针对未来信息化战争条件下航天复杂装备维修保障面临的型号种类多、模块可视化程度低、战时保障前后端衔接不足、人员训练量化评估考核手段缺乏、维修大数据难以挖掘和复用等瓶颈问题,以典型武器装备为对象,提出一种基于增强现实技术、数字孪生内核驱动的维修保障与人员训练系统框架,阐述了数字孪生模型构建、故障在线诊断、维修流程诱导、人员动态评估等关键环节的技术途径,论述了航天复杂装备辅助维修系统的开发与集成要点并展示了原型系统,为实现靠前保障、快速保障提供了可行的技术路径.

机器可读标准是当前国内外标准数字化转型的发展方向和研究重点.本文从机器可读标准的基本概念出发,阐述机器可读标准的基本定义和发展阶段,提出机器可读标准在航天智能制造中的应用方法,最后以运载火箭焊缝质量智能判读为对象打通机器可读标准的建模、转化以及应用全链路,初步实现了焊缝缺陷判读标准由单纯的文本阅览向知识驱动工业场景的模式转变,为机器可读标准在航天领域的应用提供指导.

机器人原位测量是当前航天大型构件制造重要的发展趋势,针对大型金属构件机器人原位测量面临的非朗伯表面光学测量和弱几何微纹理表面点云匹配两大技术挑战,本文提出了一种基于光度-面结构光多传感器融合的高精度测量方法.该方法将一定数量的LED光源添加到传统条纹投影测量装置中,实现对高亮反射表面的高精度法向量估计,并将表面法向量信息与条纹投影测量的点云信息进行融合,同时设计多模态几何特征描述子提高点云匹配精度,实现测量精度的整体优化.该方法用于贮箱壁板面型测量,实验结果验证了其有效性.

针对导弹舱段对接主要依靠手工作业的现状,设计一种六自由度并联调姿托架,可完成舱段偏航、俯仰、自转全姿态位置调整,实现舱段自动化、高效率对接.首先建立调姿托架的三维模型并对其结构进行介绍;其次对模型进行运动学理论分析,得到了自由度、运动学方程及其正反解,并利用ADAMS软件对调姿托架进行运动学仿真,获得自由度计算结果以及相关位姿曲线,验证了理论分析结果;最后对研制的调姿托架进行了实验验证,结果证明了调姿平台设计的合理性.

针对新形势下航天飞行器关重件机加车间日益显现的工艺优化周期长、资源配置效率低、质量保证手段单一等瓶颈问题,引入数字孪生(Digital twin)的理念、手段、工具和方法,结合机加车间的生产运行特点,提出了基于数字孪生技术的航天关重件机加车间集成框架;阐述了孪生环境、映射枢纽以及使能平台等核心功能要素的内涵;论述了通过孪生数据实现加工工艺优化、混流排产与调度以及质量诊断、预测与控制的技术途径;讨论了机加车间孪生系统的开发与集成要点,从而实现车间动态迭代优化与高效协同管控的目标.

针对目前航天制造车间生产管控中存在的效率低、精细度差、动态响应能力不足等难题,研究了基于数字孪生的制造车间生产管控方法,设计了基于跨网段信息异步交互的航天数字孪生车间架构,提出了航天数字孪生车间的基本组成和虚实融合的制造车间分层管控模式,阐述了面向不同对象的制造智能(MI)和商业智能(BI)场景应用,为军工企业车间生产管控提供了可行的技术途径.

针对数控机床可靠性评估依赖于寿命分布模型和试验信息(或者实际使用数据),且数控装备日益复杂,零部件、子系统繁多,难以准确评价数控装备可靠性,提出一种面向性能退化的数控装备服役可靠性评估方法.该方法首先通过Lloyd算法将性能退化数据矢量化,进而通过隐马尔科夫模型和查普曼-柯尔莫哥洛夫方程(Chapman-Kolmogorov,C-K)微分方程,实现利用离散数据对连续性能退化过程的建模,最终实现对数控装备服役可靠性的评估.将所提方法应用于某型铣床和滚柱直线导轨副的服役可靠性评估,评估结果更精确.通过验证可以得出该方法的可行性和有效性,可以广泛应用于数控装备服役可靠性评估.

针对国内航天器舱段对接主要采用“手工装配”模式难以满足日益增长的产量需求的现状,提出了一种新型航天器舱段对接模式,基于TwinCAT研究设计了舱段数字化柔性自动对接平台的控制系统,控制系统关联融合了多自由度调姿、数字化测量、柔性装配等先进技术.介绍了平台机构与测量系统,解析了控制系统架构,设计了对接控制流程,应用TwinCAT的电子凸轮等运动控制模块、ST语言和顺序功能图等实现了对舱段对接过程的编程并且通过EtherCAT总线实时控制电动机和平台,基于力控组态软件设计上位机界面.最后通过实验验证了控制系统的可行性,减少了人工劳动力,有效提高了航天器舱段对接的效率,足以满足未来航天器型号任务的需求.

