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CN111832185A - Precise assembly simulation method and system based on skin model - Google Patents

Precise assembly simulation method and system based on skin model Download PDF

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CN111832185A
CN111832185A CN202010717471.XA CN202010717471A CN111832185A CN 111832185 A CN111832185 A CN 111832185A CN 202010717471 A CN202010717471 A CN 202010717471A CN 111832185 A CN111832185 A CN 111832185A
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workpiece
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CN111832185B (en
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马嵩华
宋凯乐
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Shandong University
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Abstract

本公开提供了一种基于蒙皮模型的精确装配仿真方法及系统,为了在装配仿真中结合工件的几何公差,根据形状,位置和方向公差生成零件的蒙皮模型,并识别出零件蒙皮模型的配合面和载荷边界条件;在几何公差方面,采用二次优化方法对基于SMS的多体装配进行建模,并确定配合面的相对位置,接触点承受额外的载荷并进一步变形,随后,由于接触变形,零件的相对定位将进一步移动;如果生成了新的接触点,则将使用变形的SMS和降低的负载开始二次优化的另一迭代;平衡所有负载后,迭代停止,零件全部组装好,实现了多个零件的精确装配仿真;同时通过多次重复上述装配仿真模拟,能够根据得到的装配偏差进行有效的公差分析。

Figure 202010717471

The present disclosure provides an accurate assembly simulation method and system based on a skin model. In order to combine the geometric tolerance of the workpiece in the assembly simulation, a skin model of the part is generated according to the tolerance of shape, position and direction, and the skin model of the part is identified. The mating surfaces and load boundary conditions of Contact deformation, the relative positioning of the part will move further; if a new contact point is generated, another iteration of the secondary optimization will begin with the deformed SMS and reduced load; after all loads are balanced, the iteration stops and the part is fully assembled , to achieve accurate assembly simulation of multiple parts; at the same time, by repeating the above assembly simulation simulation multiple times, effective tolerance analysis can be carried out according to the obtained assembly deviation.

Figure 202010717471

Description

基于蒙皮模型的精确装配仿真方法及系统Precise assembly simulation method and system based on skin model

技术领域technical field

本公开属于装配仿真技术领域,尤其涉及一种基于蒙皮模型的精确装配仿 真方法及系统。The present disclosure belongs to the technical field of assembly simulation, and in particular relates to an accurate assembly simulation method and system based on a skin model.

背景技术Background technique

本部分的陈述仅仅是提供了与本公开相关的背景技术信息,不必然构成在 先技术。The statements in this section merely provide background information related to the present disclosure and do not necessarily constitute prior art.

关于制造误差和测量不确定性,每个制造的工件上不可避免存在几何公差。 为了确保在这些的基础上,大规模装配中仍具有零件互换性,定义了几何公差 的概念,从装配的角度指定几何公差的限制,此外,人工制品的功能要求取决 于公差累积的影响;因此,建立合理准确的公差是一项至关重要的任务,它可 以确保制造过程的功能和质量,同时优化生产成本并尊重制造工具;几何尺寸 和公差(GD&T)方案应在早期设计过程中实施,其目的是通过定义制造的几何 缺陷的局限性,确保在与公差相关的制造和检验成本方面确保足够的产品质量。With regard to manufacturing errors and measurement uncertainty, geometric tolerances inevitably exist on each manufactured workpiece. In order to ensure that parts are still interchangeable in large-scale assemblies on the basis of these, the concept of geometric tolerance is defined, and the limits of geometric tolerance are specified from the perspective of assembly. In addition, the functional requirements of artefacts depend on the effect of tolerance accumulation; Therefore, establishing reasonably accurate tolerances is a critical task that ensures the functionality and quality of the manufacturing process, while optimizing production costs and respecting the manufacturing tooling; Geometric Dimensioning and Tolerancing (GD&T) schemes should be implemented early in the design process , whose purpose is to ensure adequate product quality in terms of manufacturing and inspection costs associated with tolerances, by defining the limits of geometric defects of manufacture.

发明人发现,在大多数商用计算机辅助公差(CAT)系统中,几何公差是通 过转换理想曲面产生的,它缺乏对几何公差的机理和形式的理解,因此与国际 公差标准(即GD&T和ISO几何产品规范(GPS)标准)不一致;另外,这种近 似不能满足精确预测装配公差的需求,特别是对于高精度装配;并且不足以覆 盖整个产品生命周期中的几何公差;装配仿真是产品设计过程中最重要的问题 之一,是公差分析的基础;在设计过程中,由形状缺陷引起的这些公差可分为 形状公差、方向公差和位置公差;为了提高公差分析和综合的精度,必须考虑 上述因素并将其综合到装配仿真建模中;发明人发现,现有的装配仿真方法忽略了几何公差和接触变形的综合影响,由于在制造过程中会产生几何公差,在 组装过程中会产生接触变形,这两者都会影响组装质量;在组装过程中,两者 相互影响并影响最终组装质量。The inventors found that in most commercial computer-aided tolerancing (CAT) systems, the geometrical tolerances are produced by transforming ideal surfaces, which lacks an understanding of the mechanism and form of geometrical tolerances, and therefore is not consistent with international tolerance standards (i.e. GD&T and ISO geometry). Product Specification (GPS) standards) are inconsistent; in addition, this approximation does not meet the need to accurately predict assembly tolerances, especially for high-precision assemblies; and is not sufficient to cover geometric tolerances throughout the product life cycle; assembly simulation is an integral part of the product design process One of the most important issues is the basis of tolerance analysis; in the design process, these tolerances caused by shape defects can be divided into shape tolerance, orientation tolerance and position tolerance; in order to improve the accuracy of tolerance analysis and synthesis, the above factors must be considered And integrated it into the assembly simulation modeling; the inventors found that the existing assembly simulation method ignores the combined effects of geometric tolerance and contact deformation, due to the geometric tolerance generated in the manufacturing process, contact deformation will occur in the assembly process. , both of which affect the assembly quality; during the assembly process, the two influence each other and affect the final assembly quality.

