Simulator dome assembly fixture and method

Abstract

The present application belongs to the field of assembly of a simulator dome structure, and relates to a simulator dome assembly tool and method. The tool comprises a top cover assembly tool and a main body assembly tool. The use of a special dome assembly tool can ensure that the assembled dome and projector support meet the use requirements. On the one hand, the assembly precision of the dome is improved, and the step difference between the dome segments is eliminated. The formation of a perfect circle between the dome segments is conducive to the generation of a projection image correction algorithm, thereby improving the projection effect and quality. On the other hand, the assembly quality of the dome is improved. The projector has a large mass and a long force arm, and generates a large force and torque during the movement of the simulator. The improvement of the assembly quality helps to ensure the connection quality between the dome segments, so that the stress on the dome is uniform, the deformation of the dome during the movement of the simulator is small, and the service life of the dome and the imaging stability of the projection are improved. The method can also be applied to the splicing and forming of other large-size segmented spheres with high assembly quality requirements.

Description

Technical Field

[0001] This invention belongs to the field of helicopter simulator dome structure assembly, and relates to a simulator dome assembly tooling and method. Background Technology

[0002] The helicopter simulator dome uses a carbon fiber honeycomb sandwich structure. The dome's diameter spans over 7 meters while ensuring a minimal net weight of no more than 500 kg. This is to guarantee that the simulator's weight and moment of inertia do not exceed the performance limitations of a six-degree-of-freedom motion platform. The assembly step differences between the dome segments must be minimized, ensuring a smooth and flat surface so that the assembled dome is nearly spherical, thus facilitating high-quality projection. The large size and weight of the dome, coupled with the high precision requirements for assembly dimensions, make large-size dome assembly a technically demanding process. Currently, the industry typically assembles dome segments manually. Assembly holes are either pre-fabricated during segment formation or made on-site during assembly. However, the lack of on-site positioning tools makes it difficult to guarantee the assembly step differences between large-size dome segments and the flatness of the joints. After manual assembly, additional puttying and sanding are required at the joints, making the entire assembly process time-consuming, labor-intensive, and risky of rework. This invention patent describes a dedicated dome screen auxiliary installation positioning fixture and assembly method for assembling simulator dome screens and projector brackets. The presence of positioning components on the assembly fixture ensures that the assembly step difference between large-size dome screen segments remains within a reasonable range during simulator dome screen assembly, while also ensuring that the flatness of the seams between the segments meets projection quality requirements. Furthermore, this fixture can increase production capacity during small-batch continuous production of simulator dome screens. Summary of the Invention

[0003] The purpose of this invention is to ensure that the assembled dome screen and projector bracket meet the usage requirements by using positioning fixtures for dome screens and projector brackets.

[0004] Technical solution

[0005] A simulator dome screen assembly fixture; comprising a top cover assembly fixture 1 and a main body assembly fixture 2;

[0006] The top cover assembly fixture 1 is an umbrella-shaped support frame structure. The umbrella-shaped support frame is equipped with three layers of positioning parts A3, B4 and C5. Each layer of positioning parts consists of several positioning plates arranged circumferentially on the outer edge of the umbrella-shaped support frame. Four projector bracket positioning components 6 are installed on the umbrella-shaped support frame.

[0007] The main assembly fixture 2 is a structural component that matches the shape of the dome screen. Three layers of positioning components D are arranged circumferentially around the structural component. Positioning components D include 7, 8, and 9 as shown in the figure. Components 7-9 have the same shape and structure, differing only in their positioning angles. Each layer of positioning components D has four positioning plates. The bottom of the structural component has a base 10. Both the structural component and the support have pin holes, which are evenly distributed around the support. The structural component is positioned on the support via pins 11, and rotates relative to the column of the main assembly fixture 2 via bearings 12. The main assembly fixture and the top cover assembly fixture are connected via columns, with positioning pins 13 assisting in positioning at the connection.

[0008] Furthermore, it also includes a support foot 14, which is disposed at the bottom of the support frame.

[0009] Furthermore, it also includes a lifting ring 15, which is disposed on the top of the top cover assembly fixture.

