Method for generating profile data of a composite structural component
By identifying key feature points in composite material parts and using a finite element model deformation library for data registration, the problem of low contouring efficiency in the inspection of large composite material parts is solved, and rapid and efficient contouring data generation is achieved.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- CHINA BUILDING MATERIALS (SHANGHAI) AVIATION TECH CO LTD
- Filing Date
- 2022-12-19
- Publication Date
- 2026-05-19
AI Technical Summary
Existing technologies for ultrasonic nondestructive testing of large composite material parts suffer from problems such as large deviations between the actual component and the digital model, which prevent the equipment from generating a scanning path. Furthermore, the manual sampling and profiling process is cumbersome, time-consuming, and inefficient.
By identifying the key feature points of the composite part, the deformation point data in the finite element model deformation library is registered with the sampled data, and the deformation point data that meets the preset tolerance requirements is selected as the final deformation data to generate composite contour data.
It improves the efficiency of composite material contour data generation, reduces the number of sampling points and time costs, and enables rapid contour data processing.
Smart Images
Figure CN115798652B_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of reverse engineering of composite material parts, and more particularly to a method for generating contour data for composite structural parts. Background Technology
[0002] In the manufacturing and use of aerospace composite structural components, ultrasonic non-destructive testing is a key technology for detecting defects and evaluating structural performance. Currently, major aircraft manufacturers such as Airbus and Boeing widely use large-scale water-jet ultrasonic C-scan technology to inspect large composite components. This technology automatically plans the scanning path based on the component's digital model, enabling rapid and automated inspection of large structural components. However, large-scale water-jet ultrasonic C-scan technology is only suitable for inspecting composite components produced in stable batches where curing deformation can be controlled to a small level. During production, however, there are often significant deviations between the actual component and the original digital model. For example, for test pieces produced in unstable batches, large deviations between the actual structural component and the original digital model are common, making it impossible for the equipment to generate a scanning path based on the digital model. Furthermore, when the object being inspected is large, the cumulative deviation can also cause calibration point deviations to exceed equipment requirements, preventing the equipment from generating a scanning path based on the digital model.
[0003] Therefore, in many cases, the inspection of large composite material parts requires manual point sampling and profiling to model the part and plan the scanning path. Manual point sampling and profiling requires manual operation of equipment to collect coordinates point by point on the part to obtain a point data file. The equipment then uses this data to perform profiling. This method is cumbersome and time-consuming. Therefore, when the actual part deviates significantly from the original digital model, the profiling process is time-consuming, resulting in low profiling efficiency. Summary of the Invention
[0004] The purpose of this invention is to provide a method for generating contour data for composite structural components, so as to improve the efficiency of generating contour data for composite components.
[0005] The method for generating contour data for the composite structural component includes: determining N key feature points (N being a positive integer) based on the shape of the composite component to be contoured; sampling points on the assembled composite component according to the N key feature points to obtain sampling point data; acquiring a finite element model deformation library, which includes K sets of deformation results obtained by solidifying and simulating the original digital model according to solidified deformation parameters, each set of deformation results including a deformed digital model and deformation point data obtained by sampling points on the deformed digital model according to the N key feature points (K being a positive integer); registering the deformation point data of the K sets of deformation results with the sampling point data respectively, and selecting a set of deformation point data whose distance between the registered sampling point data and the deformation point data meets a preset tolerance requirement as the final deformation data; and converting the final deformation data into composite contour data.
[0006] The beneficial effects of the composite structural component contouring data generation method provided by this invention are as follows: It generates composite contouring data by registering deformation point data from a finite element model deformation library with sampling data obtained from sampling points on the composite component, and then selecting deformation point data that meets preset tolerance requirements as the final deformation data based on the registration result. The registration between the deformation point data and the sampling data, as well as the selection of the final deformation point data, can all be processed by a program, resulting in fast processing speed. Furthermore, it reduces the number of sampling points on the composite component, shortens the sampling time, and improves the efficiency of composite contouring data generation.