发明内容SUMMARY OF THE INVENTION

本公开为了解决上述问题,提供一种基于蒙皮模型的精确装配仿真方法及 系统,通过考虑接触变形和几何公差对工件装配的影响,利用基于蒙皮模型的 方法,有效提高了装配仿真的精度,同时,根据装配仿真结果进行公差分析, 获得合理的几何公差,对工件生产的几何公差提供指导,有效避免工件组装过 程中产生的接触变形,提高了装配质量。In order to solve the above problems, the present disclosure provides an accurate assembly simulation method and system based on a skin model. By considering the influence of contact deformation and geometric tolerance on workpiece assembly, the skin model-based method is used to effectively improve the accuracy of assembly simulation. At the same time, the tolerance analysis is carried out according to the assembly simulation results, and reasonable geometric tolerances are obtained, which provide guidance for the geometric tolerance of workpiece production, effectively avoid the contact deformation during the assembly process of the workpiece, and improve the assembly quality.

根据本公开实施例的第一个方面,提供了一种基于蒙皮模型的精确装配仿 真方法,包括:According to a first aspect of the embodiments of the present disclosure, there is provided an accurate assembly simulation method based on a skin model, including:

采集待装配工件的结构参数;Collect the structural parameters of the workpiece to be assembled;

基于待装配工件的结构参数以及几何公差生成其蒙皮模型;Generate a skin model based on the structural parameters and geometric tolerances of the workpiece to be assembled;

定义待装配工件蒙皮模型的配合面和载荷边界条件;Define the mating surface and load boundary conditions of the skin model of the workpiece to be assembled;

将待装配工件蒙皮模型的装配等效为所述配合面位移和反作用力的计算, 并定义所述配合面之间距离目标函数及其约束条件;The assembly of the skin model of the workpiece to be assembled is equivalent to the calculation of the displacement and reaction force of the mating surfaces, and the distance objective function between the mating surfaces and its constraint conditions are defined;

对所述目标函数进行迭代计算,使配合面间的距离最小,获得装配仿真结 果。The objective function is iteratively calculated to minimize the distance between the mating surfaces, and the assembly simulation result is obtained.

根据本公开实施例的第二个方面,提供了一种基于蒙皮模型的精确装配仿 真系统,包括:According to a second aspect of the embodiments of the present disclosure, a precise assembly simulation system based on a skin model is provided, including:

模型构建模块,其用于采集待装配工件的结构参数;基于待装配工件的结 构参数以及几何公差生成其蒙皮模型;定义待装配工件蒙皮模型的配合面和载 荷边界条件;The model building module is used to collect the structural parameters of the workpiece to be assembled; generate its skin model based on the structural parameters and geometric tolerances of the workpiece to be assembled; define the mating surface and load boundary conditions of the skin model of the workpiece to be assembled;

目标函数构建模块,其用于将待装配工件蒙皮模型的装配等效为所述配合 面位移和反作用力的计算,并定义所述配合面之间距离目标函数及其约束条件;An objective function building module, which is used to equate the assembly of the skin model of the workpiece to be assembled as the calculation of the displacement and reaction force of the mating surface, and defines the distance objective function between the mating surfaces and its constraints;

装配仿真模块,其用于对所述目标函数进行迭代计算,使配合面间的距离 最小,获得装配仿真结果。An assembly simulation module is used to iteratively calculate the objective function, so as to minimize the distance between the mating surfaces and obtain assembly simulation results.

与现有技术相比,本公开的有益效果是:Compared with the prior art, the beneficial effects of the present disclosure are:

(1)本公开所述方案通过借助蒙皮模型模拟具有形状缺陷的真实零件,将 几何公差和局部接触变形考虑进装配仿真过程中,避免了利用等效的理想表面 代替配对的非理想表面,这些等效的表面可能会影响装配模拟的精度,并阻止 在轴孔装配中的应用;本公开所述方案可以认为配合面的接触是摩擦的,这与 实际情况是一致的,同时解决多零件装配的仿真问题;通过装配仿真获得合理 的几何公差,对生产厂家的工件生产的几何公差提供指导,有效避免工件组装 过程中产生的接触变形,提高了装配质量。(1) The solution described in the present disclosure avoids using an equivalent ideal surface to replace a paired non-ideal surface by simulating a real part with shape defects by means of a skin model, taking geometrical tolerances and local contact deformations into account in the assembly simulation process, These equivalent surfaces may affect the accuracy of the assembly simulation and prevent application in shaft-hole assembly; the solution described in this disclosure can consider the contact of the mating surfaces to be frictional, which is consistent with the actual situation, while solving multi-part Assembly simulation problems; reasonable geometric tolerances are obtained through assembly simulation, which provides guidance for the geometric tolerances of workpieces produced by manufacturers, effectively avoids contact deformation during workpiece assembly, and improves assembly quality.

(2)本公开所述方案所需的计算比现有的有限元方法所需的计算效率更高; 当前,有限元方法对于模拟装配体中的局部接触变形是可靠的;但是,对于Monte Carlo模拟,在有限元分析中对随机生成的蒙皮模型进行预处理是无效的。(2) The calculation required by the solution described in this disclosure is more efficient than that required by the existing finite element method; currently, the finite element method is reliable for simulating local contact deformations in assemblies; however, for Monte Carlo Simulation, preprocessing of randomly generated skinned models in finite element analysis is ineffective.

附图说明Description of drawings

构成本公开的一部分的说明书附图用来提供对本公开的进一步理解,本公 开的示意性实施例及其说明用于解释本公开,并不构成对本公开的不当限定。The accompanying drawings, which form a part of the present disclosure, are used to provide a further understanding of the present disclosure, and the exemplary embodiments of the present disclosure and their descriptions are used to explain the present disclosure and do not constitute an improper limitation of the present disclosure.

