飞机部件数字化调姿过程建模与仿真关键技术研究
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摘要
飞机装配是飞机制造过程中最重要、最复杂的环节之一,直接决定飞机产品的最终性能和质量。飞机部件或组件的空间定位问题是飞机装配中的共性关键问题,定位精度将直接影响飞机产品的气动外形、疲劳寿命与可靠性等。为了能够提高飞机部件姿态调整的质量与效率,目前先进的调姿技术正朝着数字化、自动化、柔性化的方向发展。本文以数字化调姿系统为研究对象,该调姿系统由飞机部件与三坐标数控定位器组成,对其逆运动学、工作空间、柔性多体动力学建模与仿真、含非理想运动关节调姿过程仿真与球头—球窝磨损建模等问题进行了深入的研究。主要研究内容包括：
介绍了飞机装配技术的发展历史、应用背景与意义。比较详细地描述了建模与仿真技术的发展、现状及其在飞机装配中的应用。
阐述了数字化调姿系统的调姿原理以及调姿系统的结构,分析了多种调姿系统结构类型的优缺点。提出了基于调姿机构逆运动学分析的轨迹规划方法,采用调姿机构正运动学法与网格搜索法分析了调姿机构的工作空间。描述了数字化调姿系统的硬件和软件集成方法。
构建了调姿系统的柔性多体动力学模型。根据调姿机构自身特点将三坐标定位器的支撑杆视为柔性体,综合运用拉格朗日方程、虚功原理与拉格朗日乘子法建立调姿机构的柔性多体动力学模型,经数值求解得到调姿过程中飞机部件和定位器的受力情况。
建立了两种典型非理想球铰关节的运动学与动力学模型。首先,分别基于Hertz接触理论与体积接触模型构建了含半球形球窝与含球带形球窝的球铰关节法向接触力模型；然后,结合改进的Coulomb摩擦力模型建立了球头与球窝关节的动力学模型；最后,建立了两种含非理想运动关节的调姿机构动力学模型,并使用多种运动路径对其进行仿真计算,分析了配合间隙、摩擦力、运动路径与球铰关节结构对调姿机构动态性能的影响,为结构设计与运动路径规划打下基础。
构建了两种球铰关节的磨损计算模型。根据之前已经构建的非理想运动关节动力学模型计算出调姿过程中各个球头与球窝的接触力、接触点位置等信息；然后,结合Archard方程建立球头与球窝的磨损模型,为了能够获得接触表面的磨损分布情况,将磨损表面离散,分别借助Hertz接触理论与体积接触模型计算接触力的分布,并以离散后的单张曲面为单元分别计算与保存其磨损量；最后,针对四定位器的调姿机构,对其调姿过程进行仿真计算。该模型能够用于调姿机构的寿命预测,为调姿机构设计提供参考。
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。
Aircraft assembly is one of the most important and complicated part of aircraft manufacturing. The final performance and quality of aircraft depend on aircraft assembly. In the process of the assembly, the accuracy of pose of component or subassembly directly affects the aerodynamic shape, fatigue life and reliability of aircraft, which is a common and key issue in aircraft assembly. To improve the quality and efficiency of pose alignment, digital, automatous and flexible technologies are introduced. The research object in this dissertation is the digital alignment pose system which consists of an aircraft component and several three coordinate numerical control positioners. Several crucial technology issues on modeling and simulation of alignment process, such as the inverse kinematics, workspace, flexibly multi-body dynamic and kinematic modeling and simulation, simulation of alignment process with non-ideal kinematic joints and wearing modeling are studied and analyzed deeply.
The development of aircraft assembly technology and key techniques of modern aircraft digital flexible assembly are introduced. Then, the development, current situation and the application of modeling and simulation in aircraft assembly are presented.
The alignment principle of alignment pose system is described. The advantage and disadvantage of several structures of alignment pose systems are discussed. A trajectory planing method based on the inverse kinematics of alignment pose mechanism is proposed. The workspace problem of alignment pose mechanism is solved by utilizing forward kinematics and grid search method. The integration of hardware and software of digital alignment pose system is presented.
The flexible multi-body dynamic model of alignment pose mechanism is constructed. In terms of the characteristic of alignment pose mechanism, the supporting poles of positioners are considered to be flexible for simulation, and the dynamic model of alignment pose mechanism is established by utilizing Lagrange equation, virtual work theory and Lagrange multipliers method. Then, the joint reaction forces of aircraft component and supporting poles are acquired by solving dynamic equation numerically.
The kinematic and dynamic models of two typical types of non-ideal spherical joints are developed. Firstly, two normal force model of spherical joint with hemi-spherical and spherical segment sockets are constructed based on Hertz contact theory and volumetric contact model, respectively. Secondly, the dynamic models of two types of spherical joints are derived form the normal force model, which are combined with modified Coulomb friction law. Finally, simulations of alignment pose mechanism are carried out for typical moving trajectories. The influences of moving trajectory, friction, clearance and structure of spherical joint on the performance of mechanism are analyzed. The simulation results are also applicable to similar mechanism design, moving trajectory planning and kinematic joint wear forecasting.
