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2022 Vol. 65, No. 18
Published: 2022-09-15
FEATURE
FORUM
RESEARCH
C0NTENTS
COVER STORY
 
1 COVER
2022 Vol. 65 (18): 1-1 [Abstract] ( 42 ) HTMLNew PDF (1052 KB)  ( 25 )
       C0NTENTS
6 CONTENTS
2022 Vol. 65 (18): 6-10 [Abstract] ( 39 ) HTMLNew PDF (387 KB)  ( 28 )
       FEATURE
14 Mechanism Research on Target Accuracy of Aircraft Assembly Tooling Based on Multi-Factor Disturbance
GENG Yuke
DOI: 10.16080/j.issn1671-833x.2022.18.014
In this paper, the source of target precision and influencing factors of aircraft assembly tooling are analyzed in detail. The design method of target precision is described. The influencing factors are quantitatively analyzed, and the influencing importance is qualitatively analyzed. As for each influencing factor, the corresponding treatment measure is given. The possibility of eliminating each influencing factor under corresponding treatment measures is analyzed and case studies are conducted. The qualitative and quantitative analysis of the tooling target precision is proposed theoretically and applied to design of assembly tooling for a certain aircraft, in which a preliminary path is explored for the unified and quantitative accuracy analysis of assembly tooling in engineering. The analysis of relevant influencing factors of target accuracy provides a basis for target accuracy design in assembly tooling design stage and cause analysis in fault stage.
2022 Vol. 65 (18): 14-22 [Abstract] ( 141 ) HTMLNew PDF (4325 KB)  ( 147 )
       COVER STORY
24 Construction and Actualizing Techniques on Virtual Assembly Prototype for Aeronautical Thin-Walled Structure With on-Site Physical Characteristics
GUO Feiyan, XIAO Qingdong, LI Hao, ZHENG Luhan,ZHANG Shuo
DOI: 10.16080/j.issn1671-833x.2022.18.024
Aiming at the problems of lacking of site physical characteristic data and model foundation for high-performance assembly of aeronautical thin-walled structural component with low stiffness, construction and actualizing techniques for virtual assembly prototype for aeronautical structures with on-site physical characteristics constraint were studied. Firstly, the technical connotation and construction framework of virtual assembly prototype were defined. Its essence was a highly quasi reality digital twin assembly system, which could not only carry out multi-scale assembly geometric and physical quantity simulation in virtual environment, but also analyze and verify assembly performance in advance. Secondly, high fidelity and dynamic construction on virtual assembly prototype for aeronautical thin-walled structure fused with on-site physical characteristics was elaborated from four implementation plans, i.e. multisource heterogeneous assembly data acquisition and processing, multi-class assembly digital twin integrated modeling, synchronous modeling of linking virtual with reality for assembly prototype system, visual modeling of assembly process and assembly quality condition. Finally, the “double line” and “different classification” comprehensive construction measures of virtual assembly prototype were adopted, which could provide the data/model basis for the virtual simulation during the assembly process and the accurate control of assembly quality. With the above research, a solid foundation for active real-time control of assembly quality can be established.
2022 Vol. 65 (18): 24-34 [Abstract] ( 125 ) HTMLNew PDF (2075 KB)  ( 254 )
       FORUM
38 Aircraft Determinate Assembly Technology and Its Application
ZHANG Yongliang，JIANG Jiefeng，BI Yunbo
DOI: 10.16080/j.issn1671-833x.2022.18.038
Determinate/determinant assembly (DA) adopts the part-to-part connection scheme, reducing the use of the jigs and fixtures, avoiding the work of shimming, fettling and final-hole-size drilling, which is gradually employed by the aircraft assembly. With the extensive application of composite materials in aircraft monolithic component, full-size determinate assembly (FSDA) is being studied and experimentally applied. Firstly, the state-of-the-art and the development of aircraft determinate assembly technology at home and abroad are reviewed. Then, the key technologies for aircraft determinate assembly are summarized, including model-based definition, assembly process optimization based on digital twin technology, tolerance prediction and statistical analysis, flexible tooling technology. Finally, a technical scheme of full-size determinate assembly was proposed for the composite panel assembly.
2022 Vol. 65 (18): 38-45，62 [Abstract] ( 146 ) HTMLNew PDF (19982 KB)  ( 109 )
46 Research and Application Progress of Deformation Control Technology for Aircraft Composite Panel Assembly
LIU Zhenyang, ZHAI Yunong, LI Dongsheng, SUI Yi
DOI: 10.16080/j.issn1671-833x.2022.18.046
Due to its excellent property, the application amount of composite materials on the new generation airframe has gradually increased. As a result, it’s of vital importance to improve the quality of assembly process and reduce the stress during assembly process. However, composite components have different characteristics from traditional metal structures. They are large in scale, nonrigid, easy to deform due to its own weight, and with large manufacture deviation. Moreover, they are easy to be damaged when confronted forced assembly. In order to meet the requirements of composite structures during assembly process, new technologies and methods need to be developed. This research takes the Airbus A320 wing box model as an example, states the typical assembly process of composite aircraft structure, and points out some problems in the process, such as high dependence on engineering experience, difficulty in prediction of gaps, and weak ability of shape adjusting; to solve those questions, three kinds of new airframe assembly technology were developed, which are assembly simulation technologies for tolerance control of composite structures, online control technology for assembling deformation of aircraft composite panels and effect of assembling deformation of cladding panel on service performance. At last, the shortcomings and the prospects in assembly deformation control technology of aircraft composite panel are pointed out.