图1为本公开实施例一中所述的基于蒙皮模型形状的精确装配仿真方法流 程图;Fig. 1 is the flow chart of the accurate assembly simulation method based on the shape of the skin model described in the first embodiment of the present disclosure;

图2(a)为本公开实施例一中所述的工件初始模型示意图;Figure 2(a) is a schematic diagram of the initial model of the workpiece described in the first embodiment of the present disclosure;

图2(b)为本公开实施例一中所述的经分段处理后的工件模型示意图;FIG. 2(b) is a schematic diagram of the workpiece model described in Embodiment 1 of the present disclosure after being segmented;

图2(c)为本公开实施例一中所述的经几何公差附加处理后的工件模型示 意图;Fig. 2 (c) is the workpiece model schematic diagram after the geometrical tolerance additional processing described in the present disclosure embodiment one;

图2(d)为本公开实施例一中所述的经重组后的蒙皮模型结果示意图;FIG. 2(d) is a schematic diagram of the result of the reorganized skin model described in Embodiment 1 of the present disclosure;

图3为本公开实施例一中所述的两配合面相对位置关系示意图;3 is a schematic diagram of the relative positional relationship between two mating surfaces described in Embodiment 1 of the present disclosure;

图4(a)为本公开实施例一中所述的施加外部负载后的接触力与变形相互 作用机制示意图;Figure 4(a) is a schematic diagram of the interaction mechanism between contact force and deformation after applying an external load as described in Embodiment 1 of the present disclosure;

图4(b)为本公开实施例一中所述的施加外部负载产生新接触点后的接触 力与变形相互作用机制示意图;Figure 4(b) is a schematic diagram of the interaction mechanism between contact force and deformation after applying an external load to generate a new contact point described in Embodiment 1 of the present disclosure;

图4(c)为本公开实施例一中所述的施加另一外部负载后的接触力与变形 相互作用机制示意图;Figure 4(c) is a schematic diagram of the interaction mechanism between contact force and deformation after applying another external load as described in the first embodiment of the present disclosure;

图4(d)为本公开实施例一中所述的施加另一外部负载产生新接触点后的 接触力与变形相互作用机制示意图;4(d) is a schematic diagram of the interaction mechanism between contact force and deformation after applying another external load to generate a new contact point as described in Embodiment 1 of the present disclosure;

图5为本公开实施例一中所述的接触变形的迭代算法流程图;5 is a flowchart of the iterative algorithm for contact deformation described in Embodiment 1 of the present disclosure;

图6为本公开实施例二中所述的具体装备仿真实例示意图;FIG. 6 is a schematic diagram of a specific equipment simulation example described in Embodiment 2 of the present disclosure;

图7为是否考虑接触变形对于X分布情况的影响示意图。FIG. 7 is a schematic diagram showing whether the influence of contact deformation on the X distribution is considered.

具体实施方式Detailed ways

下面结合附图与实施例对本公开作进一步说明。The present disclosure will be further described below with reference to the accompanying drawings and embodiments.

应该指出,以下详细说明都是例示性的,旨在对本公开提供进一步的说明。 除非另有指明,本文使用的所有技术和科学术语具有与本公开所属技术领域的 普通技术人员通常理解的相同含义。It should be noted that the following detailed description is exemplary and intended to provide further explanation of the present disclosure. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs.

需要注意的是,这里所使用的术语仅是为了描述具体实施方式,而非意图 限制根据本公开的示例性实施方式。如在这里所使用的,除非上下文另外明确 指出,否则单数形式也意图包括复数形式,此外,还应当理解的是,当在本说 明书中使用术语“包含”和/或“包括”时,其指明存在特征、步骤、操作、器 件、组件和/或它们的组合。It should be noted that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to limit the exemplary embodiments according to the present disclosure. As used herein, unless the context clearly dictates otherwise, the singular is intended to include the plural as well, furthermore, it is to be understood that when the terms "comprising" and/or "including" are used in this specification, it indicates that There are features, steps, operations, devices, components and/or combinations thereof.

实施例一:Example 1:

本实施例的目的是提供一种基于蒙皮模型的精确装配仿真方法。The purpose of this embodiment is to provide an accurate assembly simulation method based on a skin model.

一种基于蒙皮模型的精确装配仿真方法,包括:An accurate assembly simulation method based on a skin model, including:

采集待装配工件的结构参数;Collect the structural parameters of the workpiece to be assembled;

基于待装配工件的结构参数以及几何公差生成其蒙皮模型;Generate a skin model based on the structural parameters and geometric tolerances of the workpiece to be assembled;

定义待装配工件蒙皮模型的配合面和载荷边界条件;Define the mating surface and load boundary conditions of the skin model of the workpiece to be assembled;

将待装配工件蒙皮模型的装配等效为所述配合面位移和反作用力的计算, 并定义所述配合面之间距离目标函数及其约束条件;The assembly of the skin model of the workpiece to be assembled is equivalent to the calculation of the displacement and reaction force of the mating surfaces, and the distance objective function between the mating surfaces and its constraint conditions are defined;

对所述目标函数进行迭代计算,使配合面间的距离最小,获得装配仿真结 果。The objective function is iteratively calculated to minimize the distance between the mating surfaces, and the assembly simulation result is obtained.

进一步的,所述结构参数包括工件尺寸、曲线参数以及纹路等常规参数;Further, the structural parameters include conventional parameters such as workpiece size, curve parameters and lines;

如图1所述展示了本公开所述的基于蒙皮模型形状的精确装配仿真方法流 程图,为了在装配仿真中结合工件的几何公差,所述几何公差根据产品设计要 求进行指定;根据形状,位置和方向公差生成零件的蒙皮模型SMS(skin model shapes);利用GeoSpelling(一种用于表达规范语义的正式语言)来识别SMS 的配合面和载荷边界条件,所述载荷边界条件包括施加力和扭矩的作用点、大 小和方向,约束的位置和方向;在几何公差方面,采用二次优化方法对基于SMS 的多体装配进行建模,并确定配合面的相对位置,如Hertz理论所解释的,接 触点承受额外的载荷并进一步变形,随后,由于接触变形,零件的相对定位将进一步移动;如果生成了新的接触点,则将使用变形的SMS和降低的负载开始 二次优化的另一迭代;平衡所有负载后,迭代停止,零件全部组装好,实现了 多个零件的精确装配仿真。As shown in FIG. 1, the flow chart of the accurate assembly simulation method based on the shape of the skin model described in the present disclosure is shown. In order to combine the geometric tolerance of the workpiece in the assembly simulation, the geometric tolerance is specified according to the product design requirements; according to the shape, Position and orientation tolerances generate SMS (skin model shapes) of the part; utilize GeoSpelling (a formal language for expressing specification semantics) to identify mating surfaces and load boundary conditions for the SMS, which include applied forces and torque, the position and direction of constraints; in terms of geometric tolerance, a quadratic optimization method is used to model SMS-based multibody assemblies, and the relative positions of mating surfaces are determined, as explained by Hertz theory , the contact point is subjected to additional load and deforms further, subsequently, the relative positioning of the part will move further due to the contact deformation; if a new contact point is generated, another step of the quadratic optimization will begin with the deformed SMS and reduced load One iteration; after all loads are balanced, the iteration stops and the parts are all assembled, realizing accurate assembly simulation of multiple parts.

