基于虚拟现实的卫星装配工艺设计方法及其应用
摘要
卫星等复杂产品的装配工艺规划是一项难度很大的工作,它需要耗费大量的人力、物力和财力,影响产品的装配质量、周期和成本。虚拟现实技术为解决上述问题提供了一种新的、低成本的快速手段。本文针对卫星装配生产中存在的问题开展虚拟装配工艺设计方法及其关键技术的研究,具有重要的理论意义和应用价值。
阐述了虚拟装配工艺设计的主要内容和特点,分析了卫星装配工艺设计中存在的问题,明确了卫星虚拟装配工艺设计实现的目标,在此基础上,提出了卫星虚拟装配工艺设计系统的体系结构和工作流程。从功能上将系统分为CAD建模子系统、虚拟装配工艺规划子系统、文档生成与现场示教子系统以及两个接口部分,从流程上将系统分为模型数据获取阶段、支持工艺规划的虚拟操作阶段、虚拟装配顺序规划和路径规划阶段、以及装配现场应用和示教阶段。
研究了虚拟环境下的装配建模技术。在分析虚拟装配模型表达的信息需求和满足的基本要求的基础之上,提出了基于层次约束结构的虚拟装配模型,将产品信息在虚拟环境下分为产品层、部件层、零件层、特征层、几何面层以及面片层来表达,并建立各层元素之间的约束关系。实现了CAD系统和虚拟装配系统之间的数据转换,将CAD系统的信息分解为几何信息、拓扑信息、层次结构信息和装配约束信息,通过不同途径分别提取出来转换到虚拟环境,在此基础上建立产品的装配模型。建立了根据虚拟装配模型生成的虚拟装配场景图的结构,从而方便执行虚拟环境下的装配和拆卸操作。
研究了基于几何约束的虚拟装配操作定位技术,从而为支持虚拟环境下交互式装配工艺规划和评价奠定基础。提出了面向虚拟装配的层次式碰撞检测算法,从包容盒层、空间分割块层、几何面层、精确面片层四个层次进行递进式判断,一方面可有效提高算法的精度和效率,另一方面可直接返回发生碰撞的几何面对,从而为虚拟环境下的约束识别提供依据。提出了基于几何面约束求解的精确定位方法,从而对零件进行快速、准确的定位。提出了几何约束动态识别和管理的有效机制,通过碰撞检测、零件匹配、几何面匹配、优先关系选择等步骤提高约束识别的效率和准确性,设计了约束管理器对虚拟环境下的几何约束进行动态维护和管理,实现了基于几何约束的零件运动导航。
研究了虚拟环境下的装配顺序规划和路径规划。针对自动装配顺序规划和交互式装配顺序规划都存在的问题,提出了一种智能装配顺序推理和交互式装配顺序规划评价相结合的方法。提出了优先约束表的概念,利用它对零件之间的优先约束关系进行有效表达。设计了与优先约束表紧密结合的基于蚁群算法的装配序列规划过程,利用它生成初始优化的装配顺序。以初始优化的装配顺序作为引导,在虚拟环境下进行交互式装配规划、仿真和评价,充分发挥装配人员的经验和知识,在实现装配工具精确定位和操作仿真的基础上,考虑工具操作空间对装配顺序的影响,不断生成新的优先约束和评价准则,从而规划出更加优化的装配顺序。不断反复和完善,直到得到满意、合理、实用的最佳装配顺序为止,最后给出了装配路径的生成和优化方法。
研究了根据虚拟装配规划的结果生成工艺文件的方法和装配现场示教。通过对虚拟装配过程中产生的工艺信息进行有效组织和表达,建立了面向过程的装配工艺模型,转换成实际生产中要求的工序工步的形式,得到产品的工艺目录树,以此为基础进行装配工艺信息的编辑、补充和完善。采用XML技术实现了工艺文件的灵活定制、动态生成、网上浏览和打印输出,利用Web技术实现装配信息浏览和现场示教。
设计并开发了面向卫星的虚拟装配工艺设计系统,并在中国空间技术研究院总装与环境工程部获得初步应用。
The assembly process of complicated product is a difficult work, which consumes a great deal of manpower, material and finance, and affects production quality, cost and cycle. Virtual reality technology provides a new and low-cost way to solve these problems. This paper studies VR-based assembly process design method and its key technologies oriented to satellite etc, which has important theorical and pratical values.
The contents and features of virtual assembly process design are expatiated, the existing problems in assembly process design for satellite are analysised, and the objectives of virtual assembly process design for satellite are pointed out. Then the architecture and workflow of virtual assembly process design system orieted to satellite is proposed. According to function decomposion the system can be divided into CAD modeling subsystem, virtual assembly process planning subsystem, process document generation and assembly training subsystem, and two interfaces between them. The workflow of the system includes model data obtaining phase, virtual operation phase, assembly sequence planning and path planning phase, and application and training phase.