2022 Vol. 65 (18): 46-54，78 [Abstract] ( 90 ) HTMLNew PDF (46473 KB)  ( 110 )
55 Analysis on Key Technologies of Dual-Robot Collaborative Assembly for Narrow Space of Aircraft
LIU Hongwei，PAN Xin，ZHANG Qi，ZHANG Haosong，LI Pengcheng，TIAN Wei
DOI: 10.16080/j.issn1671-833x.2022.18.055

Aiming at the problem of large assembly workload, high quality and precision requirements of hole making in aircraft narrow space, an intelligent control technology of dual-robot guided cooperative operation for aircraft narrow space was proposed. The key technologies of dual-robot trajectory planning and cooperative off-line simulation, robot collaborative visual servoing control compensation, and quick change of multi-function terminal actor design are investigated. The processing of the target hole position is completed while ensuring the safe operation of the robot system and the workpiece, in order to improve the assembly accuracy, reduce the assembly space occupation, provide support for the design of the inlet performance. Experiments show that the absolute positioning error of the robot is reduced to ±0.1mm by visual servoing control.
2022 Vol. 65 (18): 55-62 [Abstract] ( 74 ) HTMLNew PDF (22590 KB)  ( 97 )
63 Study on Rotary Ultrasonic Drilling Process of C/SiC Ceramic Matrix Composite
CHEN Shaoshuai，GU Fan，ZHU Yinran，GUO Yingjie，BI Yunbo，DONG Huiyue
DOI: 10.16080/j.issn1671-833x.2022.18.063
In this paper, considering the characteristics of high hardness and difficult machining of C/SiC ceramic matrix composites, we studied the optimization strategy of robotic rotary ultrasonic drilling technology. The drilling defects of ceramic matrix composites were analyzed, and the defect evaluation method based on the tearing area of the exit was adopted. The influence of the spindle speed, feed speed, ultrasonic amplitude and other process parameters on the hole quality and diameter accuracy was studied through orthogonal experiments. Variance analysis and range analysis methods were used to determine the optimal process parameters. On this basis, a tool wear test was further carried out, and the results showed that for the C/SiC ceramic matrix composite laminated plate with a thickness of 8 mm, 40 holes can be drilled with a brazing diamond trepanning drill, the hole diameter accuracy is up to H9, and the tearing area factor is within 0.2. Finally, a step drilling process strategy of “fast followed by slow” is proposed to ensure the drilling quality and efficiency at the same time.
2022 Vol. 65 (18): 63-70 [Abstract] ( 82 ) HTMLNew PDF (13952 KB)  ( 73 )
71 Hand-Held Visual Inspection Method for Countersink Hole Quality Measuring During Aircraft Assembling
ZHANG Hui，PAN Xin，LI Haiwei，DU Jie，LUO Zhiguang，GUO Feiyan
DOI: 10.16080/j.issn1671-833x.2022.18.071
In aircraft structures, there are a lot of standard connection holes. In order to ensure the assembly quality, it is necessary to detect the quality of the countersink holes. The visual inspection equipment based on robot or machine tool has the problems of low positioning accuracy, difficult to reach local position and easy to be affected by ambient light. In this study, a hand-held visual detection method for checking the quality of the countersink holes is proposed. The sub-pixel detection algorithm for the diameter and depth of the countersink is developed, and a hand-held visual detection device is designed. The mechanical structure, hardware system and software system are described in detail. The diameter and the countersink depth measured by this method are compared with the test results of the third party certification. The results show that the accuracy of diameter measurement is better than 0.01 mm, and the accuracy of depth is better than 0.1 mm. The hand-held vision detection equipment designed in this study has high detection accuracy, wide application and is not affected by ambient light.
2022 Vol. 65 (18): 71-78 [Abstract] ( 86 ) HTMLNew PDF (12689 KB)  ( 38 )
79 Interface Slip Analysis of Combined Jeffcott Rotor With Bolted Joint
YANG Yang，LONG Yang，ZHAO Binbin，SUN Qingchao
DOI: 10.16080/j.issn1671-833x.2022.18.079
Aiming at the problems of uneven distribution of mechanical properties of the connection interface after the actual assembly of aero-engine rotor and the fretting slip of the connection interface during service, this paper takes the combined Jeffcott rotor as the research object and comprehensively considers the distribution law of the actual bolt preload. Firstly, the mechanical analysis of the connection interface of the combined rotor under high-speed rotation is carried out, and influence mechanism of the preload on the connection interface slip is revealed. Secondly, based on the measured preload data, the finite element model of combined Jeffcott rotor is constructed to simulate the slip process of the connection interface. Finally, the influence of the mean value and dispersion of preload on the slip law of rotor interface is systematically analyzed. The results show that the mean value of preload mainly affects the amount of interface slip, but has little effect on the uniformity of slip distribution, while the dispersion of preload will significantly affect the uniformity of slip distribution. In the actual assembly process, by reducing the dispersion of bolt preload distribution, the adverse effect of interface non-uniform slip on the connection performance of combined rotor can be reduced.
