Analysis and Control of Assembly Deviation of Large-Size Thin-Walled Shell Based on Improved Jacobian-Torsor Model

doi:10.12141/j.issn.1000-565X.230636

Abstract

Abstract:

The large-size thin-walled shell has large size and mass, and is easy to deform with strict assembly accuracy requirement. In order to meet the high-precision requirement of spacecraft shell docking assembly, it is necessary to actively predict and control the shell assembly deviation. In this paper, a large thin-walled shell is taken as the research object. Based on the small displacement spinor method, the key characteristic errors of cabin are characterized, the geometric error spinor expression of the cabin and the constraint relationship between the spinor parameters are obtained. Then, the cumulative paths of parallel and series assembly chains considering the key feature errors of the shell are established, the assembly deviation of the cabin is characterized based on the Jacobian spinor theory, and an assembly deviation transfer model of the cabin based on the improved Jacobian spinor is obtained. Moreover, the Monte Carlo simulation method is used to numerically simulate the shell assembly step difference qualification rate of the improved Jacobian-Torsor model, with the results being compared with the simulation analysis results. Based on which, a calculation method for quantifying the contributions of various errors is proposed. Finally, by taking the minimum total processing cost as the optimization objective, and the variation relationship of various errors as well as the requirements of assembly order difference as the constraint conditions, an optimal allocation strategy for cabin tolerance considering the error contribution is proposed. The success rate of cabin assembly and the qualified rate of assembly order difference before and after the optimization are then compared, finding that the proposed method increases the qualified rate from the original 88.12% to 99.56%. The research method proposed in this paper provides theoretical reference for designers to carry out active tolerance design.

Key words: shell assembly, assembly deviation, Jacobian-Torsor, tolerance modeling, tolerance optimal allocation

CLC Number:

TH161.7

YI Yali, YANG Zeyu, WEI Rui, ZHAO Minjie, JIN Herong. Analysis and Control of Assembly Deviation of Large-Size Thin-Walled Shell Based on Improved Jacobian-Torsor Model[J]. Journal of South China University of Technology(Natural Science Edition), 2024, 52(12): 32-42.

Figures/Tables 18

Fig.1

Fig.2

Fig.3

Fig.4

Fig.5

Fig.6

Fig.7

Fig.8

Fig.9

Table1

Standard deviation of spinor parameters"

参数类型	标准差		标准差
$Δ ω s i$	$1 . 6 ˙ × 10 - 2$	$Δ α h i$	$1 . 4 ˙ × 10 - 3$
$Δ α s i$	$1.114 827 × 10 - 4$	$Δ β h i$	$1 . 4 ˙ × 10 - 3$
$Δ β s i$	$1.114 827 × 10 - 4$	$Δ ω d i$	$1 . 6 ˙ × 10 - 3$
$Δ u h i$	$1.08 3 ˙ × 10 - 2$	$Δ α d i$	$1.114 827 × 10 - 4$
$Δ υ h i$	$1.08 3 ˙ × 10 - 2$	$Δ β d i$	$1.114 827 × 10 - 4$

Table1

Fig.10

Fig.11

Fig.12

Fig.13

Table 2

Contribution of each kind of error"

误差名称		各类误差的贡献度/%
误差名称		$Δ u 2 → 3$	$Δ υ 2 → 3$	$H$
壳体直径误差		0.00	0.00	69.66
壳体特征误差	平面	54.30	75.53	19.84
壳体特征误差	定位孔	33.20	14.85	7.10
变形误差		12.90	9.62	3.40

Table 2

Table 3

Optimal allocation results of shell characteristic tolerance"

尺寸类型	尺寸与公差/mm			尺寸类型	尺寸与公差/mm
尺寸类型	初始	再分配		尺寸类型	初始	再分配
直径ϕD	$300 - 1 + 1$	$300 - 0.5 + 0.5$	位置度ϕt		0.05	0.05
直径ϕT_h	$100 + 0.015$	$100 + 0.01$	垂直度T		0.10	0.05

Table 3

Fig.14

Fig.15

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