Method for assembling large equipment engines and mating equipment docking system

Abstract

The application discloses an assembling method of a large equipment engine, comprising the following steps: S1, judging whether the assembling can be successfully completed through virtual assembling, if the judging result is that the assembling can be successfully completed, obtaining the characteristic point coordinates corresponding to the center axis position required by the real assembling, if the assembling cannot be successfully completed, obtaining the interference region and the interference depth; S2, outputting the characteristic point coordinates obtained in S1 to a docking assembling control system, so as to establish a real docking coordinate system, and cooperating with a docking device in a real docking site to complete the real docking assembling of the related components of the large equipment engine. The application provides an assembling method of a large equipment engine, which is different from the existing automatic assembling technology in essence, that is, the point cloud file of the assembling surface is used for virtual assembling calculation, the optimal center axis is obtained, the optimal center axis is used for guiding the subsequent real automatic docking assembling, and thus the one-time docking assembling success target is achieved.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of large equipment docking assembly. More particularly, the present application relates to a method for assembling an engine of a large equipment used in the assembly of aerospace equipment and a matching equipment docking system. BACKGROUND

[0002] For the aerospace field, the drawings of the engine combustion chamber and the pipeline are strictly confidential and are not provided to the suppliers, so the detailed dimensions of the assembly surface cannot be obtained. In the prior art, the physical docking assembly includes two steps: the docking assembly of the combustion chamber rear opening and the pipeline, and the docking assembly of the combustion chamber front opening and the actuator.

[0003] In the docking assembly of the combustion chamber rear opening and the pipeline, due to the complexity of the assembly and the extremely high precision requirement, most domestic units still use relatively traditional manual operation to complete it. The position of the pipeline needs to be moved and adjusted by the experience of workers with the help of tooling. This process sometimes needs to consume a long time and repeated docking assembly may occur. At the same time, since the equipment is very expensive, if the surface is damaged during the assembly process, the consequences are incalculable. The measurement data of the assembly surface before assembly relies on manual measurement and manual input, and the error caused by human is large. The data of the assembled product cannot be accurately calculated. In addition, because the parts are large in volume and heavy in weight, it is difficult to move and rotate around the product axis. Further, because of the sealing problem after the product is assembled, it is also impossible to use measuring tools to measure the assembly data. These are not conducive to the digital production of the product. The out-of-tolerance data of the measured combustion chamber assembly surface cannot be used to accurately locate the out-of-tolerance parts, resulting in a long work period, low efficiency and large workload for repairing the out-of-tolerance parts of the product.

[0004] In order to solve the problems existing in the manual operation, only one or two large aerospace production units in China have developed relatively automatic assembly technology at present. However, these researches basically stop at the auxiliary measurement method, and are mainly to improve the measurement accuracy and enrich the measurement means, such as intelligent visual measurement. The purpose of the research is only to use optical measurement means to establish the center axis for docking, to change the original manual operation tooling into an automatic control system for assisting manual operation, so that manual operation is more convenient, which is essentially different from the real automation and intelligentization.

[0005] Meanwhile, these technologies only conducted research on virtual assembly on a small scale. They used a high-precision testing equipment, a free-arm testing system, to measure the actual data of the mating parts of the product. Then, using foreign 3D modeling and reverse engineering software, they performed circular fitting by modeling and collecting the 3D coordinates of spatial points to calculate the installation distance from the pipe's assembly surface to the fitted surface of the combustion chamber. After product testing, data acquisition took 60 minutes, data analysis took 5 minutes, and trial assembly took 120 minutes, for a total of 185 minutes, approximately 3 hours. This method uses insufficient spatial point data for virtual assembly and cannot accurately reflect the shape of the actual assembly surface. Therefore, the calculation results of virtual assembly are inaccurate and cannot guide the correction of out-of-tolerance surfaces, still carrying the risk of assembly failure. Furthermore, the level of automation and informatization is relatively low, failing to solve the problem of complete reliance on manual labor. Summary of the Invention

[0006] One object of the present invention is to solve at least the above-mentioned problems and / or defects, and to provide at least the advantages described below.

[0007] To achieve these objectives and other advantages of the present invention, a method for assembling a large equipment engine is provided, comprising:

[0008] S1. The virtual assembly is used to determine whether the assembly can be successfully completed. If the result is that the assembly can be successfully completed, the coordinates of the feature points corresponding to the central axis position required for the physical assembly are obtained. If not, the area and depth of interference are obtained.

[0009] S2. Output the feature point coordinates obtained in S1 to the docking assembly control system to establish a physical docking coordinate system, and cooperate with the docking device at the physical docking site to complete the physical docking assembly of the engine-related components of the large equipment.

[0010] The virtual assembly process includes:

[0011] S10. Based on the comprehensive detection unit set up at the physical docking site, obtain the feature points on the assembly surface of the workpiece to be docked;

[0012] S11. The virtual assembly terminal receives the feature points transmitted back by the integrated detection unit, and after preprocessing, performs virtual assembly calculations based on the three-dimensional virtual assembly software. If the assembly gap is negative, it is considered to have a central axis position available for assembly; otherwise, based on the interference index of each pose, the interference interval and interference depth are marked.

[0013] Preferably, in S11, the virtual assembly calculation process includes:

[0014] S110. Based on the preprocessed ASC file and feature point coordinate file, locate the screw holes on the flange on the point cloud, and establish a coordinate system with the central axis of the metal step in the ASC file.

[0015] S111. Based on the coordinate system of the metal step, obtain the mating surface of the non-metal step;

[0016] S112. Parametrically slice the mating surfaces and convert each slice to a polar coordinate system to obtain a profile curve that reflects the shape distribution of all mating surfaces.

[0017] S113. Within the predetermined tolerance range Ⅰ along the XOZ plane, search and determine the assembly pose Ⅰ where the assembly gap of the same mating surface is negative when the center offset is different. For the case of multiple mating surfaces, it is necessary to search separately according to the different predetermined tolerance ranges Ⅱ of metal-nonmetal and metal-metal to obtain the assembly pose Ⅱ where the assembly gap of each mating surface is negative.