[0007] In one possible embodiment, registering the deformation point data of the K sets of deformation results with the sampling data includes: selecting a set of deformation results from the finite element model deformation library; registering the deformation point data of the deformation results with the sampling data, obtaining the maximum deformation distance between the deformation point data and the sampling data, storing the deformation distance corresponding to the deformation result, and marking the deformation result as registered data; repeatedly selecting a set of unmarked deformation results from the finite element model deformation library, registering the deformation point data with the sampling data, obtaining and storing the deformation distance, and marking the deformation result as registered data, until the deformation point data of all K sets of deformation results are registered to obtain the deformation distance.
[0008] For example, selecting a set of deformation point data whose distance between the registered sampling data and the deformation point data meets a preset tolerance requirement as the final deformation data includes: comparing the deformation distances in K sets of deformation results to obtain a sorting of K deformation distances d1>d2>…>d i >0>d i+1 >…>d k ; Judgment |d i |or|d i+1|Is it less than or equal to the preset tolerance; if |d i If the deformation distance d is less than or equal to the preset tolerance, then... i The corresponding deformation point data is used as the final deformation data, or, if |d i+1 If the deformation distance d is less than or equal to the preset tolerance, then... i+1 The corresponding deformation point data is used as the final deformation data.
[0009] If |d i |or|d i+1 If all values are greater than the preset tolerance, then the fitting deformation distance d i The corresponding deformation modulus and deformation distance d i+1 The corresponding deformation model is used to obtain the fitted model; based on the deformation distance d i The corresponding deformation point data and deformation distance d i+1 The corresponding deformation point data is used to calculate the coordinates of N key feature points of the fitted mathematical model to obtain the fitting point data of the fitted mathematical model; the fitting point data is used as the final deformation data.
[0010] Fitted deformation distance d i The corresponding deformation modulus and deformation distance d i+1 The corresponding deformed numerical model is used to obtain the fitted numerical model, and the fitting equation applied is: a and b are calculation parameters; the key feature point with the largest distance between the fitted digital model and the composite part is selected as the target key feature point, and the fitting deformation distance between the target key feature point on the fitted digital model and the target key feature point on the composite part is a*d. i According to the deformation distance d i The corresponding coordinates (x1, y1, z1) of the target key feature points on the deformed digital model, and the deformation distance d i+1 The corresponding coordinates (x2, y2, z2) of the target key feature point on the deformable digital model and the fitted deformation distance a*d i System of simultaneous equations Calculate the coordinates (x3, y3, z3) of the target key feature point on the fitted mathematical model, where x, y, and z are unknowns; repeat the process based on the deformation distance d. i The coordinates of the key feature points and the deformation distance d on the corresponding deformed digital model i+1 The coordinates of key feature points on the corresponding deformed digital model are used to calculate the coordinates of key feature points on the fitted digital model, and the coordinates of N key feature points on the fitted digital model are obtained as the final deformed data.
[0011] Optionally, after obtaining the composite material contouring data, the method further includes: inputting the composite material contouring data into a non-destructive testing device for non-destructive testing.
[0012] Optionally, after obtaining the composite material contouring data, the method further includes: performing contouring using the composite material contouring data to obtain a composite material contouring digital model; and inputting the composite material contouring digital model into a non-destructive testing device for non-destructive testing.
[0013] For example, the curing deformation parameters include the changes in specific heat and thermal conductivity with temperature and degree of curing, the constitutive model of the material, the definition of internal resin curing heat generation in heat transfer analysis, and the degree of curing value for each incremental step.
[0014] The preset tolerance is 10mm.
[0015] In one possible embodiment, the key feature points include: geometric corner points on the composite material, and / or, pre-defined mating points on the composite material. Attached Figure Description
[0016] Figure 1 This is a flowchart illustrating the method for generating contour data for composite structural components according to an embodiment of the present invention.
[0017] Figure 2 This is a schematic diagram illustrating the registration of deformation point data and sampling point data from a set of deformation results selected from the finite element model deformation library according to an embodiment of the present invention.
[0018] Figure 3 The fitting deformation distance d in this embodiment of the invention i The corresponding deformation modulus and deformation distance d i+1 A schematic diagram of the fitted digital model obtained from the corresponding deformed digital model. Detailed Implementation
[0019] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions in the embodiments of this invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this invention. All other embodiments obtained by those skilled in the art based on the embodiments of this invention without inventive effort are within the scope of protection of this invention. Unless otherwise defined, the technical or scientific terms used herein should have the ordinary meaning understood by those skilled in the art. The terms "comprising" and similar expressions used herein mean that the element or object preceding the word covers the element or object listed following the word and its equivalents, but do not exclude other elements or objects.