Product assembly modeling in virtual environment is studied. Analyzing the basic requirements of virtual assembly model, a hierarchically constraints-based virtual assembly model is proposed, which includes product layer, subassembly layer, part layer, feature layer, surface layer and polygon layer, and the constraint relationships in these layers. Data transformation from CAD to virtual reality is realized, which divides the CAD information into geomtry information, topology information, structure hiberarchy information and assembly constraint information, and transformed them into virtual environment by different ways. The virtual assembly scenegraph is erected according to virtual assembly model, which can be support interative assembly operation in virtual environment.
Geometry constraint based virtual assembly position technology is studied. A hierarchically collision detection algorithm oriented to virtual assembly is proposed, which includes bounding box layer, space division cell layer, surface layer and polygon layer. The algorithm can improve accuracy and efficiency on one hand, on the other hand the algorithm can return colliding surface pairs for constraint recognization. Surface based constraint solving method is proposed, which can be used for rapid and accurate part positioning in virtuan environment. Dynamic constraint recognization and management method is proposed. According to collision detection, part matching, surface matching and priority selection, the accuracy and efficiency of constraint recognization can be improved. A geometry constraint manager is designed, and motion navigation based on geometry constraint is realized.
Virtual assembly sequence planning and path planning is studied. Aimed at the limitations of automated assembly sequence planning and interative assembly sequence planning, a combined approach based on intelligent assembly sequece reasoning and interactive assembly evaluation is proposed. After the precedence constraint relationships between parts are generated and represented by defining a precedence constraint table, the ant colony optimization algorithm is applied to generate initial optimized assembly sequence. This sequence can be interactively simulated, evaluated and optimized by virtual assembly. During the assembly process new precedence constraints and evaluation rules will be recognized, and assembly tool positioning and operation space verification is realized, a more practical and optimal assembly sequence is then replaned, and once again evaluated by virtual assembly simulation. This is an iterative process until the best assembly sequence is obtained.
The method of generating assembly process documents and assembly training are studied. A process-orieted assembly process model is erected to represent assembly process information during virtual assembly, this assembly process model can be transformed into working procedures and steps, and then the assembly process tree is obtained, based on which the user can perform assembly process editing. A method based on XML technology is applied to design, generate and output assembly process card, and web-based assembly training system is realized for assembly traning and guiding.
An integrated virtual assembly process design system oriented to satellite is developed, and has been applied in China Academy of Space Technology.
阐述了虚拟装配工艺设计的主要内容和特点,分析了卫星装配工艺设计中存在的问题,明确了卫星虚拟装配工艺设计实现的目标,在此基础上,提出了卫星虚拟装配工艺设计系统的体系结构和工作流程。从功能上将系统分为CAD建模子系统、虚拟装配工艺规划子系统、文档生成与现场示教子系统以及两个接口部分,从流程上将系统分为模型数据获取阶段、支持工艺规划的虚拟操作阶段、虚拟装配顺序规划和路径规划阶段、以及装配现场应用和示教阶段。
研究了虚拟环境下的装配建模技术。在分析虚拟装配模型表达的信息需求和满足的基本要求的基础之上,提出了基于层次约束结构的虚拟装配模型,将产品信息在虚拟环境下分为产品层、部件层、零件层、特征层、几何面层以及面片层来表达,并建立各层元素之间的约束关系。实现了CAD系统和虚拟装配系统之间的数据转换,将CAD系统的信息分解为几何信息、拓扑信息、层次结构信息和装配约束信息,通过不同途径分别提取出来转换到虚拟环境,在此基础上建立产品的装配模型。建立了根据虚拟装配模型生成的虚拟装配场景图的结构,从而方便执行虚拟环境下的装配和拆卸操作。
研究了基于几何约束的虚拟装配操作定位技术,从而为支持虚拟环境下交互式装配工艺规划和评价奠定基础。提出了面向虚拟装配的层次式碰撞检测算法,从包容盒层、空间分割块层、几何面层、精确面片层四个层次进行递进式判断,一方面可有效提高算法的精度和效率,另一方面可直接返回发生碰撞的几何面对,从而为虚拟环境下的约束识别提供依据。提出了基于几何面约束求解的精确定位方法,从而对零件进行快速、准确的定位。提出了几何约束动态识别和管理的有效机制,通过碰撞检测、零件匹配、几何面匹配、优先关系选择等步骤提高约束识别的效率和准确性,设计了约束管理器对虚拟环境下的几何约束进行动态维护和管理,实现了基于几何约束的零件运动导航。
研究了虚拟环境下的装配顺序规划和路径规划。针对自动装配顺序规划和交互式装配顺序规划都存在的问题,提出了一种智能装配顺序推理和交互式装配顺序规划评价相结合的方法。提出了优先约束表的概念,利用它对零件之间的优先约束关系进行有效表达。设计了与优先约束表紧密结合的基于蚁群算法的装配序列规划过程,利用它生成初始优化的装配顺序。以初始优化的装配顺序作为引导,在虚拟环境下进行交互式装配规划、仿真和评价,充分发挥装配人员的经验和知识,在实现装配工具精确定位和操作仿真的基础上,考虑工具操作空间对装配顺序的影响,不断生成新的优先约束和评价准则,从而规划出更加优化的装配顺序。不断反复和完善,直到得到满意、合理、实用的最佳装配顺序为止,最后给出了装配路径的生成和优化方法。
研究了根据虚拟装配规划的结果生成工艺文件的方法和装配现场示教。通过对虚拟装配过程中产生的工艺信息进行有效组织和表达,建立了面向过程的装配工艺模型,转换成实际生产中要求的工序工步的形式,得到产品的工艺目录树,以此为基础进行装配工艺信息的编辑、补充和完善。采用XML技术实现了工艺文件的灵活定制、动态生成、网上浏览和打印输出,利用Web技术实现装配信息浏览和现场示教。