本领域技术人员应当清楚,几何公差是系统偏差和随机偏差的组合,系统 偏差的特征是确定性的,可预测的和可再现的;相反,制造过程中不可预测的 波动会产生随机偏差;设计的公差可以限制几何公差,所述设计的公差由设计 的公差由设计人员根据产品设计要求指定。以控制组件的质量和功能;因此, 本公开采用待装配工件的几何公差生成SMS,所述几何公差由设计人员根据产品 设计要求指定;基于几何公差的SMS来生成具有代表性的工件表面轮廓以逼近 实际表面。It should be clear to those skilled in the art that geometric tolerance is a combination of systematic and random deviations, and the characteristics of systematic deviations are deterministic, predictable and reproducible; on the contrary, unpredictable fluctuations in the manufacturing process will produce random deviations; design The tolerance can limit the geometric tolerance, the tolerance of the design is specified by the designer according to the product design requirements. to control the quality and function of the assembly; therefore, the present disclosure uses the geometric tolerance of the workpiece to be assembled to generate the SMS, which is specified by the designer according to product design requirements; the SMS based on the geometric tolerance generates a representative workpiece surface profile to close to the actual surface.

具体的,所述蒙皮模型的生成过程具体如下:Specifically, the generation process of the skin model is as follows:

可以通过数学方法(例如二阶形状和随机场方法)或通过制造过程仿真或 零件原型测量的结果来创建用于几何公差建模的SMS;本实施例中采用零件原型 测量的结果来进行蒙皮模型的创建,并且需要确保等效的蒙皮模型表面与指定 的公差一致,所述指定的公差由设计人员根据产品设计要求指定;所述蒙皮模型 的生成,首先需要对工件结构进行分割,以独立地处理每个表面;每个表面均 附有根据设计公差产生的几何公差;不同的公差会限制不同种类的几何特征, 例如形状公差会限制固有特征,而方向公差和位置公差会限制情况特征;在蒙 皮模型构建中,当模拟几何公差时,会将它们合并添加到原始标称模型中;所 述蒙皮模型的构件经过三个步骤:分段、几何公差附加和重组;如图2所示, 将生成具有指定公差的蒙皮模型;图2中所述的SMS的不平坦度已按比例缩放 以轻松查看几何公差,其他的建模问题-非连接,面连接,钝角和锐二面角的定 义以及网格尺寸和偏差大小的定义属于本领域技术人员所公知的,故此处不再 赘述。The SMS for geometric tolerance modeling can be created through mathematical methods (such as second-order shape and random field methods) or through the results of manufacturing process simulations or part prototype measurements; the results of part prototype measurements are used in this example for skinning The creation of the model, and it is necessary to ensure that the surface of the equivalent skin model is consistent with the specified tolerance, and the specified tolerance is specified by the designer according to the product design requirements; the generation of the skin model requires first segmentation of the workpiece structure, To treat each surface independently; each surface is accompanied by geometric tolerances based on design tolerances; different tolerances limit different kinds of geometric features, for example, shape tolerances limit intrinsic features, while orientation and position tolerances limit situations features; in the construction of the skinned model, when geometric tolerances are simulated, they are merged and added to the original nominal model; the components of the skinned model go through three steps: segmentation, geometric tolerance addition, and reorganization; as shown in the figure 2 will generate a skinned model with specified tolerances; the unevenness of the SMS described in Figure 2 has been scaled for easy viewing of geometric tolerances, other modeling issues - non-joining, face-joining, obtuse and sharp The definition of the dihedral angle, and the definition of the mesh size and the deviation size are well known to those skilled in the art, so they will not be repeated here.

进一步的,所述装配仿真方法将SMS的装配等效于为所述配合面位移和反 作用力的计算,并定义所述配合面之间距离的目标函数及其约束条件,具体包 括如下步骤:Further, described assembly simulation method is equivalent to the assembly of SMS for the calculation of described mating surface displacement and reaction force, and defines the objective function and constraint condition of the distance between described mating surfaces, specifically comprises the steps:

在配合面上,接触变形和相对位置相互依赖,接触点由配合面的相对位置 决定;然而,配合表面的相对位置随着接触变形而变化,为了加快相对位置的 求解速度,假定SMS是刚性的,小位移扭转理论(SDT)用于刚体位移理论用于 计算两个皮肤表面之间的初始接触点;在SDT理论中,以中心点表示的表面位 移如下:On the mating surface, the contact deformation and the relative position are interdependent, and the contact point is determined by the relative position of the mating surface; however, the relative position of the mating surface changes with the contact deformation. In order to speed up the solution of the relative position, the SMS is assumed to be rigid , Small Displacement Torsion Theory (SDT) is used in rigid body displacement theory to calculate the initial point of contact between two skin surfaces; in SDT theory, the surface displacement expressed as a center point is as follows:

SDT=[r t]T=[α β γ u v w]T (1)SDT = [rt] T = [α β γ uvw] T (1)

其中r和t分别是刚体的旋转和平移,r分别包含围绕x,y和z方向的三 个旋转角度α,β和γ;u,v和w分别是沿x,y和z方向的平移;where r and t are the rotation and translation of the rigid body, respectively, r contains three rotation angles α, β and γ around the x, y and z directions, respectively; u, v and w are the translations along the x, y and z directions, respectively;