[0020] To address the problems existing in the prior art, embodiments of the present invention provide a method for generating contour data for composite structural components. See the appendix to the specification. Figure 1 The method in this embodiment includes:
[0021] S101: Based on the shape of the composite part to be modeled, determine N key feature points, where N is a positive integer.
[0022] In S101, in one possible embodiment, the key feature points are located at positions where structural features are prominent on the composite material, so that the positions of the key feature points can be quickly and accurately identified on both the composite material and the digital model.
[0023] In one specific embodiment, key feature points are located at positions on the composite material where structural features are prominent. Key feature points include geometric corner points on the composite material, and / or, pre-defined docking points on the composite material, etc. The pre-defined docking point is a pre-defined connection point between the composite material and an external structure.
[0024] S102: Based on N key feature points, use a scanning device to collect data from the assembled composite parts.
[0025] In S102, acquiring sampling data includes: clamping the composite part and preparing the scanning equipment, and sampling points at key feature points using the scanning equipment to complete the sampling operation of the composite part and obtain sampling data.
[0026] In one possible embodiment, the scanning device is an ultrasonic C-scan device.
[0027] S103: Obtain the finite element model deformation library, which includes K sets of deformation results obtained by solidifying the original digital model according to the solidified deformation parameters. Each set of deformation results includes the deformed digital model and deformation point data obtained by sampling the deformed digital model according to the N key feature points. K is a positive integer.
[0028] In S103, in one possible embodiment, the curing deformation parameters include the changes in specific heat and thermal conductivity with temperature and degree of curing, the constitutive model of the material, the definition of internal resin curing heat generation in heat transfer analysis, the degree of curing value for each incremental step, and so on. Adjusting the values of the curing deformation parameters allows the original numerical model to be deformed into a deformed numerical model; different values of the curing deformation parameters result in different deformed numerical models.
[0029] In one possible embodiment, since both the composite material and the deformed digital model are obtained by solidifying and deforming the original digital model, the positions of the corresponding key feature points can be determined on the deformed digital model according to the structural characteristics. By sampling the deformed digital model based on N key feature points, the deformation point data corresponding to the deformed digital model can be obtained.
[0030] S104: Register the deformation point data of K groups of deformation results with the sampling data respectively, and select a group of deformation point data whose distance between the registered sampling data and the deformation point data meets the preset tolerance requirements as the final deformation data.
[0031] See Figures 2 to 3 In S104, in one possible embodiment, the deformation point data of the K groups of deformation results are registered with the sampling data, including: selecting a group of deformation results from the finite element model deformation library; registering the deformation point data of the deformation results with the sampling data, obtaining the maximum deformation distance between the deformation point data and the sampling data, storing the deformation distance and the deformation result accordingly, and marking the deformation result as registered data; repeatedly selecting a group of unmarked deformation results from the finite element model deformation library, registering the deformation point data with the sampling data, obtaining and storing the deformation distance, and marking the deformation result as registered data, until the deformation point data of the K groups of deformation results are all registered to obtain the deformation distance.
[0032] In one possible embodiment, point cloud registration methods include: iterative nearest point algorithm, Kalman filter algorithm, robust point matching algorithm, etc.
[0033] A set of deformation point data whose distance between the registered sampling data and the deformation point data meets the preset tolerance requirement is selected as the final deformation data. This includes: comparing the deformation distances in K sets of deformation results to obtain the sorting of K deformation distances: d1>d2>…>d i >0>d i+1 >…>d k Determine |d i |or d i+1 |Is it less than or equal to the preset tolerance; if |d i If the deformation distance d is less than or equal to the preset tolerance, then... i The corresponding deformation point data is used as the final deformation data, or, if |d i+1 If the deformation distance d is less than or equal to the preset tolerance, then... i+1 The corresponding deformation point data is used as the final deformation data.
[0034] For example, the preset tolerance is 10mm.
[0035] In one possible embodiment, if |d i | and |d i+1 If all values are less than or equal to the preset tolerance, then compare |d. i and |d i+1 |, if |d i |>|d i+1 |Then the deformation distance d i+1 The corresponding deformation point data is used as the final deformation data, if |d i+1 |>|d i |Then the deformation distance d i The corresponding deformation point data is used as the final deformation data.