激光直接标识技术以其标识符号和标识对象一体化,且成本低、安全可靠等优点成为零件生产过程唯一标识的主要手段之一,通过激光直接标识技术的应用能够对航天产品研制过程中的制造信息进行全面追踪、集成、管理,为航天产品生产过程精细化管控和质量问题快速追溯提供一种有效手段.

During the automatic docking of cylindrical workpieces, it may be necessary to measure the orientation of workpieces accurately without targets.For this reason, aprecision scanning method without targets was utilized.The point cloud data was obtained by a laser profile sensor, and the postures were determined by a comprehensive method.Based on Monte-Carlo simulation, the accuracies of the axis fitting method and bus section fitting method were compared, and a new comprehensive method was proposed further.In this study, the pitch angle was obtained by the axis fitting method, the deflection angle was obtained by the bus section fitting method, and the measurement accuracy was significantly improved.In addition, to balance the accuracy and efficiency, the relationship among the number of intercepted ellipses, the number of contour points on each ellipse, and the precisionwere discussed.Finally, aprototype experiment was conducted to prove the validity and accuracy of the comprehensive method.It is proved that the absolute accuracy of the axis attitude is better than0.02°, and the standard deviation is less than 0.01°.

The digital workshop is the key basement of fulfillment of intelligent manufacturing for aerospace manufacturing enterprises.In order to realize the independent decision-making and self-organizing of the workshop,the equipment interconnection,automatic perception,virtual monitoring and real-time analysis have received considerable attention in industry.This research is originated from the China's first construction project of digital workshop in aerospace industry.Based on virtual reality (VR) technology and the information communications technology (ICT),the real-time data acquisition and management from workshop floor,the modeling of production resources schedule and human-machine interactive information visualization with 3D / 2D interface are developed.Integrated with MES,the production operation monitoring and evaluation platform driven by real-time data from workshop floor is realized to achieve transparent production,so as to improve the level of production operation management.

针对航天产品目前主流多轴多激励随机振动环境试验的跟踪精度与控制稳定性不佳问题,对基于驱动谱耦合修正优化的算法进行了研究.根据多轴随机试验的振动控制原理与方法,提出用比例均方根迭代修正与系统频响特性更新均衡调控的方式提高试验控制系统驱动谱的跟踪精度,给出了相应的控制策略:根据参考谱中各控制谱的相干系数选择修正方法,相干系数小于0.95时,用更新系统频响矩阵的方法实现对驱动谱的修正;相干系数大于0.95时,用修正参考谱下三角矩阵的方法实现对驱动信号的修正,以此不断减小控制偏差.两点两激励的仿真控制结果表明:各控制点自谱控制效果好,满足工程要求.建立两振动台对细长条试件进行振动试验,结果表明控制响应自功率谱和动态范围均满足工程试验要求.

Objective To evaluate the operational reliability of a certain type of aerospace turning-assembly-welding composite machining equipment in the operational process.Methods At first, common failure modes of the equipment were studied and its failure data was obtained during operational process. Then, the reliability evaluation model of the turning-assembly-welding composite machining equipment using the Bayesian method was proposed with small-sized sample failure data. The complex problem on Posterior integration in Bayesian theory was solved by the Markov Chain Monte Carlo (MCMC) theory.Results The lifetime Weibull distribution of turning-assembly-welding composite machin-ing equipment was determined. Furthermore, the mean time between failures (MTBF) of turning-assembly-welding com-posite machining equipment was calculated based on the Bayesian method.Conclusion The evaluation result is slightly lower than that of the design. The main reason is that more failure data appeared in the early operational process. The failure rate will decrease and the MTBF will increase in the stable operational process. So the MTBF of the machining equipment basically meets the design requirement.

The invention relates to the technical field of welding processes of large thin-walled cylindrical parts and provides a real-time adjustment system for welding seams of circular-seam friction stir welding of cylinder sections. The system comprises a 2D laser ray sensor, a measuring data acquisition and analysis module, a real-time adjustment module, a servo control unit, a feeding transmission unit and a welding execution mechanism adjustment platform. The invention further discloses a real-time adjustment method for the welding seams. According to the system and the method, a real-time scanned outline image of a butt-joint circular seam of the cylinder sections is used as input of the whole system, the coordinate position of a welding stir head is adjusted in real time according to micro-deformation of an actual welding seam track, and therefore the track of the stir head coincides with the central position of an actual workpiece butt-joint seam, and the requirement for friction stir welding seam tracking of the large thin-walled cylinder sections of aerospace products is met.

The intelligent production system of aerospace large thin-walled structure parts is studied with the launch vehicle structure as the production object. By designing the overall scheme and defining the key elements of the rocket structure intelligent production, the intelligent manufacturing production mode of large thin-walled structure parts and the feasible way to realize the intelligent production are explored in order to improve the product quality and production efficiency.