机械产品装配偏差分析方法研究进展与展望

doi:10.3901/JME.2023.09.212

摘要/Abstract

摘要： 机械产品装配是制造过程的最终阶段,装配质量对机械产品的服役性能和可靠性有直接影响。建立合理的数学模型描述机械产品装配过程中的偏差传递、累积和淹没规律,对产品的容差设计与故障诊断,并进一步提高产品性能和服役周期具有重要意义。归纳并总结了现有机械产品装配偏差分析的理论方法,从基于刚性假设的偏差分析与考虑柔性变形的偏差模型两个方面系统地论述了目前机械产品装配偏差传递分析的研究进展。刚性偏差分析围绕尺寸链模型与确定性定位模型展开,并对基于尺寸链理论的雅可比旋量方法做了详细介绍与具体的应用分析。对于主流的柔性装配偏差传递建模方法,详细论述了影响系数法与装配偏差场传递模型的理论建模过程与及其应用范围,并从大型结构装配的现场应用出发,对装配偏差场传递模型进行了具体的案例分析。针对目前航空航天等领域机械产品大尺寸、高承载的发展趋势,提出了对于局部刚性整体柔性的大型结构装配偏差预测的难点以及研究展望。

关键词: 装配偏差分析, 装配尺寸链, 影响系数法, 偏差场

Abstract: Mechanical assembly is the final stage of the manufacturing process of the products. Assembly quality has a direct impact on the service performance and reliability of mechanical products. The establishment of the mathematical model, which may describe the transmission, accumulation and annihilation of deviation in the assembly process, is of great significance for tolerance design, fault diagnosis, and further improve the performance and service life of the products. The existing theoretical methods of assembly deviation analysis of mechanical products are summarized. Research progress of the assembly deviation analysis of the mechanical products is discussed through the deviation analysis based on rigid assumption and the analysis methods considering flexible deformation. The rigid deviation analysis is carried out around the dimension chain model and the deterministic locating method. The Jacobian-Torsor method based on dimension chain theory is introduced and analyzed in detail. The theoretical modeling process and application scope of the method of influence coefficient and assembly deviation field model are discussed in detail, which are the methods of flexible assembly deviation analysis. A specific case analysis of assembly deviation field model is carried out based on the engineering application of the assembly for large structure. Finally, the difficulties and research prospects of the analysis of the assembly deviation of the local rigid and integral flexible large-scale structure are discussed, which are aimed at the development trend of large size and high capacity of mechanical products in aerospace and other fields.

Key words: assembly deviation analysis, assemble dimension chain, method of influence coefficients, deviation field

中图分类号:

TH113

余海东, 高畅, 赵勇, 袁可. 机械产品装配偏差分析方法研究进展与展望[J]. 机械工程学报, 2023, 59(9): 212-229.

YU Haidong, GAO Chang, ZHAO Yong, YUAN Ke. Progress and Prospect on Assembly Deviation Propagation of Mechanical Products[J]. Journal of Mechanical Engineering, 2023, 59(9): 212-229.