在公差设计领域,位移通常很小,并且通常线性化,对于离散表面Sj的任 何法线向量nj,i,在刚体位移之后,其方向将发生如下变化:In the field of tolerance design, the displacements are usually small and usually linearized, for any normal vector n j,i of the discrete surface S j , after rigid body displacement, its orientation will change as follows:

n′j,i=nj,i-nj,i×rj (2) 配合面之间的距离是解决初始接触点的基本约束;对于表面Sj上的顶点Aj,i,它 沿着该线段的法线方向(nj+1,i)投影到Sj+1上最接近的投影Aj+1,i,如图3所示,Sj,i和Aj+1,i之间的距离dj,i可以表示为:n′ j,i =n j,i -n j,i ×r j (2) The distance between mating surfaces is the basic constraint for solving the initial contact point; for the vertex A j,i on the surface S j , it is along the Projection to the closest projection A j+1,i on S j+1 along the normal direction (n j+1,i ) of the line segment, as shown in Figure 3, S j,i and A j+1,i The distance d j,i between can be expressed as:

Figure BDA0002598746300000071
Figure BDA0002598746300000071

位移后的距离d′j,i为:The distance d' j, i after displacement is:

Figure BDA0002598746300000072
Figure BDA0002598746300000072

忽略二阶项后,将所述位移的距离d'j,i进行线性化,线性化的结果如下所示:After ignoring the second-order term, the distance d' j,i of the displacement is linearized, and the linearization result is as follows:

Figure BDA0002598746300000073
Figure BDA0002598746300000073

其中Cj和Cj+1分别是Sj和Sj+1的中心点;where C j and C j+1 are the center points of S j and S j+1 , respectively;

因此,对于整个工件,所述距离约束可以按矩阵形式重新组织如下:Therefore, for the entire workpiece, the distance constraints can be reorganized in matrix form as follows:

d′=A·SDTs+d (6)d′=A·SDTs+d (6)

由于采用了刚体位移理论,保证了配合面之间不会发生互穿,因此,d'j,i应该大于或等于零。Since the rigid body displacement theory is adopted, it is ensured that no interpenetration occurs between the mating surfaces. Therefore, d' j,i should be greater than or equal to zero.

进一步的,所述平衡约束的确定,具体包括:Further, the determination of the balance constraint specifically includes:

对于每个SMS,接触点负责承受内部和外部负载;在组装过程中,应平衡外 力F,外扭矩T和内力或支撑反作用力R,并且平衡约束可以表示为:For each SMS, the contact point is responsible for bearing internal and external loads; during assembly, the external force F, external torque T and internal force or support reaction force R should be balanced, and the balance constraint can be expressed as:

Figure BDA0002598746300000074
Figure BDA0002598746300000074

其中,j表示不同的待装配表面表面,i为表面j上不同的离散点,k为表 面j施加力的序号,q为表面j上施加扭矩的序号,Lj,i是力点与物体中心之间 的距离,以前的大多数研究都是基于无摩擦,非粘合剂接触的假设;但是,摩 擦力极大地影响了装配模拟的精度,也可以通过选择小于μRj,i(μ为摩擦系数) 和接触点切线方向的值,使用方程式(7)对其进行建模;作为另一个约束,d′j,i的值应大于或等于零,另外,如果距离d′j,i大于零,则反作用力Rj,i的值相应地 为零;如果Rj,i大于零,则d′j,i=0;因此,所述距离约束与平衡约束的组合约束可 以表示为:Among them, j represents different surfaces to be assembled, i is different discrete points on surface j, k is the serial number of the applied force on surface j, q is the serial number of applied torque on surface j, and L j,i is the difference between the force point and the center of the object The distance between the ) and the value of the tangent direction of the contact point, which is modeled using equation (7); as another constraint, the value of d' j,i should be greater than or equal to zero, and if the distance d' j,i is greater than zero, then The value of the reaction force R j,i is correspondingly zero; if R j,i is greater than zero, then d′ j,i =0; therefore, the combined constraint of the distance constraint and the equilibrium constraint can be expressed as:

RTd′=0 (8)R T d′=0 (8)

此后,SMS的组装模拟等效于找到位移SDT和反作用力R,该位移SDT和反 作用力R使配合面之间的距离最小并满足上述约束,如下所示:After that, the assembly simulation of the SMS is equivalent to finding the displacement SDT and the reaction force R that minimize the distance between the mating surfaces and satisfy the above constraints, as follows:

Figure BDA0002598746300000081
Figure BDA0002598746300000081

此外,问题以矩阵形式的二次目标和二次约束进行重组,即Furthermore, the problem is restructured with quadratic objectives and quadratic constraints in matrix form, i.e.

Figure BDA0002598746300000082
Figure BDA0002598746300000082

Figure BDA0002598746300000083
Figure BDA0002598746300000083

上述问题可以通过二次优化算法来解决,为了加快求解速度,本实施例采 用计算二次物镜的Hessian函数来进行求解。The above problem can be solved by a quadratic optimization algorithm. In order to speed up the solution speed, the present embodiment adopts the Hessian function of calculating the secondary objective lens to solve.

进一步的,由于随着装配负荷的增加,局部接触变形对叠层偏差的影响不 可忽略,由于外部载荷在配合面上引起的接触变形在拓扑上显示出变化,因此, 确定局部接触变形对装配偏差的影响至关重要;Further, since the influence of local contact deformation on the lamination deviation is not negligible with the increase of assembly load, and the contact deformation caused by external load on the mating surface shows topological changes, therefore, it is determined that the effect of local contact deformation on the assembly deviation is impact is crucial;