[0036] In one possible embodiment, if |d i |or|d i+1 If all values are greater than the preset tolerance, then the fitting deformation distance d i The corresponding deformation modulus and deformation distance d i+1 The corresponding deformation model is used to obtain the fitted model; based on the deformation distance d i The corresponding deformation point data and deformation distance d i+1 The corresponding deformation point data is used to calculate the coordinates of N key feature points of the fitted mathematical model, thereby obtaining the fitting point data of the fitted mathematical model; the fitting point data is then used as the final deformation data.
[0037] In one specific embodiment, the fitted deformation distance d i The corresponding deformation modulus and deformation distance d i+1 The corresponding deformed numerical model is used to obtain the fitted numerical model, and the fitting equation applied is: a and b are calculation parameters. The key feature point with the largest distance between the fitted digital model and the composite part is selected as the target key feature point. The fitting deformation distance between the target key feature point on the fitted digital model and the target key feature point on the composite part is a*d. i According to the deformation distance d i The coordinates (x1, y1, z1) and deformation distance d of the target key feature point A on the corresponding deformable digital model. i+1 The coordinates (x2, y2, z2) of the target key feature point B on the corresponding deformation model and the fitted deformation distance a*d i System of simultaneous equations Calculate the coordinates (x3, y3, z3) of the target key feature point C on the fitted mathematical model, where x, y, and z are unknowns. Repeat the process based on the deformation distance d. i The coordinates of the key feature points and the deformation distance d on the corresponding deformed digital model i+1 The coordinates of the key feature points on the corresponding deformed digital model are calculated, and the coordinates of the key feature points on the fitted digital model are obtained as the final deformed data.
[0038] In one possible embodiment, when calculating the coordinates of key feature points on the fitted mathematical model, the corresponding deformation distance d is selected based on the currently calculated key feature points on the fitted mathematical model. i The coordinates of the key feature points and the deformation distance d on the corresponding deformed digital model i+1 Substitute the coordinates of the key feature points on the corresponding deformed digital model into the system of equations. Perform the calculation.
[0039] S105: Convert the final deformation data into composite material contouring data.
[0040] In S105, in one possible embodiment, the coordinate system of the final deformation data is the original coordinate system of the digital model. Converting the final deformation data into composite material contouring data includes: unifying the final deformation data to the device coordinate system to obtain the sampling point data for composite material contouring.
[0041] In one possible embodiment, after obtaining the composite material contouring data, the method further includes: inputting the composite material contouring data into a non-destructive testing device for non-destructive testing.
[0042] In one possible embodiment, after obtaining the composite material contouring data, the method further includes: performing contouring using the composite material contouring data to obtain a composite material contouring digital model; and inputting the composite material contouring digital model into a non-destructive testing device for non-destructive testing.
[0043] The method for generating contour data for composite structural components of the present invention generates a finite element model deformation library by adjusting curing deformation parameters. The deformation point data in the finite element model deformation library is then registered with the sampling data obtained from sampling points on the composite component. Based on the registration result, deformation point data that meets preset tolerance requirements is selected as the final deformation data. The registration between the deformation point data and the sampling data, as well as the selection of the final deformation point data, can all be processed by a program, resulting in fast processing speed. Furthermore, it can reduce the number of sampling points on the composite component, shorten the sampling time, and improve the efficiency of generating composite contour data.
[0044] In one possible embodiment, the finite element model deformation library can be obtained by performing solidified deformation simulation on the original digital model based on solidified deformation parameters during the conformal process of composite structural components.
[0045] In one possible embodiment, the deformation simulation of the original digital model can be completed in advance, and then the finite element model deformation library can be obtained by directly acquiring the deformation results. Obtaining the finite element model deformation library by directly acquiring the deformation results can further reduce the time spent in generating composite material contouring data, making composite material contouring more efficient.
[0046] While embodiments of the present invention have been described in detail above, it will be apparent to those skilled in the art that various modifications and variations can be made to these embodiments. However, it should be understood that such modifications and variations fall within the scope and spirit of the invention as set forth in the claims. Furthermore, the invention described herein may have other embodiments and can be implemented or carried out in various ways.