参考文献

[1] 王国庆,林忠钦. 航天结构产品精确高效制造工程展望[J]. 工业工程与管理,2016,21(4):1-5+136. WANG Guoqing,LIN Zhongqin. The perspective on accurate and efficient manufacturing engineering of aerospace structures[J]. Industrial Engineering and Management,2016,21(4):1-5+136.
[2] DESROCHERS A,RIVIERE A. A matrix approach to the representation of tolerance zones and clearances[J]. International Journal of Advanced Manufacturing Technology,1997,13(9):630-636.
[3] DAVIDSON J K,MUJEZINOVIC A,SHAH J J. A new mathematical model for geometric tolerances as applied to round faces[J]. ASME Journal of Mechanical Design,2002,124(4):609-622.
[4] CHASE K W,GAO J,MAGLEBY S P. General 2-D tolerance analysis of mechanical assemblies with small kinematic adjustments[J]. Journal of Design and Manufacturing,1995,5:263-274.
[5] CHASE K W,GAO J,MAGLEBY S P,et al. Including geometric feature variations in tolerance analysis of mechanical assemblies[J]. IIE Transactions,1996,28(10):795-807.
[6] GLANCY C G,CHASE K W. A second-order method for assembly tolerance analysis[C]//Proceedings of the ASME Design Engineering Technical Conferences,1999:21-44.
[7] GAO J,CHASE K W,MAGLEBY S P. General 3-D tolerance analysis of mechanical assemblies with small kinematic adjustments[J]. IIE Transactions,1998,30(4):367-377.
[8] WITTWER J W,CHASE K W,HOWELL L L. The direct linearization method applied to position error in kinematic linkages[J]. Mechanism and Machine Theory,2004,39(7):681-693.
[9] LEISHMAN R C,CHASE K W. Direct linearization method kinematic variation analysis[J]. ASME Journal of Mechanical Design,2010,132(7):071003.
[10] 王洋,王春河. 基于特征的装配尺寸链自动生成及分析的研究[J]. 计算机辅助设计与图形学学报,1998,10(2):138-144. WANG Yang,WANG Chunhe. Research on feature-based assembly tolerance chain generating and analyzing automatically[J]. Journal of Computer-Aided Design and Comper Graphics,1998,10(2):138-144.
[11] 杨将新,顾大强,吴昭同. 基于神经网络的机械加工成本-公差模型[J]. 中国机械工程,1996,7 (6):41-42. YANG Jiangxin,GU Daqiang,WU Zhaotong. Cost-tolerance model of machining based on neural network[J]. China Mechanical Engineering,1996,7 (6):41-42.
[12] 吴昭同,杨将新. 计算机辅助公差优化设计[M]. 杭州:浙江大学出版社,1999. WU Zhaotong,YANG Jiangxin. Computer aided tolerance optimization design[M]. Hangzhou:Zhejiang University Press,1999.
[13] 孙绍民. CAD环境中公差分析与综合的研究[D]. 哈尔滨:哈尔滨工业大学,1997. SUN Shaomin. Study on tolerance analysis and synthesis in CAD environment[D]. Harbin:Harbin Institute of Technology,1997.
[14] 唐健钧,田锡天,耿俊浩,等. 基于多维矢量环的装配偏差源敏感度分析[J]. 机械工程学报,2015,51(17):156-161. TANG Jianjun,TIAN Xitian,GENG Junhao,et al. Sensitivity analysis of assembly deviation source based on multidimensional vector loop[J]. Journal of Mechanical Engineering,2015,51(17):156-161.
[15] 余觉,赵勇,牛书峰,等. 直接线性化方法及其在液体火箭发动机管路装配中的应用[J]. 上海交通大学学报,2016,50(6):957-962. YU Jue,ZHAO Yong,NIU Shufeng,et al. Direct linearization method and its application in the assembly of pipelines of rocket engine[J]. Journal of Shanghai Jiao Tong University,2016,50(6):957-962.
[16] GREENWOOD W H,CHASE K W. Worst case tolerance analysis with nonlinear problems[J]. ASME Journal of Engineering for Industry,1988,110(3):232-235.
[17] GAO J,CHASE K W,MAGLEBY S P. Comparison of assembly tolerance analysis by the direct linearization and modified Monte Carlo simulation methods[C]//Proceeding of the AMSE Design Engineering Technical Conferences,1995,82(1):353-360.
[18] GREENWOOD W H,CHASE K W. A new tolerance analysis method for designers and manufacturers[J]. Journal of Engineering for Industry,1987,109(2):112-116.
[19] LAFOND P,LAPERRIERE L. Jacobian-based modeling of dispersions affecting predefined functional requirements of mechanical assemblies[C]//Proceedings of IEEE International Symposium on Assembly and Task Planning,1999:20-25.