随着施加的外部负载,如图4a所示,两个接触点之间的反作用力R1 j,i产生 的变形Δ1 j,i和Δ1 j+1,i可能会生成如图4b所示的另一个接触点。由于防止了新产 生的接触点,所以仅允许小得多的Δ1'j,i偏离。则Δ1'j,i和Δ1'j+1,i的允许总和应为 d1 min,d1 min也是配合表面的最小距离,除了接触点上的零距离外,即当施加外部 负载时,如图4a所示,在接触点之间由反作用力R1 j,i产生的变形Δ1 j,i和Δ1 j+1,i可能会生成其他接触点,如图4b所示。由于来自新产生的接触点的阻力,仅允 许小得多的Δ1'j,i变形。Δ1'j,i和Δ1'j+1,i的允许总和应为d1 min,d1 min也是接触面的最 小距离,接触点的距离为零,即With the applied external load, as shown in Fig. 4a, the deformations Δ 1 j,i and Δ 1 j+1, i generated by the reaction force R 1 j,i between the two contact points may generate as shown in Fig. 4b another point of contact shown. Since new contact points are prevented, only much smaller deviations of Δ 1 ' j,i are allowed. Then the allowable sum of Δ 1 ' j,i and Δ 1 ' j+1,i shall be d 1 min , which is also the minimum distance from the mating surface, except for the zero distance on the contact point, i.e. when an external load is applied , as shown in Fig. 4a, the deformations Δ 1 j,i and Δ 1 j+1,i caused by the reaction force R 1 j,i between the contact points may generate other contact points, as shown in Fig. 4b. Due to the resistance from the newly created contact point, only a much smaller Δ 1 ' j,i deformation is allowed. The allowable sum of Δ 1 ' j,i and Δ 1 ' j+1,i should be d 1 min , d 1 min is also the minimum distance of the contact surface, and the distance of the contact point is zero, namely

Figure BDA0002598746300000091
Figure BDA0002598746300000091

接触变形取决于反作用力。相应地,反作用力

Figure RE-GDA0002652663880000099
减小到R1'j,i,这不满足载 荷边界约束;反作用力与接触变形之间的下一轮相互作用是从不平衡的外力
Figure RE-GDA0002652663880000092
开始的,如图4c所示。新发现的接触点将在第二次迭代中变形(图4d中所示)。The contact deformation depends on the reaction force. Correspondingly, the reaction force
Figure RE-GDA0002652663880000099
reduced to R 1 ' j,i , which does not satisfy the load boundary constraint; the next round of interaction between the reaction force and the contact deformation is the external force from the unbalanced
Figure RE-GDA0002652663880000092
started, as shown in Figure 4c. The newly discovered contact points will be deformed in the second iteration (shown in Fig. 4d).

在研究反作用力与接触变形之间的相关性的基础上,我们提出了一种迭代 方法来评估组装的具有接触变形的SMS的相对位置,如图5所示。它可用于确 定每个点的位移在非理想表面上引起的局部表面变形。通常,评估弹性接触问 题的基本理论是赫兹理论。基于赫兹理论,第r次迭代中单个接触点的弹性变 形

Figure BDA0002598746300000092
可以计算如下:Based on the study of the correlation between the reaction force and the contact deformation, we propose an iterative method to evaluate the relative position of the assembled SMS with contact deformation, as shown in Fig. 5. It can be used to determine the local surface deformation on non-ideal surfaces caused by the displacement of each point. Usually, the basic theory for evaluating elastic contact problems is Hertzian theory. Elastic deformation of a single contact point in the rth iteration based on Hertz theory
Figure BDA0002598746300000092
It can be calculated as follows:

Figure BDA0002598746300000093
Figure BDA0002598746300000093

其中,Rr j,i和ρr j,i分别是表面接触点上的反作用力和平均曲率,Ej是Sj的弹 性模量。由于Rr j+1,i等于Rr j,i,因此可以使用公式(12)将Δr'j+1,i替换为Δr'j,i,然 后where R r j,i and ρ r j,i are the reaction force and average curvature at the surface contact points, respectively, and E j is the elastic modulus of S j . Since R r j+1,i is equal to R r j,i , Δ r ' j+1,i can be replaced by Δ r ' j,i using equation (12), then

Figure BDA0002598746300000094
Figure BDA0002598746300000094

如果配合表面具有相同的材料性能,则可以将式(13)简化如下:If the mating surfaces have the same material properties, equation (13) can be simplified as follows:

Figure BDA0002598746300000095
Figure BDA0002598746300000095

其中,Δr'j,i是第r次迭代中接触点的临时位移。经过一轮迭代后,SMS随之 变形。在这种情况下,仅外力Fr j,k的一部分被减小的反作用力R'j,i平衡。对于变 形的SMS,将不平衡的力和扭矩作为负载边界约束导入到下一个迭代中。此步骤 的图在图5中以灰色突出显示,随后开始下一轮二次优化,迭代过程将继续进 行,直到所有外力和扭矩平衡为止。where Δ r ' j,i is the temporary displacement of the contact point in the rth iteration. After one iteration, the SMS morphs with it. In this case, only a part of the external force F r j,k is balanced by the reduced reaction force R' j,i . For deformed SMS, unbalanced forces and torques are imported into the next iteration as load boundary constraints. The graph of this step is highlighted in grey in Figure 5, after which the next round of secondary optimization begins, and the iterative process continues until all external forces and torques are balanced.

实施例二:Embodiment 2:

本实施例的目的是提供一种基于蒙皮模型的精确装配仿真系统。The purpose of this embodiment is to provide an accurate assembly simulation system based on a skin model.

一种基于蒙皮模型的精确装配仿真系统,包括:An accurate assembly simulation system based on a skin model, including:

模型构建模块,其用于采集待装配工件的结构参数;基于待装配工件的结 构参数以及几何公差生成其蒙皮模型;定义待装配工件蒙皮模型的配合面和载 荷边界条件;The model building module is used to collect the structural parameters of the workpiece to be assembled; generate its skin model based on the structural parameters and geometric tolerances of the workpiece to be assembled; define the mating surface and load boundary conditions of the skin model of the workpiece to be assembled;

目标函数构建模块,其用于将待装配工件蒙皮模型的装配等效为所述配合 面位移和反作用力的计算,并定义所述配合面之间距离目标函数及其约束条件;An objective function building module, which is used to equate the assembly of the skin model of the workpiece to be assembled as the calculation of the displacement and reaction force of the mating surface, and defines the distance objective function between the mating surfaces and its constraints;

装配仿真模块,其用于对所述目标函数进行迭代计算,使配合面间的距离 最小,获得装配仿真结果。An assembly simulation module is used to iteratively calculate the objective function, so as to minimize the distance between the mating surfaces and obtain assembly simulation results.

实施例三:Embodiment three:

本实施例的目的是提供一种基于蒙皮模型的公差分析方法。The purpose of this embodiment is to provide a skin model-based tolerance analysis method.

