framed Wing-Body Docking Based on Measured Model
DU Kunpeng，ZHENG Wei，LI Shuanggao，NIU Zhen，PENG Yun
DOI: 10.16080/j.issn1671-833x.2022.12.024
The docking of large parts is an important part of aircraft assembly. Due to the complex shape, large size and strict tolerance requirements of the docking surface of the docking joint of the frame-type wing-body, only using the posture control points as the docking datum often makes it difficult for the frame-type wing-body docking surface to match accurately. In order to obtain the optimal target posture of the framed wing-body docking, this paper proposes an optimization method for the wing-body docking posture based on the measured model. Firstly, the measured model of wing-body docking is constructed, and the initial target posture of the wing is obtained by fitting the posture control points using the weighted least squares algorithm. Then, by analyzing the wing posture constraints, a posture optimization model is established, and the particle swarm algorithm is used to solve the problem. Finally, a certain wing-body simulation part is used for application verification. The analysis results meet the requirements of relative position accuracy and coordination accuracy between wings and bodies, which verifies the effectiveness of the proposed method.
2022 Vol. 65 (12): 24-33 [Abstract] ( 158 ) HTMLNew PDF (20238 KB)  ( 262 )
       FORUM
36 Research on Construction of Digital Twin Model and Deviation Transfer Analysis of Cabin Door of Airplane
WANG Zhongqi，YANG Pan，CHEN Shijie,ZHAO Yang，WU Yonglin，FENG Pujia，CHANG Zhengping
DOI: 10.16080/j.issn1671-833x.2022.12.036
Aiming at the problems of difficult quality inspection and control and serious accumulation of assembly errors in the manufacturing process of civil aircraft parts, the research on deviation transmission in aircraft assembly process is carried out. Firstly, the assembly process of certain type of hatch is analyzed. Based on the MBD model, the modeling idea of digital twin model—“point cloud data reconstruction theoretical model + multi-stage derivative information mounting such as manufacturing, assembly and debugging” is proposed. The key construction technology of digital twin model for assembly process is given, and the digital twin model of a part of hatch is established. Secondly, based on the assembly characteristics of digital twin model, the Jacobian spinor model is modified through the variation relationship of key features of parts, and a deviation transfer calculation method based on digital twin is proposed. Finally, taking two parts of a mechanism assembly of the hatch as an example, the assembly deviation of the component is simulated and calculated by 3DCS software. Compared with the theoretical calculation and simulation results, the results show that the deviation transfer calculation method mentioned is effective and reliable.
2022 Vol. 65 (12): 36-47 [Abstract] ( 142 ) HTMLNew PDF (31703 KB)  ( 216 )
48 Research on Large Aircraft Final Assembly Pulsation Line Technology
YANG Feng, MU Zhiguo, FAN Junhua, WANG Shuaibang
DOI: 10.16080/j.issn1671-833x.2022.12.048
With the development of economy, demand for large-scale military and civilian aircraft grows rapidly nowadays. However, most aircraft manufacturers must face the condition that the production capacity cannot meet the demand, and are unable to achieve high-quality, punctual and large-quantity production. Thus, technology research on large aircraft final assembly pulsation line was developed. Based on the situation, designing disciplines, ideas and implementations were proposed including process and platform design, key craft equipment, material delivering and full element controlling of pulsation-line. Therefore, accessible measures were raised for large aircraft final assembly pulsation line. Meanwhile, the measures can also help researching for digital and intelligent aircraft assembly line toward a higher level.
2022 Vol. 65 (12): 48-55/62 [Abstract] ( 234 ) HTMLNew PDF (55210 KB)  ( 473 )
56 Research on Auxiliary Assembly System Based on Spatial Augmented Reality
QIN Yubo, MU Xinwei, ZOU Fang
DOI: 10.16080/j.issn1671-833x.2022.12.056
Manual assembly is an important link in the aircraft assembly process. However, due to the variety of assembly parts, complex assembly locations, and numerous assembly processes, the assembly efficiency is low and the assembly quality is difficult to guarantee, which severely affects the quality and efficiency of the overall aircraft assembly. Based on the analysis of tracking registration technology and projector-camera calibration technology in spatial augmented reality auxiliary assembly applications, and on the basis of 3D machine vision technology research, this paper develops a full-process projection-guided auxiliary assembly system with functions of projection information edit, workpiece positioning and guidance information projection. By projecting auxiliary assembly information on the surface of aircraft workpieces, the system can simplify complex assembly processes. It can be seen from the verification experiment that the use of this system can significantly improve the assembly efficiency and assembly quality, and greatly shorten the assembly cycle.