[0010] Furthermore, the position of the projector positioning component on the main assembly fixture is set according to the specific position of the projector on the dome screen.

[0011] Furthermore, the umbrella-shaped support frame and structural components are all made of Q235 steel.

[0012] Furthermore, the positioning plate is a movable structure, and its position can be adjusted through the waist-shaped hole 16 provided on the umbrella-shaped support frame or structural component.

[0013] Furthermore, the support has 10 evenly distributed pin holes around its circumference, allowing for 36-degree angle adjustments each time.

[0014] A method for assembling a simulator dome screen includes the following steps:

[0015] a) Complete the ground assembly of dome assembly fixtures 1 and 2, and use a laser tracker to adjust the spatial position of each positioning component A3, positioning component B4, positioning component C5, projector bracket positioning assembly 6, and positioning component D, so that the error between the actual relative position and the theoretical relative position of each positioning component is within a reasonable range.

[0016] b) After separating the fasteners connecting the top cover assembly fixture 1 and the dome main body assembly fixture 2, use the lifting ring 15 at the top of the top cover assembly fixture to separate the top cover assembly fixture 1 from the dome main body assembly fixture 2, and gently place the top cover assembly fixture 1 on a flat ground.

[0017] c) Position each spherical petal of the dome dome using positioning parts A3, B4, and C5 on the dome assembly fixture. After positioning, holes are drilled between the spherical petals and bolts are used for connection.

[0018] d) Use the projector bracket positioning component 6 on the top cover assembly fixture to complete the positioning and installation of the four projector bracket components on the left and right sides;

[0019] e) Using the lifting ring 15 at the top of the top cover assembly fixture 1, the assembled dome top cover and projector bracket are hoisted together onto the dome main assembly fixture 2.

[0020] f) Positioning of the top cover assembly fixture and the main body assembly fixture is completed by using positioning pin 13, and bolts are used to fasten the top cover assembly fixture and the main body assembly fixture.

[0021] g) Use pin 11 to lock the positioning hole on the main body assembly fixture 2 with the positioning hole on the base 10, and use the third layer positioning part 5 of the top cover assembly fixture 1 and the positioning part D on the two side arms of the main body assembly fixture 2 to complete the positioning and connection of the left and right main body petals of the dome.

[0022] h) Remove the pin 11 from the previous step, rotate the two side arms of the main assembly fixture 2 by 36 degrees, and reinsert the pin 11 to complete the positioning and connection of the two main dome petals.

[0023] i) Continue in this manner to complete the positioning and connection of the remaining 6 main spherical petals of the dome screen;

[0024] j) After separating the standard parts connecting the dome top cover to the dome body, use the lifting ring 15 to lift the top cover assembly fixture 1 and the dome top cover together from the dome body assembly fixture 2.

[0025] k) After separating the dome top cover from the top cover assembly fixture 1, lift the dome top cover and reconnect it to the dome body;

[0026] Finally, the assembled dome screen is separated from the main dome screen assembly fixture 2 and hoisted onto the motion platform.

[0027] Technical effect

[0028] By utilizing specialized jigs for dome assembly, it is ensured that the assembled dome and projector bracket meet usage requirements. This improves assembly precision by eliminating step differences between the spheres, ensuring a perfect circle between them, which facilitates the generation of projection image correction algorithms and thus enhances projection effect and quality. Furthermore, it improves assembly quality. Because projectors are heavy and have long lever arms, they generate significant forces and torques during simulator movement. Improved assembly quality helps ensure even stress distribution between spheres, minimizing deformation during simulator movement and extending the dome's lifespan and improving projection stability. This method can also be applied to the assembly of other large-sized segmented spheres requiring high-precision assembly. Attached Figure Description

[0029] Figure 1 Main view of the structure;

[0030] Figure 2 Top view of the structure. Detailed Implementation

[0031] The present invention will be further described below with reference to embodiments. The following description represents only a portion of the embodiments of the present invention, not all of them. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.

[0032] Example 1

[0033] The positioning plate uses a laser tracker to determine its theoretical position, ensuring that the tooling produced matches the digital model.

