支持机翼无余量装配的容差分析技术研究
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摘要
飞机产品具有很高的装配准确度要求。飞机的制造和装配误差是影响装配准确度的重要因素。容差和工艺余量分别是控制零件制造误差和补偿产品装配累积误差的重要参数。支持无余量装配的容差分析技术采用微分数学理论和计算机仿真手段，能够有效地解决由于误差积累而产生的修配、返工和报废等问题。本文结合某型飞机机翼装配，对支持无余量装配的容差分析技术进行研究，主要研究内容包括：
1)系统、深入地分析了飞机机翼研制中对容差分析与综合技术的技术需求和应用需求；
2)基于船体无余量装配技术的理论、方法和实践，提出了飞机产品无余量装配技术的概念、方法。
3)在详细分析常用的容差建模和飞机装配方法的特点和不足的基础上，提出了支持机翼无余量装配的容差建模方法，建立了相应的容差语义信息模型，本模型包含了装配单元之间的约束关系、父子装配单元之间的从属关系和零部件的余量、尺寸及其容差等信息。
4)基于支持无余量装配的容差语义信息模型，提出了计算机装配尺寸链生成算法，采用降维法和微分法完成了装配尺寸链的计算。分析了协调环修改对装配尺寸链的影响，推导了最大修配量的计算公式。
5)基于CATIA V5和CAA FOR CATIA V5，设计了支持机翼无余量装配的容差分析原型系统，并完成了部分功能的开发。
Aircraft is a kind of special product that requires strict veracity of assembly. Error is the primary factor that affects assembly and manufacturing veracity. Tolerance restricts manufacturing error of part, and allowance redeems the error that comes into being in the process of product assembly. By means of calculus and computer-simulation, tolerance analysis technique for zero-allowance assembly can effectually solve problems during assembly and maintenance. This thesis studies tolerance analysis technique for zero-allowance assembly, and its application in assembly process of one aircraft's airfoil.
The main contents of the thesis are as follows:
1) Made a systematic and comprehensive analysis on the technical and applicative requirements of tolerance analysis and synthesis during the process of aircraft's life cycle.
2) Based on the theory of hill's zero-allowance assembly, proposed concepts and methods for aircraft's zero-allowance assembly.
3) Analyzed the characteristics and disadvantages of tolerance modeling technique and aircraft assembly in common use. Presented a method for tolerance modeling, namely 'tolerance modeling supporting airfoil's zero-allowance assembly'. Then tolerance semantic information model for airfoil's zero-allowance assembly is presented. This model includes three kinds of information: constraints between assembly component, affiliation relation between inherited assembly components and allowance, dimension and tolerance information about part and components.
4) Based on tolerance semantic information model for zero-allowance assembly, presented an algorithm that can generate assembly tolerance chain. The assembly tolerance-chain is calculated using dimensional simplifying method
and differential coefficient method. Analyzed the influence of concerted chain modification on assembly tolerance-chain. Derived the formula for maximal quantity of repair computation.
5) Based on CATIA V5 CAD Software and CAA FOR CATIA V5 Toolbox, designed and developed a tolerance analysis prototype system for airfoil's zero-allowance assembly.
1)系统、深入地分析了飞机机翼研制中对容差分析与综合技术的技术需求和应用需求；
2)基于船体无余量装配技术的理论、方法和实践，提出了飞机产品无余量装配技术的概念、方法。
3)在详细分析常用的容差建模和飞机装配方法的特点和不足的基础上，提出了支持机翼无余量装配的容差建模方法，建立了相应的容差语义信息模型，本模型包含了装配单元之间的约束关系、父子装配单元之间的从属关系和零部件的余量、尺寸及其容差等信息。
4)基于支持无余量装配的容差语义信息模型，提出了计算机装配尺寸链生成算法，采用降维法和微分法完成了装配尺寸链的计算。分析了协调环修改对装配尺寸链的影响，推导了最大修配量的计算公式。
5)基于CATIA V5和CAA FOR CATIA V5，设计了支持机翼无余量装配的容差分析原型系统，并完成了部分功能的开发。
Aircraft is a kind of special product that requires strict veracity of assembly. Error is the primary factor that affects assembly and manufacturing veracity. Tolerance restricts manufacturing error of part, and allowance redeems the error that comes into being in the process of product assembly. By means of calculus and computer-simulation, tolerance analysis technique for zero-allowance assembly can effectually solve problems during assembly and maintenance. This thesis studies tolerance analysis technique for zero-allowance assembly, and its application in assembly process of one aircraft's airfoil.