[0018] Preferably, in S112, a polar coordinate system is established for each point P in the point cloud, centered at the origin O, and the polar radius R and polar angle α of each point are obtained by the following formula:

[0019] R ｉ =|P i O|

[0020]

[0021] In the above formula, i represents the variable index in the set, P xi This represents the coordinates of point P(Px,Pz) on the X-axis. xi This represents the coordinates of point P(Px,Pz) on the Z-axis;

[0022] All points are sorted from smallest to largest based on the polar angle α to obtain an ordered cross-sectional profile distributed in a counterclockwise direction.

[0023] The subdivided ordered point cloud is then subjected to quadratic polar coordinates to obtain a given hole / shaft part and a specified center offset, thereby generating the R-Theta curve shown in the figure.

[0024] Preferably, in S113, the corresponding interference index for each pose is obtained using the following formula:

[0025]

[0026] In the above formula, (Δx', Δz′) represents the center offset in the XOZ coordinate system, e rj(Δx,Δz) represents the maximum interference distance erj obtained based on the center offset (Δx,Δz), where j represents the number of segments of the three stepped axes, and the value ranges from 1 to 3.

[0027] Preferably, in S2, the physical docking and assembly process includes:

[0028] S20. Install the pipe to be installed on the accompanying tooling of the automated guided vehicle (AGV) so that the pipe to be installed and the accompanying tooling can be transported to the six-degree-of-freedom platform of the installation and testing station by the AGV.

[0029] S21. The combustion chamber, arc-shaped support frame, direct components, actuators and their accompanying tooling are transported to the designated location of the testing station by the corresponding AGV.

[0030] S22. Place a target ball at the feature point of the rear opening of the combustion chamber and the pipe to be installed. Record the coordinates of the point using a laser tracker. Combine the coordinates of the feature point transmitted from S1 to determine the static docking coordinate system of the rear opening and the motion coordinate system of the pipe to be installed. Feed back the 6D deviation between the two coordinate systems to the T-Mac six-dimensional attitude measuring instrument.

[0031] The S23, a six-degree-of-freedom platform and its slide table transport the pipe to be installed. Combined with the values ​​of the T-Mac six-dimensional attitude measuring instrument, a closed-loop motion system is formed. Finally, the pipe to be installed is connected to the rear opening of the combustion chamber and assembled after the two coordinate systems coincide.

[0032] S24. Using the above S22 and S23 process, complete the assembly of the actuator and the front opening of the combustion chamber, and after the fastening bolts of the front opening and the components at the top cover of the actuator are installed, perform an airtightness test.

[0033] A large equipment engine assembly method is provided with an equipment docking system, which is configured to include a virtual docking subsystem and a physical assembly subsystem, as well as a data acquisition unit that provides assembly data or on-site docking data for each subsystem. The virtual docking subsystem, the physical assembly subsystem, and the data acquisition unit are connected as one unit through an industrial switch network.

[0034] The virtual docking subsystem includes a comprehensive testing unit and a virtual assembly terminal.

[0035] The physical assembly subsystem includes: multiple laser trackers, a six-degree-of-freedom platform, an assembly robot, a linear guide slide, a field control box, an explosion-proof operation screen and / or signboard, a T-Mac six-dimensional attitude measuring instrument, a target ball, and accompanying tooling for fixing the parts to be docked.

[0036] Preferably, the industrial switch network includes:

[0037] A fiber optic ring network constructed using at least two 100 Mbps managed switches;

[0038] A serial fiber optic network constructed using two managed switches with optical ports;

[0039] Layer 3 Gigabit managed switch I and Layer 3 Gigabit managed switch II are respectively connected to fiber optic ring network and serial fiber optic network for communication.

[0040] Among them, the laser tracker, six-degree-of-freedom platform, field control box, field explosion-proof operation screen and / or signboard are constructed in the workstation at the workshop level through a fiber optic ring network to form at least two sets of control units;

[0041] The data acquisition units distributed in the workstations at the workshop level are connected to the data server and monitoring terminal in the workshop level control room via a serial fiber optic network and a three-layer gigabit managed switch II.

[0042] Each control unit is connected to the virtual assembly terminal in the workshop control room via a fiber optic ring network and a three-layer gigabit network management switch I.

[0043] Preferably, the linear guide slides are arranged opposite each other on both sides of the docking equipment, and the assembly robot is mounted on the linear guide slides;

[0044] The control cabinet of the assembly robot is connected to the virtual assembly terminal and central control cabinet in the workshop control room via a three-layer gigabit network management switch I.

[0045] Preferably, the three-layer gigabit managed switch I communicates with the enterprise-level intelligent warehousing system, intelligent transfer system, upper-level management and control system, and comprehensive detection unit through a corresponding security router.

[0046] The present invention has at least the following beneficial effects: The present invention organically integrates virtual assembly and physical assembly, thereby realizing a complete process solution from assembly calculation to automatic docking assembly.

[0047] Furthermore, the assembly method of the present invention differs fundamentally from existing automated assembly technologies in that it first performs virtual assembly calculations using the point cloud file of the assembly surface to obtain the optimal center axis, and then uses the optimal center axis to guide the subsequent automatic docking and assembly of physical objects, thereby achieving the goal of successful docking and assembly in one go.