[0034] The dome screen assembly fixture consists of two parts: the dome A assembly fixture and the dome B assembly fixture. During assembly, the dome A assembly fixture is assembled on the ground first, leaving the top cover (②) unassembled. After the dome A components are assembled, the legs (④) and projector bracket positioning (①) of the dome A assembly fixture are removed, and the entire assembly is hoisted to the dome B assembly fixture for docking. The docking interface uses a 40H7 / g6 pin hole fit to restrict rotation, and a φ280 clearance fit in the middle main positioning to restrict the relative position of the fixtures. The main positioning has a guiding structure. The positioning structure of the dome B assembly fixture has a rotation function, and the double-sided symmetrical structure (⑥) avoids uneven weight distribution and allows for multi-station positioning. The dome A assembly fixture weighs 2.2t. After docking with the dome B assembly fixture, the total weight of the fixture is approximately 8t. The base (⑦) contacts the bottom surface at 1.5㎡, and the base is fixed using M24*200 expansion bolts.

[0035] The ball block A assembly fixture is an independent, separable structure. The main frame is supported by four legs, with an overall weight of approximately 2.5 tons. The fixture has three detachable positioning rings. First, it is assembled with the ball block B assembly fixture. A laser tracker is used to adjust each positioning ring to ensure consistency. Screws and pins are used for positioning and fixing. The product and fixture are positioned using pins on the positioning rings and the product's process holes, with an overall positioning accuracy of ±0.3. After separating the ball block A assembly fixture, the legs are used to place the fixture on a flat surface for ball block A assembly. Then, the product top cover, fixture legs, and projector bracket positioning plate need to be removed. The fixture is then lifted back onto the ball block B assembly fixture using a hoisting device on the top cover for reassembly.

[0036] The assembly fixture for ball block B is the main body of the complete assembly fixture, and its structure is roughly divided into three parts: column, positioning arm, and base. First, the foundation needs to be reinforced. After determining the fixture's position, a laser tracker is used to adjust the base level. After fixing the base, the column is pre-installed. The components are fitted with an H6 / h6 clearance. The laser tracker is used to measure the reference hole on the column to determine the column's tilt dimension, which should not exceed 1mm. Next, standard parts are used to connect the positioning arm and the column. The laser tracker is used to assemble and adjust the positioning components on the positioning arm. All positioning components are detachable. The laser tracker is used to ensure the assembly position of each positioning component. The positioning arm is a rotatable multi-station structure. The rotation and positioning of each station are achieved by the turntable structure on the column. The turntable and the base have corresponding positioning holes, with a positioning accuracy of H7 / r6. The positioning pins are quick-connect structures, allowing for repeated positioning. The product and fixture are positioned using the pins on the positioning components on the positioning arm and the product's process holes, with an overall positioning accuracy of ±0.3. Finally, the assembly interface of the ball block A at the top of the column is an H7 / r6 precision clearance fit. The top of the column has a guide structure to facilitate the installation of the ball block A assembly tool. After the tool is connected, it is fixed in place using locating pins and screws.

[0037] Example 2

[0038] Simulator dome screen assembly fixture; including top cover assembly fixture 1 and main body assembly fixture 2;

[0039] The top cover assembly fixture 1 is an umbrella-shaped support frame structure. The umbrella-shaped support frame is equipped with three layers of positioning parts 3, 4, and 5. Each layer of positioning parts consists of several positioning plates arranged circumferentially on the outer edge of the umbrella-shaped support frame. Four projector bracket positioning components 6 are installed on the umbrella-shaped support frame.

[0040] The main assembly fixture 2 is a structural component that matches the shape of the dome screen. Three layers of positioning components D are arranged circumferentially around the structural component. Positioning components D include 7, 8, and 9 as shown in the figure. Components 7-9 have the same shape and structure, differing only in their positioning angles. Each layer of positioning components has four positioning plates. The bottom of the structural component has a base 10. Both the structural component and the support have pin holes, which are evenly distributed around the circumference of the support. The structural component is positioned on the support via pins 11, and rotates relative to the column of the main assembly fixture 2 via bearings 12. The main assembly fixture and the top cover assembly fixture are connected via columns, with positioning pins 13 assisting in positioning at the connection.