2022 Vol. 65 (12): 56-62 [Abstract] ( 140 ) HTMLNew PDF (24608 KB)  ( 128 )
63 Design of Distributed-Network Integrated Test Environment for Aircraft Final Assembly
XIONG Hongrui，LI Tao，LUO Xuan，DING Xiao，TAN Fengyun
DOI: 10.16080/j.issn1671-833x.2022.12.063
This research concentrates on the high integrated complicated system architecture and the complexities at final assembly test stage. It proposes a distributed-network integrated test environment for aircraft final assembly stage towards the current long-time taken of final assembly tests, which fails to meet the needs of efficient mass production of new generation aircraft. The proposed test environment has the capacity to verify the functionalities and performance of aircraft airborne systems at production stage in a hierarchical, comprehensive, and high-efficient way. This research designs a “off-aircraft test and on-board test” final assembly test mode based on the analysis of airborne system test contents and efficiency. This mode uses the distributed architecture of “control integration-distributed test” based on Ethernet, which satisfies the needs of off-aircraft sub-systems tests, overall-aircraft collaborative tests under multi-hierarchy test processes of final assembly. It links the test parameters of multiple systems, and solves the problems of large test volume, high failure rate and difficult troubleshooting in traditional tests of final assembly. The aircraft vehicle management & flight control system is selected as a typical case study as it is highly integrated. A distributed-network integrated test environment is built for final assembly to verify the feasibility and efficiency, which achieved 52% reduction in overall tests, 60% reduction in failure rates, and 89% increase in troubleshooting efficiency.
2022 Vol. 65 (12): 63-71/85 [Abstract] ( 128 ) HTMLNew PDF (4718 KB)  ( 786 )
72 Simulation Analysis on Crucial Assembly Parameter of High Pressure Rotor in Aero-Engine
LI Lin，LIU Hao，ZHU Linbo，ZHOU Shuo
DOI: 10.16080/j.issn1671-833x.2022.12.072
High pressure rotor of the aero-engine consists of high pressure compressor (HPC) rotor and high pressure turbine (HPT) rotor, the concentricity of which is the most crucial assembly parameter, directly influences vibration of whole engine. The concentricity inspection technique hardly meets the requirement in terms of accuracy and stability. This paper developed the fast simulation program of high pressure rotor concentricity based on HPC/HPT rotors’ measured data and its installation phase. The simulation using high pressure rotor assembly parameter data samples of one aero-engine demonstrates that the simulated concentricity has high precision prediction. This paper presented the installation phase optimization technique on HPC/HPT rotors, and the simulation using above history assembly data samples and experimental verification demonstrates less concentricity expectation than the ordinary phase decision method. The results provide the model support for simulation prediction and process decision during high pressure rotor assembly, which escalates the assembly technology model application and digitalization development.
2022 Vol. 65 (12): 72-76 [Abstract] ( 125 ) HTMLNew PDF (5783 KB)  ( 343 )
77 An Approach for Aircraft Assembly Sequence Intelligent Planning Based on Case Learning
CHEN Junhao, JIA Xiaoliang
DOI: 10.16080/j.issn1671-833x.2022.12.077
Assembly sequence planning (ASP) defines the efficiency and quality of aircraft assembly. However, for the ASP of aircraft, the traditional knowledge reuse is not flexible and the solving time of canonical meta-heuristic algorithm is tedious. This paper proposes a framework based on case learning to complete the ASP of aircraft. Firstly, the characteristics of the aircraft ASP are analyzed and the aircraft ASP framework is constituted. Moreover, the aircraft ASP case is extracted from the heterogeneous information source, the aircraft ASP case is reused by process similarity, and the assembly sequence of aircraft product is inferred by genetic algorithm and case fragment. Finally, the aircraft ASP system is designed, and the feasibility and effectiveness of the framework is verified by an example of an aircraft undercarriage.
