摘要
针对飞机大部件装配过程中的两类干涉问题:蒙皮对接干涉问题和互插装配干涉问题,论文提出一套面向实际装配的干涉检测方案。首先采用激光扫描仪扫描零部件获得扫描数据,通过扫描数据处理分析,从中提取关键特征或根据其重构模型计算零部件的干涉情况,进而指导后续的装配处理。
阐述了飞机装配过程中干涉检测所用到的模板定制技术,并分析给出相关的基本理论。模板贯穿于论文的始终,根据CAD模型定制而成,主要用于辅助特征提取以及简化干涉检测过程。主要介绍了两类模板:边特征模板和插配特征模板。
提出基于统计特征的点云模型匹配技术,即通过调整自由模型与固定模型的一个或多个对应统计特征重合或一致来实现模型的匹配。基于统计特征的模型匹配分为两种情况:完全匹配和部分匹配。完全匹配是指统计特征能够完全约束自由模型的六个自由度,一次匹配成功。部分匹配是指统计特征只能约束自由模型的部分自由度,需要进一步处理才能完成模型匹配:交互调整自由模型未被约束的自由度,使得自由模型与固定模型达到视觉上的匹配,然后采用ICP算法精确匹配。两种匹配方案稳定、可靠,能够获得全局最优解。
提出基于模板的点云边特征提取方法。模板根据CAD模型定制而成,包括理论边上的离散点以及边在各点处的切矢。配准模板与点云数据,根据匹配后模板中每一离散点及对应的切矢信息构建平面,利用其对点云数据切片获得二维截面数据。在每一截面数据中,以理论离散点为界将截面数据分为两段,分别拟合这两段数据为两段曲线,其交点或切点即为实际的边特征上的点。通过曲线拟合、截面优化,不仅可以确切定位点云中的边点,而且可以插值求解点云中不存在的边点,保证了边特征的提取精度。深入研究并提出了二维对称边特征的提取技术。
提出一种基于模板的大型部件对合插配干涉检测方法。根据插入特征与配合特征(统称插配特征)的CAD模型定制模板,匹配模板与扫描数据,匹配后的模板作为重构模型参与干涉分析。将插入特征离散为一系列垂直于装配方向的平行截面,计算每一截面在运动过程中与配合特征的渗透深度、间隙以及干涉分界线,综合所有截面的干涉情况构成插配特征的干涉情况。该方法将三维求交测试问题简化为二维问题来处理,不仅能够定量计算装配件的渗透深度、间隙,而且能够给出装配件的干涉分布情况,据此定量指导后续的装配处理。
针对飞机大部件对接过程中的两类干涉问题:蒙皮对接干涉问题及互插零部件干涉问题,进行飞机大部件对接干涉分析并提出相应的解决方案:修配处理、添加垫片或者重新调姿。通过计算给出建议性的修配量、垫片的厚度以及大部件的姿态偏差,为飞机大部件对接干涉问题提供定量的指导方案。
总结飞机装配过程中的干涉检测技术,指出本文工作的主要特点,并对未来的研究工作进行展望。
To the interference problems of aircraft components assembly, the paper proposes a interference detection scheme about practical assembly. In the first, scan the assembly parts using the laser scanning to acquire scanning data. Through the scanning data handling and analysis, the key features are extracted and the interference conditions are calculated. The follow-up assembly handling is guided by the key features or interference conditions.
The technique and theory about template customizing are stated. The template is basis of the paper and customized according to CAD model. The template is used to help to extract the features and simplify the interference detection. The template is including two types: edge feature template and assembly part template.
A technology based on statistical features is proposed to matching point cloud models, i.e. through making corresponding statistical features of free model and fixed model be coinciding to finish matching. The statistical features based matching is include two circumstances: complete matching and incomplete matching. If statistical features can constrain six degrees of freedom of free model, free model and fixed model can be matching completely. If the number of constrained degrees of freedom is less than six, incomplete matching is finished and follow-up handling is required to finish model matching. The follow-up handling is as follows: interactively adjust unconstrained degrees of freedom to acquire the matching of vision of free model and fixed model, and then accurately match them using ICP algorithm. Both two matching schemes are stable and reliable, and global optimal solution is acquired.
A method based on template is proposed to extract the edges of point cloud. The template is customized according to CAD model, and it includes discrete points and their corresponding tangent vectors on the theoretical edges. After the template and point cloud are matched, point cloud is sliced by some planes to acquire sectional data. Every plane of these planes is constructed by one theoretical edge point and its corresponding tangent vector. Segment every sectional data into two parts according to the theoretical edge point, and fit the two parts into two curves. The intersection point or tangent point of the two curves is the point on the practical edges. Through curves fitting and section optimization, the practical edge points existing in point cloud can be positioned and the ones not existing in point cloud can be acquired by interpolating, so the extracting precision of edges is guaranteed. The extraction technique of 2D symmetry edge is proposed and deeply researched.
A template based interference detection technology is proposed. The template is customized according to CAD model of assembly part. Match the template with scanning data, and the template after being matched is the reconstruction model. One of two assembly parts mating each other is converted into layered parallel sectional profiles by slicing technique, and the sectional profiles are perpendicular to assembling direction. Calculate the interference conditions of every section and all of them constitute the interference conditions of three-dimension objects. The method simplifies the 3D intersection to 2D, and not only the permeation depth and clearance but also the interference distribution is given.
To solve the interference problem during aircraft components assembly, a quantitativly guiding sheme is proposed which is including repairing, filling piece and re-ajusting pose. The sheme offers suggested value including repairing value, filling piece thickness and pose deviation to guide the components assembly.
In the end, some advanced topics in the proposed methodology that needs further investigation in future are presented and addressed.
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