[20] LAPERRIERE L,EIMARAGHY H A. Tolerance analysis and synthesis using Jacobian transforms[J]. CIRP Annals -Manufacturing Technology,2000,49(1):359-362.
[21] LAPERRIERE L,DESROCHERS A. Modeling assembly quality requirements Using Jacobian or screw transforms:A comparison[C]//Proceedings of the IEEE International Symposium on Assembly and Task Planning,2001:330-336.
[22] MARZIALE M,POLINI W. A review of two models for tolerance analysis of an assembly:Jacobian and Torsor[J]. International Journal of Computer Integrated Manufacturing,2011,24(1):74-86.
[23] LAPERRIERE L,GHIE W,DESROCHERS A. Statistical and deterministic tolerance analysis and synthesis using a unified Jacobian-Torsor model[J]. CIRP Annals Manufacturing Technology,2002,51(1):417-420.
[24] DESROCHERS A,GHIE W,LAPERRIERE L. Application of a unified Jacobian-Torsor model for tolerance analysis[J]. ASME Journal of Computing and Information Science in Engineering,2003,3(1):2-14.
[25] LAPERRIERE L,GHIE W,DESROCHERS A. Statistical and deterministic tolerance analysis and synthesis using a unified Jacobian-Torsor model[J]. CIRP Annals Manufacturing Technology,2002,51(1):417-420.
[26] GHIE W,LAPERRIERE L,DESROCHERS A. Statistical tolerance analysis using the unified Jacobian-Torsor model[J]. International Journal of Production Research,2010,48(15):4609-4630.
[27] PIERRE L,TEISSANDIER D,NADEAU J P. Integration of thermomechanical strains into tolerancing analysis[J]. International Journal on Interactive Design and Manufacturing,2009,3(4):247-263.
[28] 张为民,陈灿,李鹏忠,等. 基于雅可比旋量法的实际工况公差建模[J]. 计算机集成制造系统,2011,17(1):77-83. ZHANG Weimin,CHEN Can,LI Pengzhong,et al. Tolerance modeling in actual working condition based on Jacobian-Torsor theory[J]. Computer Integrated Manufacturing Systems,2011,17(1):77-83.
[29] GHIE W,LAPERRIERE L,DESROCHERS A. Models for computer aided tolerancing in design and manufacturing[M]. Springer,2007.
[30] 张为民,李国伟,陈灿. 基于雅可比旋量理论的公差优化分配[J]. 农业机械学报,2011,42(4):216-228. ZHANG Weimin,LI Guowei,CHEN Can. Optimal allocation of tolerance based on Jacobian-Torsor theory[J]. Transactions of The Chinese Society of Agricultural Machinery,2011,42(4):216-228.
[31] NI W,YAO Z. Integrating cylindricity error into tolerance analysis of precision rotary assemblies using Jacobian-Torsor model[J]. Proceedings of the Institution of Mechanical Engineers,Part C:Journal of Mechanical Engineering Science,2013,227(11):2517-2530.
[32] 程彬彬,王志越,黄美发,等. 装配体三维公差建模及分析研究[J]. 机械设计与制造,2016,302(4):76-79. CHENG Binbin,WANG Zhiyue,HUANG Meifa,et al. Research on assembly 3D tolerance modeling and analysis[J]. Machinery Design and Manufacture,2016,302(4):76-79.
[33] 陈华. 基于雅可比旋量模型的三维公差分析方法研究及在发动机装配中的应用[D]. 上海:上海交通大学,2015. CHEN Hua. Study on three-dimensional tolerance analysis method based on Jacobian-Torsor model and its application in engine assembly[D]. Shanghai:Shanghai Jiao Tong University,2015.
[34] LITWA F,GOTTWALD M,SPUDEIKO S,et al. Optimization coupling approach for/with non-static point based CAT-models[J]. Procedia CIRP,2016,43:166-171.
[35] 陈强. 基于尺寸工程的闭环质量偏差分析系统研究与应用[D]. 镇江:江苏大学,2020. CHEN Qiang. Research and application of closed-loop variation analysis system based on dimensional engineering[D]. Zhenjiang:Jiangsu University,2020.
[36] 王聪伟,于贺,许俊伟,等. 基于VisVSA的舵系统机械零位和活动间隙分析[J]. 机械设计与研究,2018,34(2):187-191. WANG Congwei,YU He,XU Junwei,et al. The mechanical zero and clearance analysis of rudder systems based on VisVSA[J]. Machine Design and Research,2018,34(2):187-191.
[37] 张高明,田洪峰. 汽车发动机的装配偏差仿真分析与公差修正[J]. 机械,2020,47(11):49-53. ZHANG Gaoming,TIAN Hongfeng. Simulation analysis of assembling deviation for automobile engine and tolerance correction[J]. Machinery,2020,47(11):49-53.