2022 Vol. 65 (12): 77-85 [Abstract] ( 118 ) HTMLNew PDF (18944 KB)  ( 89 )
       RESEARCH
86 Construction Method of Digital Twin Geometry Model for Aircraft Flexible Tooling
JIANG Shan, WANG Zhongqi, XIA Song, YANG Pan, CHANG Zhengping
DOI: 10.16080/j.issn1671-833x.2022.12.086
The state of aircraft flexible tooling is affected by temperature, workpiece state, assembly process and other factors, and is often in a time-varying state. Its twin model has large dynamic information and is complex to build. A modeling method of digital twin geometric model based on finite state machine is proposed in this paper. The dynamic mapping of physical tooling in digital space is realized by means of real-time data acquisition and preprocessing, definition of state and its transfer mechanism, and parameterized geometric entity modeling, which lays a foundation for virtual simulation based on digital twin model. Taking the wing and fuselage docking platform as the object, digital twin geometric models of the wing adjustment mechanisms are established to verify the effectiveness of the method.
2022 Vol. 65 (12): 86-91/111 [Abstract] ( 147 ) HTMLNew PDF (13376 KB)  ( 161 )
92 Research Status of Welding and Crystallization Control of Zr-Based Amorphous Alloy#br#
CHEN Guoqing, XING Ziqi, ZHANG Ge, ZHANG Binggang, Lü Shixiong
DOI: 10.16080/j.issn1671-833x.2022.12.092
Zr-based amorphous alloy, possessing high strength and excellent corrosion resistance, has attracted much eyesight of researchers in the field of materials science and engineering, and has been utilized in aerospace and electrical industries. However, it is difficult to fabricate bulk Zr-based amorphous alloy with large dimensions. Simultaneously, the crystallization behavior of Zr-based amorphous alloy in the welding process further restricts the fabrication large-size amorphous material. Based on the analysis of the weldability of Zr-based amorphous alloy, the welding methods of Zr-based amorphous alloy are overviewed, and the research progress of crystallization control is introduced. Finally, according to the problems existing in the welding of Zr-based amorphous alloy, the future research direction is prospected.
2022 Vol. 65 (12): 92-98 [Abstract] ( 79 ) HTMLNew PDF (93878 KB)  ( 128 )
99 Research Progress on Equipment Reliability Assessment Based on Health Monitoring
DING Feng，ZHANG Yixin
DOI: 10.16080/j.issn1671-833x.2022.12.099
The research progress at home and abroad for equipment reliability assessment of monitoring information was analyzed emphatically. The challenges and development directions of research in equipment reliability assessment driven by health monitoring data were presented. Based on the characteristics and demands of reliability assessment for individual equipment operation and by reviewing the issues of the traditional reliability assessment, the technique intension regarding the equipment operation reliability assessment that directed at health monitoring driven data was pointed out via dynamic modeling and fault mechanism analysis, condition signal processing, and fault feature extraction, which drew forth the unsolved problems in reliability assessment of equipment operation, and finally provided references to further research in intelligent operation maintenance and health management.
2022 Vol. 65 (12): 99-104 [Abstract] ( 127 ) HTMLNew PDF (812 KB)  ( 555 )
105 Study on Edge Collapse Area of Glass Ceramic Inner Hole in Rotary Ultrasonic Grinding
FANG Zhenlong
DOI: 10.16080/j.issn1671-833x.2022.12.105
In order to solve the problem of poor export quality of brittle materials such as engineering ceramics, rotary ultrasonic grinding technology is adopted. Based on Abaqus software, the simulation model of rotary ultrasonic grinding is established. According to the stress condition, the forming mechanism of edge collapse at the hole exit is simulated and analyzed. The experiment of rotary ultrasonic grinding of glass ceramic inner hole is designed to study the influence of different process parameters on the edge collapse area. The results show that with the increase of the depth of the inner hole, the compressive stress in the initial stage of the glass ceramics gradually changes into the tensile stress, and under the action of the tensile stress, cracks are formed and the edge collapse occurs at the exit. The edge collapse area decreases gradually with the increase of the spindle speed and the ultrasonic power. The edge collapse area increases gradually with the increase of the feed speed. Compared with the conventional grinding method, rotary ultrasonic machining can effectively reduce the area of edge collapse at the outlet. When the ultrasonic power is 100W, the area of edge collapse at the outlet is reduced by 57.8%, which greatly improves the quality of inner hole grinding.
2022 Vol. 65 (12): 105-111 [Abstract] ( 88 ) HTMLNew PDF (8315 KB)  ( 91 )
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· 'Aeronautical Manufacturing technology ' is included in EI database
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· Aeronautical Manufacturing Technology ranked No. 3 in Chinese S&T Journal Citation Reports (CJCR)
· High Quality Sci-tech Journal Classification Catalogue in Aerospace Field （2023）
· A Guide to the Core Journals of China (hosted by Peking University Library)
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