[0048] Other advantages, objectives and features of the present invention will become apparent in part from the following description, and in part from those skilled in the art through study and practice of the invention. Attached Figure Description

[0049] Figure 1 This is a system block diagram of the equipment docking system for the large equipment engine of the present invention;

[0050] Figure 2 System topology diagram for virtual assembly subsystem and physical assembly subsystem;

[0051] Figure 3 This is a schematic diagram of the algorithm flow for virtual assembly in this invention;

[0052] Figure 4 The R-Theta curve obtained when this invention is applied;

[0053] Figure 5 This is a schematic diagram showing the gap and interference values ​​corresponding to the phase angle in this invention;

[0054] Figure 6 This is a schematic diagram of the optimal center axis position obtained by virtual calculation according to the present invention;

[0055] Figure 7 This is a schematic diagram illustrating the physical assembly process of the present invention;

[0056] Figure 8 This is a schematic diagram of the overall structure of the docking platform in an embodiment of the present invention;

[0057] Figure 9 for Figure 8 Schematic diagram of the mid-plane base plate;

[0058] Figure 10 for Figure 8 A schematic diagram of the two-degree-of-freedom adjustment device on the flat base plate;

[0059] Figure 11 for Figure 8 A schematic diagram of the supporting components on the flat base plate;

[0060] Figure 12 This is a schematic diagram of the structure of the irregular workpiece docking fixture in an embodiment of the present invention;

[0061] Figure 13 for Figure 12 A schematic diagram of the clamping component. Detailed Implementation

[0062] The present invention will now be described in further detail with reference to the accompanying drawings, so that those skilled in the art can implement it based on the description.

[0063] It should be understood that terms such as “having,” “comprising,” and “including” as used herein do not imply the presence or addition of one or more other elements or combinations thereof.

[0064] It should be noted that in the description of this invention, the orientations or positional relationships indicated by terms are based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing this invention and simplifying the description. They do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as limiting this invention. In addition, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0065] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installed", "equipped", "sleeved / connected", "connected", etc., should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be a connection within two components. For those skilled in the art, the specific meaning of the above terms in this invention can be understood according to the specific circumstances.

[0066] The assembly method of the present invention mainly includes the following aspects:

[0067] 1. After installing feature points on the mounting surfaces of the engine combustion chamber and pipes, scan to obtain point cloud files at a specified density.

[0068] 2. Preprocess and coarsely register the point cloud file to obtain a computable point cloud coordinate file and feature point coordinate file.

[0069] 3. Use 3D virtual assembly software to perform virtual assembly calculations on the above point cloud coordinate files and feature point coordinate files to obtain the assembled result. If assembly is possible, the coordinates of the feature points corresponding to the optimal central axis position will be obtained. If assembly is not possible, the interference area and interference depth will be given to guide subsequent corrections to the interference area.

[0070] 4. The coordinates of the feature points that can be assembled with the optimal center axis are transmitted to the subsequent automatic docking and assembly control system to establish the docking coordinate system.

[0071] 5. The multi-degree-of-freedom docking device is responsible for transporting pipes and fixing the T-Mac six-dimensional attitude measuring instrument. The assembly robot uses a quick-change gripping actuator to fix the T-Mac six-dimensional attitude measuring instrument.

[0072] 6. Using Leica's AT960-SR laser tracker and target sphere, establish a static docking coordinate system for the rear opening of the combustion chamber based on the coordinates of the feature points along the optimal central axis.

[0073] 7. Using the AT960-SR laser tracker and target ball, establish a motion docking coordinate system based on the central axis of the pipeline for the multi-degree-of-freedom docking device.

[0074] 8. The deviation between the stationary coordinate system and the moving coordinate system of the rear opening was measured using an AT960-SR laser tracker and a T-Mac six-dimensional attitude measuring instrument, forming a closed-loop feedback for motion control. The multi-degree-of-freedom docking device was then used to control the transport of the pipeline and complete the docking assembly of the rear opening.

[0075] 9. Using Leica's AT960-SR laser tracker and target ball, establish a static docking coordinate system for the combustion chamber front opening based on the coordinates of the feature points along the optimal central axis.

[0076] 10. Using an AT960-SR laser tracker and a target ball, establish a motion docking coordinate system for the assembly robot based on the central axis of the actuator flange.

[0077] 11. The deviation between the stationary coordinate system and the moving coordinate system of the front opening was measured using an AT960-SR laser tracker and a T-Mac six-dimensional attitude measuring instrument, forming a closed-loop feedback for motion control. The assembly robot's handling actuator and the front opening docking assembly were then completed.

[0078] The effects of the above assembly method include:

[0079] Firstly, virtual assembly technology can help find the optimal assembly position (center axis) before product docking and assembly, and provide calculation results of the assembly gap and interference range after assembly according to the optimal assembly position, filling the defect that the previous assembly process could not provide assembly results, or rather, the gap in domestic assembly docking.

[0080] Secondly, the technological innovation lies in the fact that similar products tend to focus on checking the actual dimensions of the product and comparing the differences between the actual product and the design drawings. If the error between the actual dimensions and the design dimensions is too large, it is considered impossible to assemble successfully and the product must be returned for repair unconditionally. However, in reality, based on experience, if the assembly assessment of the combustion chamber and pipes of large equipment engines is correct (the clearance calculation result of virtual assembly is a negative clearance), then even if the tolerances are not appropriate, assembly can still be successful. This reduces working time and improves work efficiency.

[0081] Thirdly, the virtual assembly stage: the calculation time is controlled within 2 minutes; the trial assembly stage: the time is 0; the physical assembly stage with front and rear openings: the time is controlled within 1 hour.

[0082] In specific implementation, such as Figure 2 As shown, it is a system topology diagram of virtual assembly and physical assembly of the present invention.

[0083] In practical applications, the virtual assembly section consists of a comprehensive inspection system and a virtual assembly computer. Point cloud files and feature point coordinate files of the engine assembly surface are obtained from the comprehensive inspection system and stored on the hard drive of the virtual assembly computer. Then, 3D virtual assembly software is run to preprocess the point cloud files of the assembly surface and perform virtual assembly calculations to determine the feature point coordinates corresponding to the optimal central axis. The physical assembly section consists of a laser tracker, a six-degree-of-freedom platform, an assembly robot, a linear guide slide, an industrial switch network, a field control system, a docking assembly computer, an explosion-proof signboard, and a field explosion-proof operation screen. First, a docking coordinate system is established using a laser tracker and a target ball based on the feature point coordinates of the optimal central axis. Then, the current position of the pipes and actuators is monitored by a T-Mac six-dimensional attitude measuring instrument. The six-degree-of-freedom platform moves the pipes and docks them with the rear opening of the combustion chamber; the assembly robot moves the actuators and docks them with the front opening of the combustion chamber. After docking and assembly are completed, the assembly robot and manual labor work together to tighten all the bolts of varying lengths on the flange.