The main contents of the thesis are as follows:
1) Made a systematic and comprehensive analysis on the technical and applicative requirements of tolerance analysis and synthesis during the process of aircraft's life cycle.
2) Based on the theory of hill's zero-allowance assembly, proposed concepts and methods for aircraft's zero-allowance assembly.
3) Analyzed the characteristics and disadvantages of tolerance modeling technique and aircraft assembly in common use. Presented a method for tolerance modeling, namely 'tolerance modeling supporting airfoil's zero-allowance assembly'. Then tolerance semantic information model for airfoil's zero-allowance assembly is presented. This model includes three kinds of information: constraints between assembly component, affiliation relation between inherited assembly components and allowance, dimension and tolerance information about part and components.
4) Based on tolerance semantic information model for zero-allowance assembly, presented an algorithm that can generate assembly tolerance chain. The assembly tolerance-chain is calculated using dimensional simplifying method
and differential coefficient method. Analyzed the influence of concerted chain modification on assembly tolerance-chain. Derived the formula for maximal quantity of repair computation.
5) Based on CATIA V5 CAD Software and CAA FOR CATIA V5 Toolbox, designed and developed a tolerance analysis prototype system for airfoil's zero-allowance assembly.
引文
[1] 熊光楞，并行工程的理论与实践，北京：清华大学出版社，2001．5
[2] 王云渤等，飞机装配工艺学(修订本)，北京：国防工业出版社，1990
[3] 方红芳等，计算机辅助容差设计方法学，机械科学与技术，2000．9：714-716
[4] 闫艳，宁汝新，并行工程中的公差设计研究与开发，计算机集成制造系统-CIMS，2002(5)：43-47
[5] 康汉元，船台无余量装配，北京：人民交通出版社，1980年12月第1版
[6] Hillyard C. Dimensions and Tolerance in Shape Design. University of Cambridge, UK: ph. D. Dissertation, 1978
[7] 吴昭同，杨将新等，计算机辅助公差优化设计，杭州：浙江大学出版社，1999
[8] Z.Wu.W.H.E1Maraghy and H.A. EIMaraghy. Evaluation of cost-tolerance algorithms for design tolerance analysis and synthesis. Manufacturing Review. 1988,1(1):168-I79
[9] C.-Y. Chou and C.-L.Chang. Minimum-Loss. Assembly Tolerance Allocation by Considering Product Degradation and Time Value of Money. Advanced Manufacturing Technology. Vol. 17,NO.2,2001
[10] Lee K and Gossard D.C. A Hierarchical Data Structure for Representing Assemblies: Part Ⅰ. Computer Aided Design. 1985, 17(1): 15-19
[11] Nanxin Wang and Rulga M. Ozsoy. Representation of Assemblies for Automatic Tolerance Chain Generation. Engineering with Computers. 1990,(6): 121-126
[12] P Treacy, J B Ochs, T M Ozsoy and Nanxin Wang. Automated Tolerance Analysis for Mechanical Assemblies Modeled with Geometic Features and Relational Data Structure. Computer Aided Design. 1991, 23(6):444-453
[13] Woo-Jong Lee and T.C. Woo. Tolerances: Their Analysis and Synthesis. Journal of Engineering for Industry. Vol. 112/113,May 1990
[14] Ashraf O. Nassef, Hoda A. EIMaraghy. Allocation of Geometric Tolerances: New Criterion and Methodology. Annals of the CIRP. Vol.46,Jan 1997
[15] Z. Dong, W. Hu and D. Xue. New production cost-tolerance models for tolerance synthesis. Journal of Engineering for Industry. Vol. 116/199, May 1994
[16] 李原、邵毅、余剑峰、杨海成，面向装配的公差建模与公差特征表示，第27届国际计算机与工业工程学术会议，北京：2000
[17] 程宝蕖，飞机制造协调准确度与容差分配，北京：航空工业出版社，1987年3月
[18] 程宝蕖、崔赞斌，飞机互换协调技术，北京：国防工业出版社，1990．5
[19] Gui J K and Mantyla M. Functional Understanding of Assembly Modeling. Computer Aided Design. 1994.26(6):435-451
[20] Requicha, A.A.G. Representation of Geometric Features, Tolerance, and attributes in Solid Modelers Based on Construction Geometry. IEEE Journal of Robotics and Automation. 1986, RA2(3):156-165.
[21] Johnson, R.F. Dimensioning and Tolerancing -Final Report. R84-GM-02-2, CAM-I, Arlington, TX, May, 1984.
[22] Roy U. Feature_based Representational Scheme of A Solid Modular for Providing Dimensioning and Tolerancing Information. Robotics and Computer Integrated Manufacturing. 1988,4(3):335-345.