Claims
1. A method for generating contour data for composite structural components, characterized in that, include: Based on the shape of the composite material part to be modeled, N key feature points are determined, where N is a positive integer; Based on the N key feature points, sampling points are collected on the assembled composite part to obtain sampling data; Acquire a finite element model deformation library, which includes K sets of deformation results obtained by solidifying and simulating the original digital model according to solidified deformation parameters. Each set of deformation results includes a deformed digital model and deformation point data obtained by sampling the deformed digital model according to N key feature points, where K is a positive integer. The deformation point data of the K groups of deformation results are registered with the sampling data respectively. That is, one group of deformation results is selected from the finite element model deformation library, the maximum deformation distance between the deformation point data of the group of deformation results and the sampling data is stored in correspondence with the deformation results, and the deformation results are marked as registered data. Repeatedly select a set of unmarked deformation results from the finite element model deformation library, register the deformation point data with the sampling point data, obtain the deformation distance and store it, and mark the deformation result as registered data, until the deformation point data of K sets of deformation results are registered to obtain the deformation distance; By comparing the deformation distances in the K groups of deformation results, the K deformation distances are ranked. ; Will or Compared with the preset tolerance, a set of deformation point data whose distance between the registered sampling data and the deformation point data meets the preset tolerance requirement is selected as the final deformation data; The final deformation data is converted into composite material conforming data.
2. The method according to claim 1, characterized in that, A set of deformation point data whose distance between the registered sampling data and the deformation point data meets a preset tolerance requirement is selected as the final deformation data, including: judge or Is it less than or equal to the preset tolerance? like If the value is less than or equal to the preset tolerance, the deformation distance will be... The corresponding deformation point data is used as the final deformation data, or, if If it is less than or equal to the preset tolerance, then distance The corresponding deformation point data is used as the final deformation data.
3. The method according to claim 2, characterized in that, Also includes: like or If all values are greater than the preset tolerance, then the fitting deformation distance... Corresponding deformation model and deformation distance The corresponding deformed numerical model is used to obtain the fitted numerical model; According to deformation distance Corresponding deformation point data and deformation distance The corresponding deformation point data is used to calculate the point coordinates of N key feature points of the fitted mathematical model, thereby obtaining the fitting point data of the fitted mathematical model. The fitted point data is used as the final deformation data.
4. The method according to claim 3, characterized in that, Fitted deformation distance Corresponding deformation model and deformation distance The corresponding deformed numerical model is used to obtain the fitted numerical model, and the fitting equation applied is: a and b are calculation parameters; The key feature point with the largest distance between the fitted digital model and the composite part is selected as the target key feature point. The fitting deformation distance between the target key feature point on the fitted digital model and the target key feature point on the composite part is... ; According to deformation distance Coordinates of key feature points of the target on the corresponding deformable digital model Deformation distance Coordinates of key feature points of the target on the corresponding deformable digital model and the fitted deformation distance System of simultaneous equations Calculate the coordinates of the target key feature points on the fitted mathematical model. Where x, y, and z are unknowns; Repeat execution based on deformation distance The coordinates of key feature points and deformation distance on the corresponding deformed digital model The coordinates of key feature points on the corresponding deformed digital model are used to calculate the coordinates of key feature points on the fitted digital model, and the coordinates of N key feature points on the fitted digital model are obtained as the final deformed data.
5. The method according to claim 1, characterized in that, After obtaining the composite material contouring data, the following is also included: The composite material contour data is input into a non-destructive testing (NDT) device for NDT.
6. The method according to claim 1, characterized in that, After obtaining the composite material contouring data, the following is also included: Using the composite material contouring data, contouring is performed to obtain a composite material contouring digital model; The composite material profiling model is input into a non-destructive testing device for non-destructive testing.
7. The method according to claim 1, characterized in that, The curing deformation parameters include the changes in specific heat and thermal conductivity with temperature and degree of curing, the constitutive model of the material, the definition of internal resin curing heat generation in heat transfer analysis, and the degree of curing value for each incremental step.
8. The method according to claim 1, characterized in that, The preset tolerance is 10mm.
9. The method according to claim 1, characterized in that, The key feature points include: The geometric corner points on the composite material, and / or the preset mating points on the composite material.