[38] CAI W,HU S J,YUAN J X. A variational method of robust fixture configuration design for 3-D workpieces[J]. Journal of Manufacturing Science and Engineering,1997,119(4A):593-602.
[39] ASADA H,BY A. Kinematic analysis of workpart fixturing for flexible assembly with automatically reconfigurable fixtures[J]. IEEE Journal on Robotics and Automation,1985,1(2):86-94.
[40] DEMETER E C. Restraint analysis of fixtures which rely on surface contact[J]. Journal of Engineering for Industry,1994,116(2):207-215.
[41] SAYEED Q A,METER E C D. Machining fixture design and analysis software[J]. International Journal of Production Research,1994,32(7):1655-1674.
[42] CARLSON J S. Quadratic sensitivity analysis of fixtures and locating schemes for rigid parts[J]. Journal of Manufacturing Science and Engineering,2001,123(3):462-472.
[43] WANG M Y,LIU T,PELINESCU D M. Fixture kinematic analysis based on the full contact model of rigid bodies[J]. Journal of Manufacturing Science and Engineering,2003,125(2):316-324.
[44] MONTANA D J. The kinematics of contact and grasp[J]. The International Journal of Robotics Research,1988,7(3):17-32.
[45] LIU T,WANG M Y. An approximate quadratic analysis of fixture locating schemes[J]. Proceedings of the Automation,2003:12-14.
[46] ADAMS J D,WHITNEY D E. Application of screw theory to constraint analysis of assemblies of rigid parts[C]//Proceedings of the IEEE International Symposium on Assembly and Task Planning,1999:69-74.
[47] ADAMS J D,GERBINO S,WHITNEY D E. Application of screw theory to motion analysis of assemblies of rigid parts[C]//Proceedings of the IEEE International Symposium on Assembly and Task Planning,1999:75-80.
[48] WEILL R,DAREL I,LALOUM M. The influence of fixture positioning errors on the geometric accuracy of mechanical parts[C]//Proceedings of the CIRP Conference on PE & ME. 1991:215-225.
[49] CAI W. Robust pin layout design for sheet-panel locating[J]. The International Journal of Advanced Manufacturing Technology,2006,28(5-6):486-494.
[50] MENASSA R J. Optimization methods applied to selecting support positions in fixture design[J]. Journal of Manufacturing Science and Engineering,1991,113(4):412-418.
[51] CAI W,HU S J,YUAN J X. Deformable sheet metal fixturing:Principles,algorithms,and simulations[J]. Journal of Manufacturing Science and Engineering,1996,118(3):318-324.
[52] CAMELIO J A,HU S J,CEGLAREK D J. Impact of fixture design sheet metal assembly variation[C]//International Design Engineering Technical Conferences and Computers and Information in Engineering Conference,2002,36231:133-140.
[53] TAKEZAWA N. An improved method for establishing the process wise quality standard reports of statistical and applied research[J]. Union of Japanese Scientists and Engineers,1980,27(3):63-76.
[54] LIU S C,HU S J. An offset finite element model and its applications in predicting sheet metal assembly variation[J]. International Journal of Machine Tools and Manufacture,1995,35(11):1545-1557.
[55] LIU S C,HU S J. Variation simulation for deformable sheet metal assemblies using finite element methods[J]. Journal of Manufacturing Science and Engineering,1997,119(3):368-374.
[56] DAHLSTROM S,LINDKVIST L. Variation simulation of sheet metal assemblies using the method of influence coefficients with contact modeling[J]. Journal of Manufacturing Science and Engineering,2007,129(3):615-622.
[57] CAMELIO J A,HU S J. Compliant assembly variation analysis using components geometric covariance[J]. Journal of Manufacturing Science and Engineering,2004,126(2):355-360.
[58] HAN S,ZENG Q,LIN C,et al. Variation analysis of auto-body aluminum alloy sheet metal assembly in self-pierce riveting[J]. The International Journal of Advanced Manufacturing Technology,2014,70(1-4):701-709.