一种基于蒙皮模型的公差分析方法,所述公差分析方法采用了上述的基于 蒙皮模型的精确装配仿真方法,通过多次重复所述精确装配仿真方法,根据装 配偏差分布情况进行公差分析,利用所述装配偏差分布情况对工件进行公差分 析,进而对工件生产过程提供精确的几何公差的指导,提高工件装配质量。A skin model-based tolerance analysis method, the tolerance analysis method adopts the above-mentioned skin model-based precise assembly simulation method, and the tolerance analysis is performed according to the assembly deviation distribution by repeating the precise assembly simulation method many times, The tolerance analysis of the workpiece is carried out by using the assembly deviation distribution, thereby providing accurate geometric tolerance guidance for the workpiece production process and improving the assembly quality of the workpiece.

具体的,本实施例中采用蒙特卡洛模拟,用于显示几何公差和局部接触变 形如何影响功能要求X的值,最终目的是比较变形的配合表面和未变形的表面 的累积装配偏差;通过进行基于蒙特卡洛模拟的公差分析,以显示几何公差和 局部接触变形对装配偏差的影响;一种模拟仅考虑几何公差的影响,另一种模 拟考虑两种偏差的影响;如图6展示了一种名为RGB的组件的装配仿真实例, 所述RGB组件由三个平面部分组成,配合面的公差为0.3毫米;在面Gr和B8 之间定义了功能要求(X=100±1.50mm),并进行了1000次仿真;其中,所述功 能要求即装配偏差。Specifically, Monte Carlo simulation is used in this embodiment to show how geometric tolerances and local contact deformation affect the value of the functional requirement X. The ultimate goal is to compare the cumulative assembly deviation of the deformed mating surface and the undeformed surface; Tolerance analysis based on Monte Carlo simulation to show the effect of geometric tolerance and local contact deformation on assembly deviation; one simulation only considers the effect of geometric tolerance, and the other simulation considers the effect of both deviations; Figure 6 shows a An assembly simulation example of a component named RGB, the RGB component consists of three plane parts, and the tolerance of the mating surface is 0.3 mm; the functional requirements (X=100±1.50mm) are defined between the surfaces Gr and B8, And 1000 simulations were carried out; wherein, the functional requirement was assembly deviation.

如图7所述,展示了来自1000个模拟的X的分布,使用初始公差值(tp=0.3mm 和tf=0.3mm)并考虑零件变形的公差分析表明X满足功能要求;为了显示接触 变形的影响,在相同的1000次模拟运行中计算了X的分布而没有接触变形,如 图7所示,接触变形对X表现出相当大的影响,这表明在此示例中接触变形的 影响不可忽略;但是,配合面由于装配力而变平,因此可以将公差值定义为比 传统方法定义范围更大的范围,这也保证了X满足功能要求;而且,较大的公 差可以大大降低制造成本;特别地,对于由大量零部件组成的装配体,基于装 配仿真的装配偏差分析无疑将更加重要。此外,在1000次蒙特卡洛模拟中,考虑接触变形的每次运行的平均时间消耗为90s,与FEM相比,本公开所述方案具 有较高的执行效率。As shown in Figure 7, the distribution of X from 1000 simulations is shown, and a tolerance analysis using initial tolerance values (tp=0.3mm and tf=0.3mm) and taking part deformation into account shows that X meets the functional requirements; in order to show the contact deformation , the distribution of X was calculated in the same 1000 simulation runs without contact deformation, as shown in Fig. 7, the contact deformation exhibited a considerable effect on X, indicating that the influence of contact deformation is not negligible in this example ; However, the mating surface is flattened due to the assembly force, so the tolerance value can be defined to a wider range than that defined by the traditional method, which also ensures that X meets the functional requirements; moreover, the larger tolerance can greatly reduce the manufacturing cost ; In particular, for assemblies composed of a large number of components, assembly deviation analysis based on assembly simulation will undoubtedly be more important. In addition, in 1000 Monte Carlo simulations, the average time consumption of each run considering contact deformation is 90s, and the scheme described in the present disclosure has higher execution efficiency compared to FEM.

上述实施例提供的一种基于蒙皮模型的精确装配仿真方法及系统,完全可 以实现,具有广阔应用前景。The precise assembly simulation method and system based on the skin model provided by the above embodiments are completely achievable and have broad application prospects.

以上所述仅为本公开的优选实施例而已,并不用于限制本公开,对于本领 域的技术人员来说,本公开可以有各种更改和变化。凡在本公开的精神和原则 之内,所作的任何修改、等同替换、改进等,均应包含在本公开的保护范围之 内。The above descriptions are only preferred embodiments of the present disclosure, and are not intended to limit the present disclosure. For those skilled in the art, the present disclosure may have various modifications and changes. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present disclosure should be included within the protection scope of the present disclosure.

上述虽然结合附图对本公开的具体实施方式进行了描述,但并非对本公开 保护范围的限制,所属领域技术人员应该明白,在本公开的技术方案的基础上, 本领域技术人员不需要付出创造性劳动即可做出的各种修改或变形仍在本公开 的保护范围以内。Although the specific embodiments of the present disclosure are described above in conjunction with the accompanying drawings, they do not limit the protection scope of the present disclosure. Those skilled in the art should understand that on the basis of the technical solutions of the present disclosure, those skilled in the art do not need to pay creative efforts. Various modifications or variations that can be made are still within the protection scope of the present disclosure.

