集成化虚拟装配理论、方法及其在飞机总体布置中的应用
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摘要
由于飞机构造复杂,零部件和连接件数量大,飞机研制中装配和安装工作的劳动量占飞机制造总劳动量的50%~60%。可见,良好的装配设计和装配性能,对保证飞机质量和可靠性,降低飞机成本和提高市场竞争力具有十分重要的意义。虚拟装配技术的出现,为解决飞机装配问题提供了一种强有力的手段。虚拟装配技术可以应用在飞机研制的许多阶段。在方案阶段,利用虚拟装配技术实现飞机总体布置,生成总体布置图;工程研制阶段,对于更加详细的零部件模型,应用虚拟装配技术得到更为真实的装配方案,为飞机设计提供依据;在生产定型阶段,生成符合生产实际的装配工艺及装配仿真动画等指导生产任务。
大部分建立虚拟装配系统的方案为:在CAD中建模,再将模型导入虚拟装配系统,CAD系统与虚拟装配系统相互独立。这是一种信息单向传递方案,CAD系统中的设计工作可以传输到虚拟装配系统中,而虚拟装配设计结果难以及时反馈到其它设计活动中,虚拟装配系统容易成为信息孤岛。目前的虚拟装配技术正朝着集成化方向发展:一种集成方案为:直接在系统中通过三维操作和语音命令创建、修改、操纵和观察基于约束的模型,再进行虚拟装配,无须与其它CAD系统进行数据传输,这种方案使得CATIA、UG和ProE等传统CAD模型难以应用;另一种为:建立集成于CAD系统的虚拟装配系统,即“在CAD中增加VR功能”,直接在CAD系统上搭建虚拟装配环境,可直接继承和利用CAD成熟稳定的相关算法,但可扩展性不好,相关理论、技术也不够成熟。
为避免虚拟装配系统成为信息孤岛,基于“在CAD中增加VR功能”技术路线,本文提出了一种集成化的虚拟装配方案:
(1)建立了一个集成于CAD系统的虚拟现实环境,研究并实现了立体显示,数据手套的集成、虚拟环境中的交互技术和碰撞检测算法等内容。
(2)提出了信息双向传递的VA-CADPIM模型,克服了传统虚拟装配系统和CAD系统之间难以双向交换信息的不足,能有效提高设计者进行产品装配设计与分析的效率。
(3)建立了基于装配任务的虚拟装配工艺信息模型,存储虚拟装配操作过程中的工艺信息,能够有效地表达以装配工序为基础的装配过程,通过任务对象的交叉安装解决工序交叉和安装布置调整问题。
(4)提出了装配约束识别方法,并给出了基于运动自由度分析的虚拟装配精确定位求解方法。
(5)为满足系统功能要求,并以集成化、可扩展性,易移植性为目标建立了集成化的虚拟装配系统体系结构。
(6)基于CATIA V5R14及其二次开发环境CAA自主开发了集成化虚拟装配原型系统IVADS,该系统能够完成虚拟场景浏览、虚拟装配规划和可装配性评价等功能,并给出了某飞机前机身电子舱的虚拟装配总体布置应用实例,验证了本文理论与方法的正确性与有效性。
In product design procedure, assembly design is the phase of the largest workload and the most time-consuming. During airplane design and manufacture phases, the workload of assembly and installation is the 50~60 percent of the total because of the complexity of the airplane structure and the large quantity of components and connectors. It is obvious that assembly design and assembly performance is significant for assuring airplane quality and reliability, decreasing the cost and enhancing the market competitiveness. Virtual assembly technology becomes a powerful tool for solving airplane assembly problem. Virtual Assembly technology can be applied in many phases of airplane design and manufacture: using virtual assembly technology, general arrangement is carry out in conceptual and preliminary design phases, assembly scheme is obtained in detail design phase, and assembly process of according with actual manufacture is built as a guidance.
The main solution for virtual assembly is that, the relevant CAD models are first created using traditional CAD software, such as ProE, UGⅡor CATIA, the constructed CAD models are then converted into polygonal models and are imported into a VR environment. Adopting this solution, CAD system and virtual assembly system are isolated with each other, informations transfer uni-directionally, the design result can be transfered from CAD to virtual assembly, but not be feed back in time, virtual assembly becomes information silo. Currently, Integration for virtual assembly is the developing trend. A solution is that, designers are able to create both the solid model of a part and the assembly model of a product in 3D space by direct 3D manipulations and voice commands intuitively and easily, to perform assembly planning interactively in 3D space, and to simulate and check assembly process. Adopting this solution, virtual assembly system does not need transer information with other CAD, but also becomes isolated with other CAD. Another solution is that virtual assembly is built in CAD system, many algorithms of CAD can be directly used by this solution, but extensibility is not good, and relative theory, method is not mature.
To tackle the information silo in virtual assembly system, based on the strategy of Integrate VR into CAD, an integrated virtual assembly solution was proposed in this paper:
1. A virtual environment integrated into CAD was built, including stereo display, integrating data glove with CAD, interaction technolody in virtual environment, and collision detection algorithm so on.
2. To overcome the limitation of information exchange between traditional virtual assembly system and CAD, a VA-CADPIM model of bi-directional information transfer was presented, can effectively improve efficiency of product assembly design and analysis.
3. A virtual assembly process information model based on assembly task was established. A hierarchical assembly process was employed to express the virtual assembly process. The crossing procedure and installation adjustment were realized through the strategy of crossing assembly of task target body and an adjustment approach given herein. The method to cut down the redundant assembly task was proposed.
4. An assembly constraint recognization method was given, and the exact placement technology of component in virtual assembly environment based freedom analysis was introduced.