[23] Roy U. Tolerance Representation scheme in solid Modeling: Parts Ⅰ&Ⅱ. Proceedings of the 15th ASME Design Automation Conference. Montreal. 1989: 1-17.
[24] 方红芳．设计公差和工序公差并行设计的研究．浙江大学博士论文．1997．
[25] Etesami F.A. Mathematical Model for Geometric Tolerances. Journal of Mechanical Design. 1993,115(2) :81-86.
[26] 刘玉生，基于数学定义的平面尺寸和形位公差建模与表示技术的研究，浙江大学博士论文，2000．9
[27] 李原、邵毅、余剑峰、杨海成，面向装配的公差建模与公差特征表示，第27届国际计算机与工业工程学术会议，北京，2000
[28] 高峰，并行工程环境下的面向装配设计系统的研究与实践[D]，武汉：华中理工大学，1997
[29] 荆长生，机械制造工艺学，西安：西北工业大学出版社，1997．2
[30] 范秀敏，装配系统的公差建模与优化，上海交通大学博士学位论文，1998．7
[31] 李和仁，判断尺寸链增环和减环的几种方法，机械工艺师，1999(1)：38
[32] (苏)阿比波夫等，飞机制造工艺学，西安：西北工业大学出版社，1986．1
[33] 李逢春、秦明范，工艺尺寸的分析与计算[M]，北京：机械工业出版社，1998
[34] 同济大学数学教研室，高等数学(第四版)，上海：高等教育出版社，1996
[35] Shah, J. J. Dimension and tolerance modeling and transformations in feature based design and manufacturing. Journal of Intelligent Manufacturing. 1998, 9(5):475-488
[36] 姚任远、蔡青，飞机装配技术，北京：国防工业出版社，1993．3
[37] 何华灿，人工智能导论，西安：西北工业大学出版社，1988．6
[38] 《航空制造工程手册》总编委会，航空制造工程手册：飞机装配，北京：航空工业出版社，1993．12
[39] [苏]A．H．巴布什金，飞机结构装配方法，北京：航空工业出版社，1990．10
[40] CAGD/CAM技术论文集编委会，轰七飞机研制全面应用CAGD/CAM技术论文集，西安飞机工业公司，1989．2
[41] 姬舒平，虚拟装配环境下公差并行设计方法的研究，哈尔滨工业大学博士学位论文，2000．1
[42] T. Kandikjan, J.J. Shah, J.K. Davidson. A mechanism for validating dimensioning and tolerancing schemes in CAD systems. Computer Aided Design. 33(2001): 721-737
[43] 高飞、严隽琦等，尺寸公差模型，计算机辅助设计与图形学学报，1997(1)Vol．9，No．1：87-92
[44] Kenneth W. Chase. Alan R. Parkinson. A Survey of Research in the Application of Tolerance Analysis to the Design of Mechanical Assemblies. Research in Engineering Design. 1991 (3): 23-37
[2] 王云渤等，飞机装配工艺学(修订本)，北京：国防工业出版社，1990
[3] 方红芳等，计算机辅助容差设计方法学，机械科学与技术，2000．9：714-716
[4] 闫艳，宁汝新，并行工程中的公差设计研究与开发，计算机集成制造系统-CIMS，2002(5)：43-47
[5] 康汉元，船台无余量装配，北京：人民交通出版社，1980年12月第1版
[6] Hillyard C. Dimensions and Tolerance in Shape Design. University of Cambridge, UK: ph. D. Dissertation, 1978
[7] 吴昭同，杨将新等，计算机辅助公差优化设计，杭州：浙江大学出版社，1999
[8] Z.Wu.W.H.E1Maraghy and H.A. EIMaraghy. Evaluation of cost-tolerance algorithms for design tolerance analysis and synthesis. Manufacturing Review. 1988,1(1):168-I79
[9] C.-Y. Chou and C.-L.Chang. Minimum-Loss. Assembly Tolerance Allocation by Considering Product Degradation and Time Value of Money. Advanced Manufacturing Technology. Vol. 17,NO.2,2001
[10] Lee K and Gossard D.C. A Hierarchical Data Structure for Representing Assemblies: Part Ⅰ. Computer Aided Design. 1985, 17(1): 15-19
[11] Nanxin Wang and Rulga M. Ozsoy. Representation of Assemblies for Automatic Tolerance Chain Generation. Engineering with Computers. 1990,(6): 121-126
[12] P Treacy, J B Ochs, T M Ozsoy and Nanxin Wang. Automated Tolerance Analysis for Mechanical Assemblies Modeled with Geometic Features and Relational Data Structure. Computer Aided Design. 1991, 23(6):444-453
[13] Woo-Jong Lee and T.C. Woo. Tolerances: Their Analysis and Synthesis. Journal of Engineering for Industry. Vol. 112/113,May 1990
[14] Ashraf O. Nassef, Hoda A. EIMaraghy. Allocation of Geometric Tolerances: New Criterion and Methodology. Annals of the CIRP. Vol.46,Jan 1997
[15] Z. Dong, W. Hu and D. Xue. New production cost-tolerance models for tolerance synthesis. Journal of Engineering for Industry. Vol. 116/199, May 1994
[16] 李原、邵毅、余剑峰、杨海成，面向装配的公差建模与公差特征表示，第27届国际计算机与工业工程学术会议，北京：2000
[17] 程宝蕖，飞机制造协调准确度与容差分配，北京：航空工业出版社，1987年3月
[18] 程宝蕖、崔赞斌，飞机互换协调技术，北京：国防工业出版社，1990．5
[19] Gui J K and Mantyla M. Functional Understanding of Assembly Modeling. Computer Aided Design. 1994.26(6):435-451
[20] Requicha, A.A.G. Representation of Geometric Features, Tolerance, and attributes in Solid Modelers Based on Construction Geometry. IEEE Journal of Robotics and Automation. 1986, RA2(3):156-165.