[59] CAI N,QIAO L,ANWER N. Unified variation modeling of sheet metal assembly considering rigid and compliant variations[J]. Proceedings of the Institution of Mechanical Engineers,Part B:Journal of Engineering Manufacture,2015,229(3):495-507.
[60] YU K,JIN S,LAI X,XING Y. Modeling and analysis of compliant sheet metal assembly variation[J]. Assembly Automation,2008,28(3):225-234.
[61] STRICHER A,CHAMPANEY L,THIEBAUT F,et al. Tolerance analysis of compliant assemblies using fem simulations and modal description of shape defects[C]//ASME Biennial Conference on Engineering Systems Design and Analysis,2012:307-314.
[62] CHOI W,CHUNG H. Variation simulation of compliant metal plate assemblies considering welding distortion[J]. Journal of Manufacturing Science and Engineering,2015,137(3):330-351.
[63] MEI B,ZHU W,ZHENG P,et al. Variation modeling and analysis with interval approach for the assembly of compliant aeronautical structures[J]. Proceedings of the Institution of Mechanical Engineers,Part B:Journal of Engineering Manufacture,2019,233(3):948-959.
[64] XING Y,WANG Y. A new assembly variation analysis model based on the method of power balance for auto-body parts[J]. Assembly Automation,2014,34(3):296-302.
[65] 林忠钦,胡敏,陈关龙,等. 轿车车体装配偏差研究方法综述[J]. 机械设计与研究,1999(3):58-60. LIN Zhongqin,HU Min,CHEN Guanlong,et al. Review of autobody assembly variation research[J]. Machine Design and Research,1999(3):58-60.
[66] 胡敏,来新民,林忠钦,等. 车体多柔性件装配的误差分析[J]. 上海交通大学学报,2000 (10):1365-1368. HU Min,LAI Xinmin,LIN Zhongqin,et al. Variation analysis for multi-flexible autobody assembly[J]. Journal of Shanghai Jiao Tong University,2000 (10):1365-1368.
[67] 靳思源,沈利冰,金隼,等.飞机壁板件装配偏差的刚柔混合建模方法与应用[J].机械设计与研究,2013,29(3):58-61. JIN Siyuan,SHEN Libing,JIN Sun,et al. The rigid-flexible coupling assembly deviation modeling and application of the aircraft panel[J]. Machine Design and Research,2013,29(3):58-61.
[68] 张荣宁.飞机机身壁板件多工位装配偏差分析与建模[D]. 南京:南京航空航天大学,2016. ZHANG Rongning. Muti-station assembly variation analysis and modeling of fuselage aeronautical panels[D]. Nanjing:Nanjing University of Aeronautics and Astronautics,2016.
[69] 杜丽,梅标,朱伟东,等. 采用模糊区间分析的柔性航空结构件装配偏差预测[J]. 浙江大学学报,2019,53(9):1647-1655. DU Li,MEI Biao,ZHU Weidong,et al. Assembly variation prediction for compliant aeronautical structures using fuzzy interval analysis[J]. Journal of Zhejiang University,2019,53 (9):1647-1655.
[70] STOUT J B. Geometric covariance in compliant assembly tolerance analysis[D]. Brigham:Brigham Young University,2000.
[71] TONKS M R,CHASE K W. Covariance modeling method for use in compliant assembly tolerance analysis[C]//ASME International Design Engineering Technical Conferences and Computers and Information in Engineering Conference. 2004,46946:49-55.
[72] 陈晖,谭昌柏,王志国. 耦合几何与材料误差的柔性装配偏差统计分析[J]. 航空学报,2015,36(9):3176-3186. CHEN Hui,TAN Changbo,WANG Zhiguo. Statistical variation analysis of compliant assembly coupling geometrical and material error[J]. Acta Aeronautica ET Astronautica Sinica,2015,36(9):3176-3186.
[73] ANWER N,BALLU A,MATHIEU L. The skin model,a comprehensive geometric model for engineering design[J]. CIRP Annals-Manufacturing Technology,2013,62(1):143-146.
[74] SCHLEICH B,WARTZACK S. Approaches for the assembly simulation of skin model shapes[J]. Computer-Aided Design,2015,65:18-33.
[75] YAN X,BALLU A. Generation of consistent skin model shape based on FEA method[J]. The International Journal of Advanced Manufacturing Technology,2017,92(1-4):789-802.
[76] SAMPER S,ADRAGNA P A,FAVRELIERE H,et al. Modeling of 2D and 3D assemblies taking into account form errors of plane surfaces[J]. Computer Science,2010,9(4):790-792.