Claims (10)

1.一种基于蒙皮模型的精确装配仿真方法,其特征在于,包括:1. an accurate assembly simulation method based on skin model, is characterized in that, comprises: 采集待装配工件的结构参数;Collect the structural parameters of the workpiece to be assembled; 基于待装配工件的结构参数以及几何公差生成其蒙皮模型;Generate a skin model based on the structural parameters and geometric tolerances of the workpiece to be assembled; 定义待装配工件蒙皮模型的配合面和载荷边界条件;Define the mating surface and load boundary conditions of the skin model of the workpiece to be assembled; 将待装配工件蒙皮模型的装配等效为所述配合面位移和反作用力的计算,并定义所述配合面之间距离目标函数及其约束条件;The assembly of the skin model of the workpiece to be assembled is equivalent to the calculation of the displacement and reaction force of the mating surfaces, and the distance objective function between the mating surfaces and its constraint conditions are defined; 对所述目标函数进行迭代计算,使配合面间的距离最小,获得装配仿真结果。The objective function is iteratively calculated to minimize the distance between the mating surfaces, and an assembly simulation result is obtained. 2.如权利要求1所述的一种基于蒙皮模型的精确装配仿真方法,其特征在于,所述蒙皮模型的生成经过分段、几何公差附加和重组来实现。2 . The method for accurate assembly simulation based on a skin model according to claim 1 , wherein the skin model is generated through segmentation, geometric tolerance addition and reorganization. 3 . 3.如权利要求2所述的一种基于蒙皮模型的精确装配仿真方法,其特征在于,所述分段是将创建好的工件模型分割成独立的表面进行分别处理,所述几何公差附件是对每个表面附加指定公差所产生的几何公差,所述重组是将分割的表面按照原始模型的位置关系进行重新组合。3. An accurate assembly simulation method based on a skin model according to claim 2, characterized in that, the segmentation is to divide the created workpiece model into independent surfaces for separate processing, and the geometric tolerance is attached. It is the geometric tolerance generated by adding a specified tolerance to each surface, and the reorganization is to recombine the divided surfaces according to the positional relationship of the original model. 4.如权利要求1所述的一种基于蒙皮模型的精确装配仿真方法,其特征在于,所述约束条件包括距离约束和平衡约束。4. An accurate assembly simulation method based on a skin model according to claim 1, wherein the constraints include distance constraints and balance constraints. 5.如权利要求4所述的一种基于蒙皮模型的精确装配仿真方法,其特征在于,所述距离约束需要利用到接触点,所述接触点由待装配工件蒙皮模型的配合面的相对位置决定,所述接触点是解决所述配合面之间距离的基本条件。5. An accurate assembly simulation method based on a skin model according to claim 4, characterized in that, the distance constraint needs to use a contact point, and the contact point is determined by the matching surface of the skin model of the workpiece to be assembled. The relative position is determined, and the contact point is the basic condition for solving the distance between the mating surfaces. 6.如权利要求1所述的一种基于蒙皮模型的精确装配仿真方法,其特征在于,所述配合面的相对位置随着接触变形而变化,为了加快相对位置的求解速度,需要假定蒙皮模型属于刚性变形,所述接触点通过小位移扭转理论SDT来进行计算。6. An accurate assembly simulation method based on a skin model according to claim 1, wherein the relative position of the mating surface changes with the contact deformation. In order to speed up the solution speed of the relative position, it is necessary to assume that the The skin model is a rigid deformation, and the contact points are calculated by the small displacement torsion theory SDT. 7.如权利要求1所述的一种基于蒙皮模型的精确装配仿真方法,其特征在于,对于每个待装配工件蒙皮模型,其接触点负责承受内部和外部负载,所以,在组装过程中,应平衡外力F、外扭矩T以及支撑反作用力R,所述平衡约束表示为:7. A kind of accurate assembly simulation method based on skin model as claimed in claim 1 is characterized in that, for each to-be-assembled workpiece skin model, its contact point is responsible for bearing internal and external loads, so, in the assembly process , the external force F, external torque T and support reaction force R should be balanced, and the balance constraint is expressed as:
Figure FDA0002598746290000021
Figure FDA0002598746290000021
其中,j表示不同的待装配表面表面,i为表面j上不同的离散点,k为表面j施加力的序号,q为表面j上施加扭矩的序号,Lj,i是力点与物体中心之间的距离。Among them, j represents different surfaces to be assembled, i is different discrete points on surface j, k is the serial number of the applied force on surface j, q is the serial number of applied torque on surface j, and L j,i is the difference between the force point and the center of the object distance between.
8.如权利要求1-7任一项所述的基于蒙皮模型的精确装配仿真方法,其特征在于,采用所述基于蒙皮模型的精确装配仿真方法进行若干次装配仿真,获得装配偏差分布情况,利用所述装配偏差分布情况对工件进行公差分析,进而对工件生产过程提供精确的几何公差的指导,提高工件装配质量。8. The skin model-based precise assembly simulation method according to any one of claims 1 to 7, wherein the skin model-based precise assembly simulation method is used to perform several assembly simulations to obtain assembly deviation distribution According to the assembly deviation distribution, the tolerance analysis of the workpiece is carried out, so as to provide accurate geometric tolerance guidance for the workpiece production process and improve the assembly quality of the workpiece. 9.一种基于蒙皮模型的精确装配仿真系统,其特征在于,包括:9. An accurate assembly simulation system based on a skin model, characterized in that, comprising: 模型构建模块,其用于采集待装配工件的结构参数;基于待装配工件的结构参数以及几何公差生成其蒙皮模型;定义待装配工件蒙皮模型的配合面和载荷边界条件;The model building module is used to collect the structural parameters of the workpiece to be assembled; generate its skin model based on the structural parameters and geometric tolerances of the workpiece to be assembled; define the mating surface and load boundary conditions of the skin model of the workpiece to be assembled; 目标函数构建模块,其用于将待装配工件蒙皮模型的装配等效为所述配合面位移和反作用力的计算,并定义所述配合面之间距离目标函数及其约束条件;an objective function building module, which is used to equate the assembly of the skin model of the workpiece to be assembled as the calculation of the displacement and reaction force of the mating surfaces, and define the distance objective function between the mating surfaces and its constraints; 装配仿真模块,其用于对所述目标函数进行迭代计算,使配合面间的距离最小,获得装配仿真结果。The assembly simulation module is used for iterative calculation of the objective function, so as to minimize the distance between the mating surfaces and obtain the assembly simulation result. 10.如权利要求9所述的一种基于蒙皮模型的精确装配仿真系统,其特征在于,所述蒙皮模型的生成经过分段、几何公差附加和重组来实现。10 . The precise assembly simulation system based on a skin model according to claim 9 , wherein the skin model is generated through segmentation, geometric tolerance addition and reorganization. 11 .
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