[21] Johnson, R.F. Dimensioning and Tolerancing -Final Report. R84-GM-02-2, CAM-I, Arlington, TX, May, 1984.
[22] Roy U. Feature_based Representational Scheme of A Solid Modular for Providing Dimensioning and Tolerancing Information. Robotics and Computer Integrated Manufacturing. 1988,4(3):335-345.
[23] Roy U. Tolerance Representation scheme in solid Modeling: Parts Ⅰ&Ⅱ. Proceedings of the 15th ASME Design Automation Conference. Montreal. 1989: 1-17.
[24] 方红芳．设计公差和工序公差并行设计的研究．浙江大学博士论文．1997．
[25] Etesami F.A. Mathematical Model for Geometric Tolerances. Journal of Mechanical Design. 1993,115(2) :81-86.
[26] 刘玉生，基于数学定义的平面尺寸和形位公差建模与表示技术的研究，浙江大学博士论文，2000．9
[27] 李原、邵毅、余剑峰、杨海成，面向装配的公差建模与公差特征表示，第27届国际计算机与工业工程学术会议，北京，2000
[28] 高峰，并行工程环境下的面向装配设计系统的研究与实践[D]，武汉：华中理工大学，1997
[29] 荆长生，机械制造工艺学，西安：西北工业大学出版社，1997．2
[30] 范秀敏，装配系统的公差建模与优化，上海交通大学博士学位论文，1998．7
[31] 李和仁，判断尺寸链增环和减环的几种方法，机械工艺师，1999(1)：38
[32] (苏)阿比波夫等，飞机制造工艺学，西安：西北工业大学出版社，1986．1
[33] 李逢春、秦明范，工艺尺寸的分析与计算[M]，北京：机械工业出版社，1998
[34] 同济大学数学教研室，高等数学(第四版)，上海：高等教育出版社，1996
[35] Shah, J. J. Dimension and tolerance modeling and transformations in feature based design and manufacturing. Journal of Intelligent Manufacturing. 1998, 9(5):475-488
[36] 姚任远、蔡青，飞机装配技术，北京：国防工业出版社，1993．3
[37] 何华灿，人工智能导论，西安：西北工业大学出版社，1988．6
[38] 《航空制造工程手册》总编委会，航空制造工程手册：飞机装配，北京：航空工业出版社，1993．12
[39] [苏]A．H．巴布什金，飞机结构装配方法，北京：航空工业出版社，1990．10
[40] CAGD/CAM技术论文集编委会，轰七飞机研制全面应用CAGD/CAM技术论文集，西安飞机工业公司，1989．2
[41] 姬舒平，虚拟装配环境下公差并行设计方法的研究，哈尔滨工业大学博士学位论文，2000．1
[42] T. Kandikjan, J.J. Shah, J.K. Davidson. A mechanism for validating dimensioning and tolerancing schemes in CAD systems. Computer Aided Design. 33(2001): 721-737
[43] 高飞、严隽琦等，尺寸公差模型，计算机辅助设计与图形学学报，1997(1)Vol．9，No．1：87-92
[44] Kenneth W. Chase. Alan R. Parkinson. A Survey of Research in the Application of Tolerance Analysis to the Design of Mechanical Assemblies. Research in Engineering Design. 1991 (3): 23-37
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