Wear model of the two types of spherical joints are developed. Firstly, the contact forces and positions of contact points are obtained by utilizing the dynamic models of non-ideal spherical joints proposed previously. Secondly, the Archard's equation is employed to model the wear of balls and sockets. To acquire the distribution of wear depth, the surfaces on the ball and socket are discretized for calculating and storing wear depth. Hertz contact theory and volumetric contact model are used to obtain the distribution of contact force in the two wearing models, respectively. Finally, process simulation of alignment mechanism with four positioners is carried out. This wear model is able to be applicable for life prediction and mechanical design of alignment mechanism.
The whole work in this dissertation is summarized, and the future work is discussed.
介绍了飞机装配技术的发展历史、应用背景与意义。比较详细地描述了建模与仿真技术的发展、现状及其在飞机装配中的应用。
阐述了数字化调姿系统的调姿原理以及调姿系统的结构,分析了多种调姿系统结构类型的优缺点。提出了基于调姿机构逆运动学分析的轨迹规划方法,采用调姿机构正运动学法与网格搜索法分析了调姿机构的工作空间。描述了数字化调姿系统的硬件和软件集成方法。
构建了调姿系统的柔性多体动力学模型。根据调姿机构自身特点将三坐标定位器的支撑杆视为柔性体,综合运用拉格朗日方程、虚功原理与拉格朗日乘子法建立调姿机构的柔性多体动力学模型,经数值求解得到调姿过程中飞机部件和定位器的受力情况。
建立了两种典型非理想球铰关节的运动学与动力学模型。首先,分别基于Hertz接触理论与体积接触模型构建了含半球形球窝与含球带形球窝的球铰关节法向接触力模型；然后,结合改进的Coulomb摩擦力模型建立了球头与球窝关节的动力学模型；最后,建立了两种含非理想运动关节的调姿机构动力学模型,并使用多种运动路径对其进行仿真计算,分析了配合间隙、摩擦力、运动路径与球铰关节结构对调姿机构动态性能的影响,为结构设计与运动路径规划打下基础。
构建了两种球铰关节的磨损计算模型。根据之前已经构建的非理想运动关节动力学模型计算出调姿过程中各个球头与球窝的接触力、接触点位置等信息；然后,结合Archard方程建立球头与球窝的磨损模型,为了能够获得接触表面的磨损分布情况,将磨损表面离散,分别借助Hertz接触理论与体积接触模型计算接触力的分布,并以离散后的单张曲面为单元分别计算与保存其磨损量；最后,针对四定位器的调姿机构,对其调姿过程进行仿真计算。该模型能够用于调姿机构的寿命预测,为调姿机构设计提供参考。
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。
Aircraft assembly is one of the most important and complicated part of aircraft manufacturing. The final performance and quality of aircraft depend on aircraft assembly. In the process of the assembly, the accuracy of pose of component or subassembly directly affects the aerodynamic shape, fatigue life and reliability of aircraft, which is a common and key issue in aircraft assembly. To improve the quality and efficiency of pose alignment, digital, automatous and flexible technologies are introduced. The research object in this dissertation is the digital alignment pose system which consists of an aircraft component and several three coordinate numerical control positioners. Several crucial technology issues on modeling and simulation of alignment process, such as the inverse kinematics, workspace, flexibly multi-body dynamic and kinematic modeling and simulation, simulation of alignment process with non-ideal kinematic joints and wearing modeling are studied and analyzed deeply.
The development of aircraft assembly technology and key techniques of modern aircraft digital flexible assembly are introduced. Then, the development, current situation and the application of modeling and simulation in aircraft assembly are presented.
The alignment principle of alignment pose system is described. The advantage and disadvantage of several structures of alignment pose systems are discussed. A trajectory planing method based on the inverse kinematics of alignment pose mechanism is proposed. The workspace problem of alignment pose mechanism is solved by utilizing forward kinematics and grid search method. The integration of hardware and software of digital alignment pose system is presented.
The flexible multi-body dynamic model of alignment pose mechanism is constructed. In terms of the characteristic of alignment pose mechanism, the supporting poles of positioners are considered to be flexible for simulation, and the dynamic model of alignment pose mechanism is established by utilizing Lagrange equation, virtual work theory and Lagrange multipliers method. Then, the joint reaction forces of aircraft component and supporting poles are acquired by solving dynamic equation numerically.
The kinematic and dynamic models of two typical types of non-ideal spherical joints are developed. Firstly, two normal force model of spherical joint with hemi-spherical and spherical segment sockets are constructed based on Hertz contact theory and volumetric contact model, respectively. Secondly, the dynamic models of two types of spherical joints are derived form the normal force model, which are combined with modified Coulomb friction law. Finally, simulations of alignment pose mechanism are carried out for typical moving trajectories. The influences of moving trajectory, friction, clearance and structure of spherical joint on the performance of mechanism are analyzed. The simulation results are also applicable to similar mechanism design, moving trajectory planning and kinematic joint wear forecasting.
Wear model of the two types of spherical joints are developed. Firstly, the contact forces and positions of contact points are obtained by utilizing the dynamic models of non-ideal spherical joints proposed previously. Secondly, the Archard's equation is employed to model the wear of balls and sockets. To acquire the distribution of wear depth, the surfaces on the ball and socket are discretized for calculating and storing wear depth. Hertz contact theory and volumetric contact model are used to obtain the distribution of contact force in the two wearing models, respectively. Finally, process simulation of alignment mechanism with four positioners is carried out. This wear model is able to be applicable for life prediction and mechanical design of alignment mechanism.
The whole work in this dissertation is summarized, and the future work is discussed.
引文
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