5. To satisfy integrated virtual assembly system function, and to make targets of high integration, good expansibility and portability, a virtual assembly architecture integrated with CAD was built.
6. Based on CATIA V5R14, its 3rd part development environment and Immersion Virtual Hand SDK, a prototype system instance IVADS was developed, which can finish many functions, such as virtual scene navigation, virtual assembly planning, assemblability evaluation, and a general arrangement application for electron cabin of some airplane forward fuselage was given, accuracy and validity of theory and methods were tested.
大部分建立虚拟装配系统的方案为:在CAD中建模,再将模型导入虚拟装配系统,CAD系统与虚拟装配系统相互独立。这是一种信息单向传递方案,CAD系统中的设计工作可以传输到虚拟装配系统中,而虚拟装配设计结果难以及时反馈到其它设计活动中,虚拟装配系统容易成为信息孤岛。目前的虚拟装配技术正朝着集成化方向发展:一种集成方案为:直接在系统中通过三维操作和语音命令创建、修改、操纵和观察基于约束的模型,再进行虚拟装配,无须与其它CAD系统进行数据传输,这种方案使得CATIA、UG和ProE等传统CAD模型难以应用;另一种为:建立集成于CAD系统的虚拟装配系统,即“在CAD中增加VR功能”,直接在CAD系统上搭建虚拟装配环境,可直接继承和利用CAD成熟稳定的相关算法,但可扩展性不好,相关理论、技术也不够成熟。
为避免虚拟装配系统成为信息孤岛,基于“在CAD中增加VR功能”技术路线,本文提出了一种集成化的虚拟装配方案:
(1)建立了一个集成于CAD系统的虚拟现实环境,研究并实现了立体显示,数据手套的集成、虚拟环境中的交互技术和碰撞检测算法等内容。
(2)提出了信息双向传递的VA-CADPIM模型,克服了传统虚拟装配系统和CAD系统之间难以双向交换信息的不足,能有效提高设计者进行产品装配设计与分析的效率。
(3)建立了基于装配任务的虚拟装配工艺信息模型,存储虚拟装配操作过程中的工艺信息,能够有效地表达以装配工序为基础的装配过程,通过任务对象的交叉安装解决工序交叉和安装布置调整问题。
(4)提出了装配约束识别方法,并给出了基于运动自由度分析的虚拟装配精确定位求解方法。
(5)为满足系统功能要求,并以集成化、可扩展性,易移植性为目标建立了集成化的虚拟装配系统体系结构。
(6)基于CATIA V5R14及其二次开发环境CAA自主开发了集成化虚拟装配原型系统IVADS,该系统能够完成虚拟场景浏览、虚拟装配规划和可装配性评价等功能,并给出了某飞机前机身电子舱的虚拟装配总体布置应用实例,验证了本文理论与方法的正确性与有效性。
In product design procedure, assembly design is the phase of the largest workload and the most time-consuming. During airplane design and manufacture phases, the workload of assembly and installation is the 50~60 percent of the total because of the complexity of the airplane structure and the large quantity of components and connectors. It is obvious that assembly design and assembly performance is significant for assuring airplane quality and reliability, decreasing the cost and enhancing the market competitiveness. Virtual assembly technology becomes a powerful tool for solving airplane assembly problem. Virtual Assembly technology can be applied in many phases of airplane design and manufacture: using virtual assembly technology, general arrangement is carry out in conceptual and preliminary design phases, assembly scheme is obtained in detail design phase, and assembly process of according with actual manufacture is built as a guidance.
The main solution for virtual assembly is that, the relevant CAD models are first created using traditional CAD software, such as ProE, UGⅡor CATIA, the constructed CAD models are then converted into polygonal models and are imported into a VR environment. Adopting this solution, CAD system and virtual assembly system are isolated with each other, informations transfer uni-directionally, the design result can be transfered from CAD to virtual assembly, but not be feed back in time, virtual assembly becomes information silo. Currently, Integration for virtual assembly is the developing trend. A solution is that, designers are able to create both the solid model of a part and the assembly model of a product in 3D space by direct 3D manipulations and voice commands intuitively and easily, to perform assembly planning interactively in 3D space, and to simulate and check assembly process. Adopting this solution, virtual assembly system does not need transer information with other CAD, but also becomes isolated with other CAD. Another solution is that virtual assembly is built in CAD system, many algorithms of CAD can be directly used by this solution, but extensibility is not good, and relative theory, method is not mature.
To tackle the information silo in virtual assembly system, based on the strategy of Integrate VR into CAD, an integrated virtual assembly solution was proposed in this paper:
1. A virtual environment integrated into CAD was built, including stereo display, integrating data glove with CAD, interaction technolody in virtual environment, and collision detection algorithm so on.
2. To overcome the limitation of information exchange between traditional virtual assembly system and CAD, a VA-CADPIM model of bi-directional information transfer was presented, can effectively improve efficiency of product assembly design and analysis.
3. A virtual assembly process information model based on assembly task was established. A hierarchical assembly process was employed to express the virtual assembly process. The crossing procedure and installation adjustment were realized through the strategy of crossing assembly of task target body and an adjustment approach given herein. The method to cut down the redundant assembly task was proposed.
4. An assembly constraint recognization method was given, and the exact placement technology of component in virtual assembly environment based freedom analysis was introduced.
5. To satisfy integrated virtual assembly system function, and to make targets of high integration, good expansibility and portability, a virtual assembly architecture integrated with CAD was built.
6. Based on CATIA V5R14, its 3rd part development environment and Immersion Virtual Hand SDK, a prototype system instance IVADS was developed, which can finish many functions, such as virtual scene navigation, virtual assembly planning, assemblability evaluation, and a general arrangement application for electron cabin of some airplane forward fuselage was given, accuracy and validity of theory and methods were tested.
引文
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