[0084] Specifically, the virtual assembly steps include:

[0085] Step 1: Copy the point cloud files and accompanying documents from the integrated testing system. Using the IP address of the integrated testing system, enter the shared folder in File Explorer, then enter the login username and password. After successful verification, you can copy the point cloud files, alignment matrix text document, quadrant aperture coordinate document, quadrant sphere center point coordinate document, and quadrant sphere center point projection coordinate document from that folder.

[0086] Step two: Preprocessing of point cloud files. Besides the flanges, bolt holes, and stepped shafts required for assembly, the original point cloud graphics also contain pipe lugs, black irregular surfaces at the front of the pipes, the horn at the rear of the pipes, and the outer casing of the combustion chamber (excluding the front and rear flanges), etc., which do not need to be processed in the virtual assembly. These point cloud files need to be deleted to reduce the workload of virtual assembly calculations.

[0087] Step 3: After preprocessing the point cloud file, save it as an ASC file. Each point after processing includes three coordinates and three Euler angles.

[0088] Step four: Open the 3D virtual assembly software, import the workpiece's ASCII file and feature point coordinate file into the software, and begin virtual assembly calculations. The virtual assembly calculation process is as follows: Figure 3 As shown, it includes:

[0089] S110. Based on the preprocessed ASC file and feature point coordinate file, locate the screw holes on the flange in the point cloud, and establish a coordinate system with the central axis of the metal step in the ASC file.

[0090] S111. Based on the coordinate system of the metal steps, the distribution of mating surfaces of the non-metallic steps is analyzed.

[0091] S112. Based on the distribution of the mating surfaces, parametric slices are created for each surface. Each slice is converted to a polar coordinate system to obtain a contour curve that reflects the shape distribution of all mating surfaces. In S112, a polar coordinate system is established for each point P in the point cloud, centered at the origin O. The polar radius R and polar angle α of each point are obtained using the following formula:

[0092] R i =|P i O|

[0093]

[0094] In the above formula, i represents the variable index in the set, P xi This represents the coordinates of point P(Px,Pz) on the X-axis. xi This represents the coordinates of point P(Px,Pz) on the Z-axis;

[0095] All points are sorted from smallest to largest based on the polar angle α to obtain an ordered cross-sectional profile distributed in a counterclockwise direction.

[0096] By using the subdivided ordered point cloud (Cartesian coordinates) and converting it to quadratic polar coordinates, a given hole / shaft part and a specified center offset can be generated. Figure 4 The R-Theta curve shown is shown, where, Figure 4 The left image shows a polar coordinate system, and the right image shows the phase angle on the horizontal axis and the polar radius on the vertical axis. It can be seen that when the phase angles of the shaft and the aperture correspond, this model can be used to directly calculate the gap and interference values ​​corresponding to the phase angles. Figure 5 .

[0097] S113. Find the optimal center point position within the allowable tolerance range I. Search along the XOZ plane within the allowable tolerance range I to determine the optimal assembly pose I for the same mating surface with different center offsets. For multiple mating surfaces, it is necessary to search separately according to the different predetermined tolerance ranges II for metal-nonmetal and metal-metal, and obtain the assembly pose II with negative assembly clearance for each mating surface.

[0098] The formulas for calculating the interference index at each pose are as follows:

[0099]

[0100] Based on the above indicators, the optimal assembly pose is obtained by finding the optimal value, that is, minimizing the maximum interference depth / maximizing the minimum gap.

[0101]

[0102] like Figure 6 The obtained Δx′ and Δz′ are the offsets of the axis center point when the optimal pose is obtained. The coordinate transformation outputs the feature points of the axis that are finally used for assembly, guiding the subsequent assembly.

[0103] If the optimal center point is found successfully, i.e. the assembly gap is negative, the result is output to the corrected feature point coordinate file, thus completing the virtual assembly calculation.

[0104] If a suitable assembly clearance cannot be found, then the interference range and interference depth need to be marked to guide subsequent assembly surface correction.

[0105] Physical assembly is completed within the assembly and testing station, which includes a six-degree-of-freedom platform, two assembly robots, a laser tracker and four supporting linear slides, a T-Mac six-dimensional attitude tracker, an electronic Kanban board, two touch terminals, three hydraulic lifting platforms, four workbenches, a storage platform for actuators, and an explosion-proof cabinet and a positive pressure cabinet for the control system.

[0106] like Figure 7 As shown, the physical assembly steps include:

[0107] Step 1: The AGV of the logistics transfer system takes away the accompanying tooling of the engine pipeline of the large equipment at the testing station.

[0108] Step 2: The AGV transports the accompanying equipment of the pipeline to the large vertical warehouse.

[0109] Step 3: The large vertical warehouse takes the pipe out of the warehouse, moves it to the pipe-accompanying tool of the AGV, and clamps it in place.

[0110] Step 4: The AGV transports the pipeline and accompanying tooling to the six-degree-of-freedom platform of the testing station and clamps them in place. The AGV then withdraws from the testing station.

[0111] Step 5: The heavy-duty AGV of the logistics transfer system transports the combustion chamber of the large equipment engine, along with the arc-shaped support frame, to the designated location of the testing station, and then the heavy-duty AGV withdraws from the testing station.

[0112] Step 6: The small AGV of the logistics transfer system goes to the small warehouse to transport the direct parts of the large equipment engine to the designated location of the assembly and testing station, and then the small AGV withdraws from the assembly and testing station.

[0113] Step 7: The small AGV of the logistics transfer system goes to the explosion-proof operating room, transports the actuators and accompanying tooling to the designated location of the testing station, and then the small AGV leaves the testing station.