[77] SAMPER S,FORMOSA F. Form defects tolerancing by natural modes analysis[J]. Journal of computing and information science in engineering,2007,7(1):44-51.
[78] HOMRI L,GOKA E,LEVASSEUR G,et al. Tolerance analysis- Form defects modeling and simulation by modal decomposition and optimization[J]. Computer-Aided Design,2017,91:46-59.
[79] 王敬. 基于离散模态分解法的表面建模与装配仿真研究[D]. 杭州:浙江大学,2017. WANG Jing. Surface modeling and assembly simulation based on discrete modal decomposition[D]. Hangzhou:Zhejiang University,2017.
[80] ZHU Z,ANWER N,MATHIEU L. Statistical modal analysis for out-of-plane deviation prediction in additive manufacturing based on finite element simulation[J]. Journal of Manufacturing Science and Engineering,2019,141(11):1-35.
[81] FRANCIOSA P,GERBINO S,PATALANO S. Simulation of variational compliant assemblies with shape errors based on morphing mesh approach[J]. The International Journal of Advanced Manufacturing Technology,2011,53(1-4):47-61.
[82] 王隽. 勾画式三维网格模型的分割与编辑[D]. 杭州:浙江大学,2007. WANG Juan. Sketch-based mesh segmentation and editing[D]. Hangzhou:Zhejiang University,2007.
[83] LI H,QIU L,ZHANG S,et al. A surface modeling method for product virtual assembly based on the root mean square of the regional residuals[J]. Proceedings of the Institution of Mechanical Engineers,Part B:Journal of Engineering Manufacture,2020,234(1-2):229-242.
[84] LI Y,ZHAO Y,YU H,et al. Modeling deviation propagation of compliant assembly considering form defects based on basic deviation fields[J]. Assembly Automation,2019,39(1):226-242.
[85] CAMELIO J A,HU S J,MARIN S P. Compliant assembly variation analysis using component geometric covariance[J]. Journal of Manufacturing Science and Engineering,2004,126(2):355-360.
[86] PAN M,TANG W,XING Y. The deformation analysis,prediction,and experiment verification for thin-wall part assembly based on the fractal theory model with WNNM[J]. The International Journal of Advanced Manufacturing Technology,2017,92(9-12):4145-4159.
[87] 苏成阳,王志国. 基于网格曲面形状修改的柔性件装配偏差分析[J].中国机械工程,2019,30(19):2294-2300. SU Chengyang,WANG Zhiguo. Assembly variation analysis of compliant parts based on mesh deformation[J]. China Mechanical Engineering,2019,30 (19):2294-2300.
[88] SUN Q,ZHAO B,LIU X,et al. Assembling deviation estimation based on the real mating status of assembly[J]. Computer-Aided Design,2019,115:244-255.
[89] 徐辉,王志国. 基于曲面配准的柔性件装配偏差分析[J]. 机械制造与自动化,2020,49(3):19-21+39. XU Hui,WANG Zhiguo. Assembly deviation analysis of flexible parts based on surface registration[J]. Machine Building and Automation,2020,49(3):19-21+39.
[90] YI Y,LIU X,LIU T,et al. A generic integrated approach of assembly tolerance analysis based on skin model shapes[J]. Proceedings of the Institution of Mechanical Engineers,Part B:Journal of Engineering Manufacture,2021:235(4):689-704.
[91] 张小兵,刘海江. 基于高精度点云的密封平面装配质量评价[J]. 机械工程学报,2018,54(11):121-128. ZHANG Xiaobing,LIU Haijiang. Assembly quality evaluation of sealing planar based on high precision point cloud[J]. Journal of Mechanical Engineering,2018,54(11):121-128.
[92] MANSOUR G. A developed algorithm for simulation of blades to reduce the measurement points and time on coordinate measuring machine (CMM)[J]. Measurement,2014,54(54):51-57.
[93] 王国华,刘涛,唐增武,等. 基于局部特征配准的模型装配误差分析方法[J]. 航天制造技术,2021(3):33-36,41. WANG Guohua,LIU Tao,TANG Zengwu,et al. Model assembly error analysis method based on local feature registration[J]. Aerospace Manufacturing Technology,2021(3):33-36,41.
[94] WANG J,HUO S,LIU Y,et al. Research of fast point cloud registration method in construction error analysis of hull blocks[J]. International Journal of Naval Architecture and Ocean Engineering,2020,12:605-616.