[0041] Furthermore, it also includes support feet 14, which are located at the bottom of the support frame and provide support for the top cover assembly fixture when not in use.

[0042] Furthermore, it also includes a lifting ring 15, which is set on the top of the top cover assembly fixture and is used for assembling and separating the top cover assembly fixture from the main body assembly fixture.

[0043] Furthermore, the position of the projector positioning component on the main assembly fixture is set according to the specific position of the projector on the dome screen.

[0044] Furthermore, the umbrella-shaped support frame and structural components are all made of Q235 steel. This material allows for cost control while providing high structural rigidity and strength to meet usage requirements.

[0045] Furthermore, the positioning plate is a movable structure, and its position can be adjusted through the waist-shaped hole 16 provided on the umbrella-shaped support frame or structural component.

[0046] Furthermore, the support has 10 evenly distributed pin holes around its circumference, allowing for 36-degree angle adjustments each time. The main dome screen is divided into 10 sections, and two sections are spliced ​​together each time, so one hole is set every 36 degrees.

[0047] A method for assembling a simulator dome screen includes the following steps:

[0048] l) Complete the ground assembly of dome assembly fixtures 1 and 2, and use a laser tracker to adjust the spatial position of each positioning component A3, positioning component B4, positioning component C5, projector bracket positioning assembly 6, and positioning component D, so that the error between the actual relative position and the theoretical relative position of each positioning component is within a reasonable range.

[0049] m) After separating the connecting fasteners between the top cover assembly tool 1 and the dome main body assembly tool 2, use the lifting ring 15 at the top of the top cover assembly tool to separate the top cover assembly tool 1 from the dome main body assembly tool 2, and gently place the top cover assembly tool 1 on a flat ground.

[0050] n) Position each spherical petal of the dome dome using positioning parts A3, B4, and C5 on the dome assembly fixture. After positioning, holes are drilled between the spherical petals and bolts are used for connection.

[0051] o) Use the projector bracket positioning component 6 on the top cover assembly fixture to complete the positioning and installation of the four projector bracket components on the left and right sides;

[0052] p) Using the lifting ring 15 at the top of the top cover assembly fixture 1, the assembled dome top cover and projector bracket are hoisted together onto the dome main assembly fixture 2.

[0053] q) Positioning pin 13 is used to position the top cover assembly fixture and the main body assembly fixture, and bolts are used to fasten the top cover assembly fixture and the main body assembly fixture together.

[0054] r) The positioning holes on the main body assembly fixture 2 and the base 10 are locked together by the pin 11. The positioning and connection of the left and right main body petals are completed by the third layer positioning part 5 of the top cover assembly fixture 1 and the positioning parts D on the two side arms of the main body assembly fixture 2.

[0055] s) Remove the pin 11 from the previous step, rotate the two side arms of the main assembly fixture 2 by 36 degrees, and then reinsert the pin 11 to complete the positioning and connection of the two main dome petals.

[0056] t) Continue in this manner to complete the positioning and connection of the remaining 6 main spherical petals of the dome screen;

[0057] u) After separating the standard parts connecting the dome top cover to the dome body, use the lifting ring 15 to lift the top cover assembly fixture 1 and the dome top cover together from the dome body assembly fixture 2.

[0058] v) After separating the dome top cover from the top cover assembly fixture 1, lift the dome top cover and reconnect it to the dome body;

[0059] Finally, the assembled dome screen is separated from the main dome screen assembly fixture 2 and hoisted onto the motion platform.