[0114] Step 8: Target balls are manually placed at the feature points of the combustion chamber rear opening and the pipe. The coordinates of these points are recorded by a laser tracker. Combined with the coordinates of the optimal position feature points calculated by virtual assembly, the static docking coordinate system of the rear opening and the motion coordinate system of the pipe are determined. The 6D deviation between the two coordinate systems is fed back to the T-Mac six-dimensional attitude measuring instrument.

[0115] Step 9: Before assembly, record the rear opening assembly surface of the large equipment engine using multimedia.

[0116] Step 10: The six-degree-of-freedom platform and its sliding transport pipe, combined with the values ​​from the T-Mac six-dimensional attitude measuring instrument, form a closed-loop motion system. Finally, the pipe is connected to the rear opening of the combustion chamber until the two coordinate systems coincide.

[0117] Step 11: The pipe docking mechanism is withdrawn, and the two assembly robots apply the specified torque to the rear-opening fastening bolts. Bolts that the robots cannot assemble are completed manually.

[0118] Step 12: Install the parts with openings after manual processing.

[0119] Step 13: The docking equipment, including one laser tracker and two assembly robots, is moved to the front opening position of the combustion chamber.

[0120] Step 14: Install the T-Mac six-dimensional attitude measuring instrument onto the gripper of the actuator. After the assembly robot picks up the actuator, the current position of the actuator can be measured in real time through the T-Mac.

[0121] Step 15: Target balls are manually placed at the feature points of the combustion chamber front opening and the actuator. The coordinates of these points are recorded by a laser tracker. Combined with the coordinates of the optimal position feature points calculated by virtual assembly, the static docking coordinate system of the front opening and the motion coordinate system of the actuator are determined. The 6D deviation between the two coordinate systems is fed back to the T-Mac six-dimensional attitude measuring instrument.

[0122] Step 16: Assemble the robot's handling actuator, combine it with the values ​​from the T-Mac six-dimensional attitude measuring instrument to form a closed-loop motion system, and finally align the actuator with the front opening of the combustion chamber until the two coordinate systems coincide.

[0123] Step 17: Two assembly robots move forward to tighten the bolts with the opening and apply the specified torque.

[0124] Step 18: Manually install the components on the top cover of the actuator and complete the remaining work.

[0125] Step 19: Check the airtightness of the product.

[0126] Step 20: The heavy-duty AGV of the logistics transfer system will transport the large equipment engine products from the testing station.

[0127] Furthermore, the assembly and docking connection T_MAC steps include:

[0128] 1. Take the T-MAC device out of the red box.

[0129] 2. Power on the laser tracker and connect it to the signal cable of the T-MAC device (fixed by the winding reel). Note the corresponding positions of the red dots on the connectors at both ends.

[0130] 3. Take out the small wooden box labeled "new river kinematics" from the black Leica equipment case. Inside is a purple and green USB flash drive.

[0131] 4. Insert the purple and green USB flash drives into the USB ports on the front of the graphics workstation computer. The computer will not show that the USB flash drives exist.

[0132] 5. Double-click to open the measurement and control system software. If the USB drive is successfully recognized, the control interface can be opened normally. If it is not successfully recognized, a message will appear indicating that the dongle was not found.

[0133] 6. The measurement and control system software will automatically open the SA software; there is no need to manually double-click to open it. The SA software will also access the USB drive when it opens. If the USB drive is correctly recognized, it can be opened normally. If it is not successfully recognized, a message will appear indicating that the dongle was not found.

[0134] 7. First, measure the characteristic points of the pipe docking assembly. After the measurement is completed, guide the light to the T-MAC reflector and start transmitting the T-MAC measurement data. Then the pipe docking assembly can be carried out.

[0135] 8. After the pipeline assembly is completed, the main program issues a stop measurement command, and the measurement control system will stop the transmission of T-MAC data.

[0136] 9. At this point, you can disconnect the T-MAC connection cable and remove the T-MAC device from the six-degrees-of-freedom platform.

[0137] 10. Secure the T-MAC device to the actuator fixture on the tool table of Robot 2, but do not connect the cables yet.

[0138] 11. After robot 2 grabs the actuator fixture, it uses the fixture to pick up the docking position of the actuator to the front opening of the combustion chamber. At this time, the T-MAC cable can be connected. Note the corresponding positions of the red dots on the connectors at both ends.

[0139] 12. Operate the measurement and control system software, then measure the feature points for the actuator docking and assembly. After the measurement is completed, guide the light to the T-MAC reflector and start transmitting the T-MAC measurement data. Then the actuator docking and assembly can be carried out.

[0140] 13. After the actuator is assembled, the main program issues a stop measurement command, and the measurement control system will stop the transmission of T-MAC data.

[0141] 14. At this point, you can disconnect the T-MAC connection cable and remove the T-MAC device from the actuator fixture.

[0142] 15. Place the T-MAC device back into the red box and store it properly.

[0143] Wind the T-MAC signal cable back onto the winding spool, making sure that the connectors at both ends are suspended off the ground to prevent dust from getting in.

[0144] Example 1

[0145] A docking system for the engine of a large piece of equipment.

[0146] like Figures 1-2 As shown, it includes a virtual docking subsystem 1 and a physical assembly subsystem 2, as well as a data acquisition unit 3 (configured to include a multimedia recorder 30 and multiple security cameras 31) that provides assembly data or on-site docking data for each subsystem. The virtual docking subsystem, the physical assembly subsystem, and the data acquisition unit are connected as one unit through an industrial switch network 4.

[0147] The virtual docking subsystem includes a comprehensive testing unit 10 (also known as a comprehensive testing system) and a virtual assembly terminal 11.

[0148] The physical assembly subsystem includes: multiple laser trackers 20 installed in the workshop layer, a six-degree-of-freedom platform (also known as a workstation host) 21, an assembly robot (not shown), a linear guide slide (not shown), a field control box 22, a field explosion-proof operation screen and / or signboard 23, a T-Mac six-dimensional attitude measuring instrument (not shown), a target ball (not shown), and accompanying tooling (not shown) for fixing the parts to be docked.