设计并开发了面向卫星的虚拟装配工艺设计系统,并在中国空间技术研究院总装与环境工程部获得初步应用。
The assembly process of complicated product is a difficult work, which consumes a great deal of manpower, material and finance, and affects production quality, cost and cycle. Virtual reality technology provides a new and low-cost way to solve these problems. This paper studies VR-based assembly process design method and its key technologies oriented to satellite etc, which has important theorical and pratical values.
The contents and features of virtual assembly process design are expatiated, the existing problems in assembly process design for satellite are analysised, and the objectives of virtual assembly process design for satellite are pointed out. Then the architecture and workflow of virtual assembly process design system orieted to satellite is proposed. According to function decomposion the system can be divided into CAD modeling subsystem, virtual assembly process planning subsystem, process document generation and assembly training subsystem, and two interfaces between them. The workflow of the system includes model data obtaining phase, virtual operation phase, assembly sequence planning and path planning phase, and application and training phase.
Product assembly modeling in virtual environment is studied. Analyzing the basic requirements of virtual assembly model, a hierarchically constraints-based virtual assembly model is proposed, which includes product layer, subassembly layer, part layer, feature layer, surface layer and polygon layer, and the constraint relationships in these layers. Data transformation from CAD to virtual reality is realized, which divides the CAD information into geomtry information, topology information, structure hiberarchy information and assembly constraint information, and transformed them into virtual environment by different ways. The virtual assembly scenegraph is erected according to virtual assembly model, which can be support interative assembly operation in virtual environment.
Geometry constraint based virtual assembly position technology is studied. A hierarchically collision detection algorithm oriented to virtual assembly is proposed, which includes bounding box layer, space division cell layer, surface layer and polygon layer. The algorithm can improve accuracy and efficiency on one hand, on the other hand the algorithm can return colliding surface pairs for constraint recognization. Surface based constraint solving method is proposed, which can be used for rapid and accurate part positioning in virtuan environment. Dynamic constraint recognization and management method is proposed. According to collision detection, part matching, surface matching and priority selection, the accuracy and efficiency of constraint recognization can be improved. A geometry constraint manager is designed, and motion navigation based on geometry constraint is realized.
Virtual assembly sequence planning and path planning is studied. Aimed at the limitations of automated assembly sequence planning and interative assembly sequence planning, a combined approach based on intelligent assembly sequece reasoning and interactive assembly evaluation is proposed. After the precedence constraint relationships between parts are generated and represented by defining a precedence constraint table, the ant colony optimization algorithm is applied to generate initial optimized assembly sequence. This sequence can be interactively simulated, evaluated and optimized by virtual assembly. During the assembly process new precedence constraints and evaluation rules will be recognized, and assembly tool positioning and operation space verification is realized, a more practical and optimal assembly sequence is then replaned, and once again evaluated by virtual assembly simulation. This is an iterative process until the best assembly sequence is obtained.
The method of generating assembly process documents and assembly training are studied. A process-orieted assembly process model is erected to represent assembly process information during virtual assembly, this assembly process model can be transformed into working procedures and steps, and then the assembly process tree is obtained, based on which the user can perform assembly process editing. A method based on XML technology is applied to design, generate and output assembly process card, and web-based assembly training system is realized for assembly traning and guiding.
An integrated virtual assembly process design system oriented to satellite is developed, and has been applied in China Academy of Space Technology.
引文
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