[0060] It will be understood by those skilled in the art that, unless otherwise defined, all terms used herein (including technical and scientific terms) have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. It should also be understood that terms such as those defined in general dictionaries should be understood to have the meaning consistent with their meaning in the context of the prior art, and should not be interpreted in an idealized or overly formal sense unless defined as herein. The specific embodiments described above further illustrate the purpose, technical solutions, and beneficial effects of the present invention. It should be understood that the above descriptions are merely specific embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A simulator dome screen assembly fixture; characterized in that, Includes top cover assembly fixture (1) and main body assembly fixture (2); The top cover assembly fixture (1) is an umbrella-shaped support frame structure. The umbrella-shaped support frame is equipped with three layers of positioning parts A (3), B (4), and C (5). Each layer of positioning parts A (3), B (4), and C (5) consists of several positioning plates arranged circumferentially on the outer edge of the umbrella-shaped support frame. Four projector bracket positioning components (6) are installed on the umbrella-shaped support frame. The main assembly fixture (2) is a structural component that matches the shape of the dome screen. The structural component has three layers of positioning components D arranged circumferentially. Each layer of positioning component D has four positioning plates. The bottom of the structural component has a base (10). Both the structural component and the support have pin holes. The support has pin holes evenly distributed circumferentially. The structural component is positioned on the support by pins (11). The structural component rotates relative to the column of the main assembly fixture (2) by bearings (12). The main assembly fixture (2) and the top cover assembly fixture (1) are connected by columns. The connection has positioning pins (13) for auxiliary positioning. When in use, the following steps are included: a) Complete the ground assembly of the top cover assembly fixture (1) and the main body assembly fixture (2), and use a laser tracker to adjust the spatial position of each positioning component A (3), positioning component B (4), positioning component C (5), projector bracket positioning assembly (6), and positioning component D, so that the error between the actual relative position and the theoretical relative position of each positioning component is within a reasonable range. b) After separating the fasteners connecting the top cover assembly fixture (1) and the main body assembly fixture (2), use the lifting ring (15) at the top of the top cover assembly fixture to separate the top cover assembly fixture (1) from the dome main body assembly fixture (2), and gently place the top cover assembly fixture (1) on a flat ground. c) Using the positioning parts A (3), B (4), and C (5) on the top cover assembly fixture, the positioning of each spherical petal of the dome top cover is completed. After positioning, holes are made between each spherical petal and bolts are used for connection. d) Use the projector bracket positioning assembly (6) on the top cover assembly fixture to complete the positioning and installation of the four projector bracket assemblies on the left and right sides; e) Using the lifting ring (15) at the top of the top cover assembly fixture (1), the assembled dome top cover and projector bracket are hoisted together onto the dome main assembly fixture (2). f) Positioning of the top cover assembly fixture and the main body assembly fixture is completed by using positioning pins (13), and fastening of the top cover assembly fixture and the main body assembly fixture is completed by using bolts. g) Use pins (11) to lock the positioning holes on the main assembly fixture (2) and the positioning holes on the base (10). Use the third layer positioning component C (5) of the top cover assembly fixture (1) and the positioning component D on the two sides of the main assembly fixture (2) to complete the positioning and connection of the two main body petals of the dome screen. h) Remove the pin (11) from the previous step, rotate the two arms of the main assembly fixture (2) by 36 degrees, and reinsert the pin (11) to complete the positioning and connection of the two main spherical petals of the dome screen. i) Continue in this manner to complete the positioning and connection of the remaining 6 main spherical petals of the dome screen; j) After separating the standard parts connecting the dome top cover to the dome body, use the lifting ring (15) to lift the top cover assembly fixture (1) and the dome top cover together away from the dome body assembly fixture (2). k) After separating the dome top cover from the top cover assembly fixture (1), lift the dome top cover and reconnect it to the dome body; Finally, the assembled dome screen is separated from the main dome screen assembly fixture (2) and hoisted onto the motion platform.

2. A simulator dome assembly fixture according to claim 1; characterized in that, It also includes a support foot (14), which is located at the bottom of the support frame.

3. A simulator dome assembly fixture according to claim 1; characterized in that, It also includes a lifting ring (15), which is disposed on the top of the top cover assembly fixture.

4. A simulator dome assembly fixture according to claim 1; characterized in that, The position of the projector positioning component on the main assembly fixture is set according to the specific position of the projector on the dome screen.

5. A simulator dome assembly fixture according to claim 1; characterized in that, The umbrella-shaped support frame and structural components are all made of Q235 steel.

6. A simulator dome assembly fixture according to claim 1; characterized in that, The positioning plate is a movable structure, and its position can be adjusted by the waist-shaped hole (16) set on the umbrella-shaped support frame or structural component.

7. A simulator dome assembly fixture according to claim 1; characterized in that, The support has 10 pin holes evenly distributed around its circumference, allowing for 36-degree angle adjustments each time.

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