[0149] In practical applications, by organically integrating virtual assembly systems and physical assembly systems through industrial networks, a complete solution from assembly calculation to automatic docking assembly can be achieved.

[0150] Example 2

[0151] This second embodiment is a preferred embodiment of the present invention, such as... Figure 1As shown, it discloses the following improvements based on implementation method 1:

[0152] The industrial switch network includes:

[0153] 40; a fiber optic ring network constructed using at least two 100 Mbps managed switches.

[0154] A serial fiber optic network 41 constructed using two managed switches with optical ports;

[0155] Layer 3 gigabit managed switch I42 and Layer 3 gigabit managed switch II43 are respectively connected to fiber optic ring network and serial fiber optic network for communication.

[0156] Among them, the laser tracker, six-degree-of-freedom platform, field control box, field explosion-proof operation screen and / or signboard are constructed in the workstation at the workshop level through an optical fiber ring network to form at least two sets of control units 24;

[0157] The data acquisition units distributed in the workstations at the workshop level are connected to the data server 32 and the monitoring terminal (also known as the desktop monitoring client) 33 in the workshop level control room via a serial fiber optic network and a three-layer gigabit network management switch II.

[0158] Each control unit is connected to the virtual assembly terminal in the workshop control room via a fiber optic ring network and a three-layer gigabit network management switch I.

[0159] Working principle: Based on different control levels, different industrial switches are designed to build corresponding communication to connect the industrial layer and the enterprise layer, so that the terminals used for docking can be directly used with virtual assembly terminals, achieving integration and consolidation between subsystems, making management and subsequent control more convenient.

[0160] Example 3

[0161] This third embodiment is a preferred embodiment of the present invention, such as... Figure 1 As shown, it discloses the following improvements based on implementation method 1:

[0162] The linear guide slides are arranged opposite each other on both sides of the docking equipment, and the assembly robot is mounted on the linear guide slides.

[0163] The control cabinet (also known as KRC4) 25 of the assembly robot is connected to the virtual assembly terminal and central control cabinet 26 in the workshop control room through a three-layer gigabit network management switch I.

[0164] The three-layer gigabit managed switch I communicates with the enterprise-level intelligent warehousing system 6, intelligent transfer system 7, upper-level management and control system 8, and comprehensive detection unit through the corresponding security router 5.

[0165] Example 4

[0166] Figures 8-11 This invention illustrates a docking platform used in actual physical docking, comprising a flat base plate 101, on which a support assembly 107 is provided to mate with the flange of a conical cylinder, and a connecting plate 128 is also provided on the flat base plate 101 to contact the open end of the conical cylinder; a two-degree-of-freedom adjustment device is provided between the connecting plate 128 and the flat base plate 101 to adjust the spatial position of the connecting plate 128, the two-degree-of-freedom adjustment device being disposed on the flat base plate 101, and the connecting plate 128 being disposed on the two-degree-of-freedom adjustment device;

[0167] The connecting plate 128 is provided with a locking mechanism that abuts against the open end of the cone.

[0168] Working principle:

[0169] In the process of using this invention, the conical flange is placed on the support assembly 107, the open end of the conical is placed on the connecting plate 128, the conical is fixed on the docking platform by the locking mechanism on the connecting plate 128, and the spatial position of the connecting plate 128 is adjusted by the two-degree-of-freedom adjustment device so that the docking platform can adapt to conicals of different specifications.

[0170] In the above scheme, the top front end of the support assembly 107 has an arc-shaped groove that matches the outer shape of the flange, and the side of the arc-shaped groove has a through hole for connecting to the tapered flange. The tapered flange is connected to the arc-shaped groove through a fixing mechanism. It should be noted that the fixing mechanism can be a bolt connection, a pin connection, or any other connection method that can achieve integrated fixing of multiple components. Using this technical method, the support assembly 107 fixes the tapered flange to ensure that the tapered flange does not move or rotate during docking or movement.

[0171] In the above scheme, the two-degree-of-freedom adjustment device includes a lifting adjustment mechanism and an axial adjustment mechanism. The lifting adjustment mechanism is mounted on the flat base plate, and the axial adjustment mechanism is mounted on top of the lifting adjustment mechanism. Using this technical method, the height position of the connecting plate 128 is changed by adjusting the lifting adjustment mechanism, and the axial position of the connecting plate 128 is changed by adjusting the axial adjustment mechanism. The two-degree-of-freedom adjustment device allows the docking platform to adapt to cones of different specifications.

[0172] In the above scheme, the locking mechanism includes: a pneumatic clamp 102 and a support wheel 103. The pneumatic clamp 102 abuts against the inner arc surface of the open end of the cone, and the support wheel 103 abuts against the outer arc surface of the open end of the cone. Both the pneumatic clamp 102 and the support wheel 103 are mounted on the connecting plate 128, and the support wheel 103 is symmetrically arranged on both sides of the pneumatic clamp 102. Using this technical method, the locking device fixes the open end of the cone to ensure that the cone does not move or rotate during docking or movement.

[0173] In the above scheme, the lifting adjustment device includes: a lifting bracket 104, a lifting push rod 105 for adjusting the vertical position of the lifting bracket 104, and a drive assembly I connected to the lifting push rod 105; it also includes: a pair of limiting blocks 121 disposed on the flat base plate 101 for limiting the axial extension position of the lifting push rod 105, and each limiting block 121 is located on both sides of the lifting push rod 105. Two connecting rods hinged in the middle form an X-shaped lifting bracket 104 (this X-shaped lifting bracket 104 includes at least one layer in actual application, and can also be set into a multi-layer structure according to actual needs). The lifting bracket 104 is symmetrically arranged at both ends of the connecting plate 128. A fixing plate 116 is provided at the top of the lifting bracket 104. A slide rail I 126 is fixedly connected to one end of the bottom of the fixing plate 116. A slider I 125 is slidably connected to the slide rail I 126. One end of the upper end of the lifting bracket 104 is hinged to the fixing plate 116, and the other end is hinged to the slider I 125. A slide rail II 123 is provided on the flat base plate 101. A slider II 122 is slidably connected to the slide rail II 123. One end of the lower end of the lifting bracket 104 is hinged to the flat base plate 101, and the other end is hinged to the slider II 122.