2022 Vol. 65 (18): 79-85 [Abstract] ( 47 ) HTMLNew PDF (19277 KB)  ( 25 )
       RESEARCH
86 Research on Multi-Axial Excitation Test System and Assembly Deviation Identification of Aero-Engine
LI Lin，YUE Cong，FAN Jianyu，ZHOU Shuo
DOI: 10.16080/j.issn1671-833x.2022.18.086
The high pressure rotor of aero-engine has a typical bolted connection structure. In order to study the relationship between the assembly performance of bolted connection and the composite load, a multi-axial excitation test system with axial tension and transverse vibration excitation is developed. The experiments of the system stability and the bolt assembly deviation are both designed and tested. The experimental results show that the frequency response characteristics are stable and effective when the variation range of the front and rear axial loads is less than 0.003 kN. When bolt assembly deviations exist in different positions, both vibration response frequency and amplitude will be affected. Finally, XGBoost intelligent algorithm is established to effectively identify the location of bolt assembly deviation by using specific frequency response peak value and amplitude.
2022 Vol. 65 (18): 86-91 [Abstract] ( 65 ) HTMLNew PDF (57025 KB)  ( 76 )
92 Research on End Calibration Method of Mobile Robot Based on Photogrammetry
WANG Yifeng, LU Yongkang, LI Junqing, ZHANG Yang, LIU Wei, WANG Fuji
DOI: 10.16080/j.issn1671-833x.2022.18.092
Mobile robot in-situ processing and assembly technology has been gradually applied to the manufacture of large components, and the ability to locate the end of the robot is the key to ensure its manufacturing quality. Aiming at the problems of large measurement range, occlusion of the sight line, and complicated dynamic pose changes in the process of robot end positioning, a robot end calibration method combining single camera offline measurement positioning point and camera resection is proposed. Firstly, the positioning points in the processing area are measured offline by a photogrammetry camera and the coordinates of positioning points are obtained. Then, the spatial pose of camera is solved based on the principle of resection, and the pose relationship between the camera and robot end is calibrated. Finally, the pose parameters of the mobile robot end are obtained through the in-situ measurement of the camera attached on the robot end. Experimental results show that as the object distance is 1000 mm, the three-dimension position accuracy is better than 0.19mm, and the attitude angle accuracy is better than 0.011°, which verifies the effectiveness of the proposed method.
2022 Vol. 65 (18): 92-97 [Abstract] ( 52 ) HTMLNew PDF (2165 KB)  ( 327 )
98 Research on Sub-Pixel Detection Method of Riveting Aperture Size Based on Improved Zernike Moment
ZHANG Hanli，LI Haiwei，YU Guodong，SHEN Lin，ZHANG Xinxi，JI Li
DOI: 10.16080/j.issn1671-833x.2022.18.098
Aiming at the detection problem of aircraft riveting aperture, an improved sub-pixel detection method of riveting aperture based on Zernike moment is proposed. Firstly, the collected riveting aperture image was enhanced by histogram equalization method, smoothed by median filter method and sharpened by gradient method. Then, based on the three image segmentation methods of histogram valley bottom method, Prewitt operator edge extraction and Kirsch operator edge extraction, Canny operator edge detection was used for rough positioning and the improved Zernike moment was used for sub-pixel edge fine extraction to extract the ring area of dimple outer circle. Finally, the circle fitting was carried out in combination with RANSAC algorithm. The circle contour was generated and the radius was obtained to complete the fitting measurement. Experiments show that the detection method has strong sub-pixel accurate positioning ability, high accuracy, good stability and repeated measurement accuracy of ±10 μm.
2022 Vol. 65 (18): 98-104 [Abstract] ( 49 ) HTMLNew PDF (2237 KB)  ( 222 )
105 Research and Application of High Accuracy Localization for Assembly Assisted by Augmented Reality
HUO Zhiyu
DOI: 10.16080/j.issn1671-833x.2022.18.105
In the manual link of aircraft assembly, the combination of virtuality and reality by the AR technology can be used to display the instructions in the scene of assembly. High quality combination of virtuality and reality requires the ability of accurate localization of the AR system. This paper proposes a method of localization by using simultaneous localization and mapping (SLAM) based on the constraint of planar markers for AR-based assembly. Firstly, the AR system generates the original AR map using the SLAM method. Then, it detects the planar markers in the key frames of the AR map, and the constraint of the markers is employed on the transformation and the optimization of the key frames and the map points to build the high-quality AR map. Finally, the AR system tracks the new AR map for registration and view point tracking to enable high accuracy localization under the coordinate system of the assembly scene. The verification experiments demonstrate that the method can effectively improve the accuracy of localization of the AR system.
2022 Vol. 65 (18): 105-110 [Abstract] ( 68 ) HTMLNew PDF (7199 KB)  ( 51 )
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