飞机部件装配误差累积分析与容差优化方法研究
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摘要
在飞机研制中，合理的装配容差设计是提高装配准确度、减少研制成本、提高装配工艺性和一次装配成功率的有效途径。本文研究了面向飞机部件装配的误差累积分析与容差优化的理论和方法。以图论为基础，提出基于图的装配容差建模方法，研究装配尺寸链生成算法、矢量表示和装配误差累积分析方法，研究装配容差与装配性能自适应匹配分析方法，研究装配容差的多目标综合优化算法，完成装配容差设计功能模块的设计与开发，全文以某型飞机的一个组件为对象验证理论研究和系统的正确性和可行性，实现对飞机部件装配容差设计的支持。论文的主要研究内容如下：
分析了容差设计与设计、工艺、制造、装配等飞机研制过程之间的联系，阐述本文的研究背景和研究意义，综述容差分析与优化的国内外研究现状，提出了飞机部件装配容差设计亟待研究的关键问题。
提出了基于图的装配容差建模方法。建立了基于有向图的集成尺寸容差、形位容差和配合容差的装配容差全局模型。具体建模过程为：以由有序五元组的扩展有向图对容差元进行表示；采用图的和运算规则建立零件容差模型；采用有序五元组的扩展有向图对装配体配合容差进行表示；最后建立装配容差全局模型，并采用邻接矩阵对本模型进行表示。
研究了装配尺寸链的生成算法、向量表示和装配误差累积分析方法。给出了基于图的装配容差全局模型向基于树的装配容差全局模型转换方法，给出了基于广度优先搜索策略的装配尺寸链生成算法，并对装配尺寸链进行了向量表示；提出了基于蒙特卡罗法的装配误差累积分析方法；对装配尺寸链修配环进行了分析与计算，获得了修配环最大修配量的计算方法。
提出了装配容差与装配性能自适应匹配分析方法。以装配性能-容差的相互影响关系的统计数据为基础，采用作图法和最小二乘法拟合了装配性能-容差关系曲线，结合装配尺寸链，建立了装配容差与装配性能自适应匹配数学模型，实现了装配容差与装配性能自适应匹配分析。
提出了装配容差的多目标综合优化方法。建立了面向装配性能、加工成本、装配工艺性各个单目标的装配容差优化模型；提出了面向多目标的装配容差综合
In the process of design and manufacture of aircraft, it is very important that assembly tolerance is practically designed to meet some requirements from aircraft's performance, manufacture, assembly, cost, quality, and so on. The good tolerancing can improve assembly performance, decrease manufacturing cost, and improve manufacturable ability. This dissertation researchs the key technologies and methods on assembly error stack-up analysis and optimum tolerancing for aircraft assembly based on Gragh Theory. Thereinto, assembly tolerance modeling approach based on key features (KF) and Graph is presented; the algorithm gaining assembly dimension chain is researched; we build the self-adapting matching model between assembly tolerance and assembly performance; the integrated and optimum algorithm of assembly tolerancing for multi-objects is presented; and lastly assembly tolerancing sub-system is designed and developed. In the whole dissertation, an example about a subassembly of certain aircraft is used to prove that the methods and theories are correct and useful. The key research works covered in the dissertation are as follows.
Firstly, I analyze the relationships between design, process, manufature, assembly and assembly tolerancing. Then I discuss the research backgrounds and significances. On the basis of analyzing the actuality of internal and overseas researches on tolerancing, the dissertation presents the key unfathomed problems about assembly tolerancing for aircraft. And an example is introduced to prove the following methods and the outline of the dissertation.
The desired requirements of a tolerance model for part are: completeness, compatibility, computability and validity. We aim to achieve these requirements in a way different from former researchers. Former researchers dealt with dimension tolerance, form tolerance and position tolerance separately. So chapter 2 presents assembly tolerance modeling approach based on KFs and Graph Theory. A unified tolerance model that deals with these three tolerances is built simultaneously. KFs include point KF, line KF and plane KF. I build a meta-tolerance model with five
分析了容差设计与设计、工艺、制造、装配等飞机研制过程之间的联系，阐述本文的研究背景和研究意义，综述容差分析与优化的国内外研究现状，提出了飞机部件装配容差设计亟待研究的关键问题。
提出了基于图的装配容差建模方法。建立了基于有向图的集成尺寸容差、形位容差和配合容差的装配容差全局模型。具体建模过程为：以由有序五元组的扩展有向图对容差元进行表示；采用图的和运算规则建立零件容差模型；采用有序五元组的扩展有向图对装配体配合容差进行表示；最后建立装配容差全局模型，并采用邻接矩阵对本模型进行表示。
研究了装配尺寸链的生成算法、向量表示和装配误差累积分析方法。给出了基于图的装配容差全局模型向基于树的装配容差全局模型转换方法，给出了基于广度优先搜索策略的装配尺寸链生成算法，并对装配尺寸链进行了向量表示；提出了基于蒙特卡罗法的装配误差累积分析方法；对装配尺寸链修配环进行了分析与计算，获得了修配环最大修配量的计算方法。
提出了装配容差与装配性能自适应匹配分析方法。以装配性能-容差的相互影响关系的统计数据为基础，采用作图法和最小二乘法拟合了装配性能-容差关系曲线，结合装配尺寸链，建立了装配容差与装配性能自适应匹配数学模型，实现了装配容差与装配性能自适应匹配分析。
提出了装配容差的多目标综合优化方法。建立了面向装配性能、加工成本、装配工艺性各个单目标的装配容差优化模型；提出了面向多目标的装配容差综合
In the process of design and manufacture of aircraft, it is very important that assembly tolerance is practically designed to meet some requirements from aircraft's performance, manufacture, assembly, cost, quality, and so on. The good tolerancing can improve assembly performance, decrease manufacturing cost, and improve manufacturable ability. This dissertation researchs the key technologies and methods on assembly error stack-up analysis and optimum tolerancing for aircraft assembly based on Gragh Theory. Thereinto, assembly tolerance modeling approach based on key features (KF) and Graph is presented; the algorithm gaining assembly dimension chain is researched; we build the self-adapting matching model between assembly tolerance and assembly performance; the integrated and optimum algorithm of assembly tolerancing for multi-objects is presented; and lastly assembly tolerancing sub-system is designed and developed. In the whole dissertation, an example about a subassembly of certain aircraft is used to prove that the methods and theories are correct and useful. The key research works covered in the dissertation are as follows.
Firstly, I analyze the relationships between design, process, manufature, assembly and assembly tolerancing. Then I discuss the research backgrounds and significances. On the basis of analyzing the actuality of internal and overseas researches on tolerancing, the dissertation presents the key unfathomed problems about assembly tolerancing for aircraft. And an example is introduced to prove the following methods and the outline of the dissertation.
The desired requirements of a tolerance model for part are: completeness, compatibility, computability and validity. We aim to achieve these requirements in a way different from former researchers. Former researchers dealt with dimension tolerance, form tolerance and position tolerance separately. So chapter 2 presents assembly tolerance modeling approach based on KFs and Graph Theory. A unified tolerance model that deals with these three tolerances is built simultaneously. KFs include point KF, line KF and plane KF. I build a meta-tolerance model with five
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