[0174] The lifting push rod 105 has a through hole on its middle side for the first adjusting screw 117 to pass through, and both ends of the lifting push rod 105 are fixedly connected to the corresponding sliders II 122.

[0175] Drive component I includes: transmission component I and drive component I.

[0176] Transmission component I includes: a first adjusting lead screw 117, on which a lead screw nut I 27 is provided, and the lead screw nut I 27 is fixedly connected to the lifting push rod 105;

[0177] A lead screw mounting base I118 is fixedly connected to a flat base plate 101 and is located at the middle and end of the first adjusting lead screw 117.

[0178] Drive component I includes: coupling I119, reducer I120, and servo motor I106;

[0179] The lead screw mounting base I118 is equipped with a bearing at a position that mates with the first adjusting lead screw 117. One end of the first adjusting lead screw 117 is connected to one end of the reducer I120 via the coupling I119, and the other end of the reducer I120 is connected to the servo motor I106. Using this method, the servo motor I106 drives the reducer I120, which in turn drives the first adjusting lead screw 117 on the coupling I119 to rotate. This, in turn, causes the lead screw nut I27 to drive the slider II122 on the lifting push rod 105 to slide on the slide rail II123, ultimately adjusting the height of the connecting plate 128 on the lifting bracket 104. The limit block 121 restricts the axial movement of the lifting push rod 105 on the flat base plate 101. Through the lifting adjustment device, the docking platform can adapt to cones of different heights.

[0180] In the above scheme, the axial adjustment device includes: a sliding plate 113, a slider III 114 for adjusting the front and rear positions of the sliding plate 113, and a drive assembly II connected to the slider III 114.

[0181] A slide rail Ⅲ115 is fixedly connected to the top of the fixed plate 116, and a slider Ⅲ114 is slidably connected to the slide rail Ⅲ115.

[0182] A sliding plate 113 is fixedly connected to the top of the slider Ⅲ 114. One of the sliding plates 113 has a through hole for the second adjusting screw 112 to pass through. The two ends of the connecting plate 128 are fixedly connected to the corresponding sliding plate 113.

[0183] Drive component II includes: transmission component II and drive component II.

[0184] Transmission component II includes: a second adjusting screw 112, on which a screw nut II 124 is provided, and the screw nut II 124 is fixedly connected to the sliding plate 113;

[0185] Screw mounting base II111 is fixedly connected to the top of the fixing plate 116 and is located at the middle and end of the second adjusting screw 112;

[0186] Drive component II includes: coupling II110, reducer II109, and servo motor II108;

[0187] The lead screw mounting base II111 is equipped with a bearing at a position that mates with the second adjusting lead screw 112. One end of the second adjusting lead screw 112 is connected to one end of the reducer II109 via the coupling II110, and the other end of the reducer II109 is connected to the servo motor II108. Using this method, the servo motor II108 drives the reducer II109, which in turn drives the second adjusting lead screw 112 on the coupling II110 to rotate. This, in turn, causes the lead screw nut II124 to drive the slider III114 on the sliding plate 113 to slide on the slide rail III115, ultimately leading to the axial adjustment of the connecting plate 128 on the sliding plate 113. Through this axial adjustment device, the docking platform can adapt to cones of different lengths.

[0188] Example 5

[0189] Figures 12-13 This invention illustrates a non-standard workpiece docking fixture used in actual physical docking, comprising an L-shaped connecting plate 201. One side of the L-shaped connecting plate 201 is provided with a transfer mechanism 214 that cooperates with a six-degree-of-freedom manipulator. The invention is characterized by further including a clamping assembly disposed on the other side of the L-shaped connecting plate 201 for fixing the non-standard workpiece 208 to be docked. The L-shaped connecting plate 201 and the clamping assembly are connected via a force sensor I 202.

[0190] Working principle:

[0191] The irregularly shaped workpiece 208 is first fixed by a clamping assembly. A six-DOF robot arm connects to the transfer mechanism 214 to assemble the workpiece 208 onto other parts. During assembly, the assembly force is monitored in real time by force sensor I 202. When the irregularly shaped workpiece 208 aligns with the hole of the docking workpiece, no assembly force is generated. However, if the axis of the irregularly shaped workpiece 208 is not aligned with the hole of the docking workpiece, the surface of the irregularly shaped workpiece 208 will be pressed against the surface of the docking workpiece, generating abnormal assembly force. At this time, force sensor I 202 sends a signal to the control system, which terminates the assembly. This ensures that the irregularly shaped workpiece 208 is not damaged during the docking process.

[0192] In the above solution, the clamping assembly includes a rectangular housing, within which a clamping mechanism is disposed. The clamping mechanism is connected to the irregularly shaped workpiece to be docked via a pair of connecting mechanisms. This technical solution connects the irregularly shaped workpieces through the clamping mechanism housed within the housing and the connecting mechanism mounted on the clamping mechanism.

[0193] In the above solution, the clamping assembly is connected to the outer periphery of the L-shaped connecting plate 201 by a plurality of guide posts 203. This technical solution guides the clamping assembly under axial force via the guide posts 203, and when the clamping assembly is no longer under force, the guide posts 203 restore it to its initial position.

[0194] In the above scheme, the clamping mechanism includes: a cylinder 205, a clamp 209, a force sensor II 210, and a support block with a T-shaped structure; the piston rod of the cylinder 205 passes through the housing and is fixedly connected to the top of the clamp 209; the protruding part of the support block is connected to the bottom surface of the clamp 209 by a fixing mechanism; the force sensor II 210 is attached to the protruding shaft of the support block, and the upper surface of the force sensor II 210 is in close contact with the bottom of the clamp 209; the upper and lower surfaces of the clamp 209 are respectively provided with two guide rods 204 that can pass through the upper and lower surfaces of the housing; the housing is provided with a guide sleeve 211 at the position that cooperates with the guide rods 204. Using this technical solution, the clamp 209 is released and clamped by the cooperation of the cylinder 205 and the guide rod 204. During the clamping process, the clamping force is monitored in real time by the force sensor II 210 attached to the support block. This prevents the connecting rod 206 from falling off the clamp 209 when the clamping force is too small, and prevents the clamp 209 and the connecting rod 206 from being damaged when the clamping force is too large.

[0195] In the above solution, the connecting mechanism is provided with two connecting rods 206, one of which is an irregularly shaped connecting rod 207. The clamp is provided with grooves I 212 and II 213 that are identical in shape to the two connecting rods 206. An integrally formed limiting boss I 271 is provided on one side of the irregularly shaped connecting rod 207 that mates with groove I 212, and integrally formed limiting bosses II 261 are provided on both sides of the connecting rod 206 that mates with groove II 213. This technical solution enhances the connection stability between the clamp and the connecting rod 206, ensures that the irregularly shaped connecting rod 207 does not rotate between the connecting rod and the clamp, and restricts radial movement of the connecting rod 206 with the limiting bosses on the clamp.

[0196] The above solution is merely an illustration of a preferred example and is not limited thereto. When implementing this invention, appropriate substitutions and / or modifications can be made according to the user's needs.

[0197] The number of devices and processing scale described herein are for the purpose of simplifying the description of the invention. Applications, modifications, and variations of the invention will be readily apparent to those skilled in the art.

[0198] Although embodiments of the present invention have been disclosed above, they are not limited to the applications listed in the specification and embodiments. It can be applied to various fields suitable for the present invention. Other modifications can be readily made by those skilled in the art. Therefore, without departing from the general concept defined by the claims and their equivalents, the present invention is not limited to the specific details and examples shown and described herein.

Claims

1. A method of assembling a large equipment engine, characterized by, The method comprises the following steps: S1, judging whether the assembly can be successfully completed through virtual assembly, if the result of the judgment is that the assembly can be successfully completed, the coordinates of the feature points corresponding to the center axis position required for the physical assembly are obtained, if not, the interference region and the interference depth are obtained; S2, outputting the feature point coordinates obtained in S1 to the docking assembly control system to establish a physical docking coordinate system, and cooperating with the docking device in the physical docking site to complete the physical docking assembly of the engine-related components of the large equipment; The process of the virtual assembly comprises: S10, obtaining the feature points on the assembly surface of the workpiece to be connected based on the comprehensive detection unit arranged in the physical docking site; S11, the virtual assembly terminal receives the feature points returned by the comprehensive detection unit, and after preprocessing, the virtual assembly calculation is performed based on the three-dimensional virtual assembly software, if the assembly gap is negative, it is considered that there is a center axis position available for assembly, otherwise, based on the interference index of each pose, the interference interval and the interference depth are marked out; In S11, the process of the virtual assembly calculation comprises: S110, positioning the screw holes on the flange based on the ASC file and the feature point coordinate file obtained by preprocessing, establishing a coordinate system based on the center axis of the metal step in the ASC file; S111, obtaining the mating surface of the non-metal step based on the coordinate system of the metal step; S112, parameterizing the slices, and converting each slice to polar coordinates to obtain a profile curve that can reflect the shape distribution of the entire mating surface; S113, searching for the assembly pose I of the same mating surface with a negative assembly gap at different center offsets along the XOZ plane within a predetermined tolerance range I, and for multiple mating surfaces, separate searches are required according to the different predetermined tolerance range II of metal-nonmetal and metal-metal to obtain the assembly pose II of each mating surface with a negative assembly gap; In S112, for each point P in the point cloud, an polar coordinate system is established with the origin O as the center point, and the polar radius R and the polar angle a of each point are obtained by the following formula: In the above formula, i denotes the sequence number of the variable in the set, P xi denotes the coordinate of the point P (P x , P z ) in the X axis, P zi denotes the coordinate of the point P (P x , P z ) in the Z axis; Sort all points from small to large based on the polar angle a to obtain an ordered cross section profile distributed counterclockwise; Using the subdivided ordered point cloud, a secondary polar coordinate is performed to obtain the corresponding R-Theta curve for the given hole / axis part and the specified center offset; In S113, the interference index of each pose is obtained by the following formula: In the above formula, represents the center offset in the XOZ coordinate system, represents the maximum interference distance e obtained on the basis of the center offset (Δx, Δz) rj , j represents the number of segments of the three-segment stepped shaft, and the value range is 1-3.

2. The assembling method of a large-scale equipment engine according to claim 1, wherein In S2, the physical docking assembly process comprises: S20, installing the pipeline to be installed on the accompanying tool of the automatic guided vehicle (AGV) to transport the pipeline to be installed and the accompanying tool to the six-degree-of-freedom platform of the measurement station through the AGV; S21, transporting the combustion chamber, arc-shaped support frame, straight part, actuator and accompanying tool to the specified position of the measurement station through the corresponding AGV; S22, placing target balls at the feature points of the combustion chamber rear opening and the pipeline to be installed, recording the point coordinates through the laser tracker, combining the feature point coordinates transmitted from S1 to determine the stationary butt joint coordinate system of the rear opening and the motion coordinate system of the pipeline to be installed, and feeding back the 6D deviation between the two coordinate systems to the T-Mac six-dimensional attitude measuring instrument; S23, the six-degree-of-freedom platform and its sliding table carry the pipeline to be installed, and form a closed-loop motion system in combination with the numerical value of the T-Mac six-dimensional attitude measuring instrument, finally butt joint the pipeline to be installed into the rear opening of the combustion chamber, and assemble after the two coordinate systems coincide; S24, using the above S22, S23 process to complete the assembly of the actuator and the front opening of the combustion chamber, and after the installation of the parts at the fastening bolts of the front opening and the actuator top cover, carry out the air tightness test.

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