A structure assembly system based on measured data of a laser tracker

Abstract

The application relates to a structure assembly system based on actual measurement data of a laser tracker and belongs to the field of virtual assembly simulation. Actual data of actual parts are obtained through the laser tracker, virtual assembly is carried out according to the measurement data by using virtual assembly technology, clearance adjustment, interference error reporting and the like are included, the optimal clearance is ensured, the parts with interference are prompted to be processed or replaced in advance, and then the one-time assembly success rate is ensured. The application lays a foundation for assembly process optimization.

Description

Technical Field

[0001] This invention belongs to the field of virtual assembly simulation, specifically relating to a structural component assembly system based on measured data from a laser tracker. Background Technology

[0002] Large and complex components are characterized by their large overall size, numerous structural features, and relatively high manufacturing precision. However, existing virtual assembly technologies, based on theoretical product models, result in significant deviations in structural positioning and fitting from the actual product's condition. To achieve high-precision and high-efficiency assembly of complex components, research is needed on virtual assembly methods for complex components based on measured data, employing digital measurement methods and key feature reverse reconstruction techniques. This will provide a theoretical basis for high-precision positioning and accurate fitting of complex structural features.

[0003] Virtual assembly simulation technology refers to the use of virtual reality technology to pre-assemble designed components, analyze and evaluate them, improve unreasonable component structures, and optimize assembly process schemes. This technology can shorten product development cycles, reduce product development costs, and improve assembly feasibility.

[0004] For example, the patent "Virtual Assembly System and Virtual Assembly Method Based on Spacecraft Assembly Simulation Technology" (application number 200810180605.8, publication number 101739478) proposes a spacecraft virtual assembly system including a computer-aided design (CAD) modeling module, a virtual assembly planning module, and an assembly process design module, and provides a virtual assembly simulation analysis method based on the system.

[0005] The patent "Visual Simulation System for Aircraft Assembly Site" (application number 201110059898.6, publication number 102117367) discloses a visual simulation system for aircraft assembly site that includes an assembly simulation database module, an assembly simulation technology module, and an assembly visualization expression system.

[0006] However, the assembly simulation objects of the above patents all use theoretical design models and lack actual product shape and size data. The assembly process schemes obtained by simulating the assembly process based on theoretical shape data often cannot reflect the actual situation.

[0007] Compared to the assembly process of large aerospace components, the assembly and welding of large structural parts involves the overall assembly of multiple parts on a unified platform according to a specific assembly sequence and requirements. This differs significantly from the assembly process of large aircraft components, primarily in the large number of assembled parts and the complex positioning relationships. Positioning involves both between parts and between parts and tooling. After structural assembly, tack welding is required. Therefore, the assembly process for large structural parts cannot simply replicate the aerospace assembly model. Instead, it must fully utilize advanced technologies such as digitalization, automation, and dynamic measurement and real-time adjustment during the assembly process to achieve precise welding of large structural parts based on digitalization. Summary of the Invention

[0008] (a) Technical problems to be solved

[0009] The technical problem to be solved by this invention is how to provide a structural component assembly system based on measured data from a laser tracker, so as to solve the bottleneck problem of excessive interference and gaps in the welding process of large and complex components.

[0010] (II) Technical Solution

[0011] To solve the above-mentioned technical problems, the present invention proposes...

[0012] A structural component assembly system based on measured data from a laser tracker, characterized in that the system includes: a data management module, an assembly scheme module, and an individual management module;

[0013] The data management module is used to establish a database. The database organizes and manages data in a three-level structure of batch, individual, and part. Under the batch, all design models, assembly sequence, assembly requirements, and assembly gaps of the assembly individual are managed. The design models of individuals under the same batch all come from this batch. Different assembly process cards can be created under the batch to store the assembly sequence, requirements, and gaps of different processes. Users can select different assembly processes for assembly according to the actual situation. That is, a batch can create multiple assembly schemes.

[0014] The assembly scheme module stores the assembly sequence, requirements, and clearances for different processes. Users can select different assembly processes for assembly based on the actual situation.

[0015] A batch can create any number of assembly individuals. When creating an assembly individual, the corresponding assembly scheme is selected. The theoretical data of the design model and the actual measurement data of each assembly part are stored under the individual.

[0016] (III) Beneficial Effects

[0017] This invention proposes a structural component assembly system based on measured data from a laser tracker. The system obtains actual data of the actual parts using a laser tracker and performs virtual assembly using virtual assembly technology based on the measurement data. This includes gap adjustment, interference error reporting, etc., to ensure that the optimal gap is obtained, and to provide prompts for interfering parts so that they can be dealt with or replaced in advance, thereby ensuring a high success rate of assembly on the first attempt.

[0018] This invention strengthens the control of the assembly and welding process. It utilizes 3D laser scanning measurement technology to scan and measure the turret body after spot welding, obtaining its external dimensions. These dimensions are then compared with a standard digital model to obtain the deformation value. Similarly, the assembled turret body is scanned and compared to obtain the welding deformation. The large-scale 3D measurement, virtual simulation, and adjustment of turret body parts have accumulated a wealth of manufacturing process data. Through statistical analysis based on this big data, the impact of factors such as processing errors and clearance requirements on the final assembly accuracy can be obtained, laying the foundation for optimizing the assembly process. Attached Figure Description

[0019] Figure 1 This is a diagram illustrating data management.

[0020] Figure 2 To create an assembly process flowchart;

[0021] Figure 3 The interface diagram for assembling and mounting the model;

[0022] Figure 4 Individual management flowchart;

[0023] Figure 5 Schematic diagram for obtaining weld volume;

[0024] Figure 6 This is a flowchart of the assembly simulation based on the tracker. Detailed Implementation

[0025] To make the objectives, contents, and advantages of the present invention clearer, the specific embodiments of the present invention will be described in further detail below with reference to the accompanying drawings and examples.

[0026] This solution is a virtual assembly method for structural components based on measured data. It uses digital measurement methods to perform high-precision laser scanning measurement of the key features of the structural components and reverse reconstruction. Then, based on the measured data of the product, it carries out virtual assembly of the integrated structure, evaluates the positioning quality of the parts, determines the amount of repair, and achieves zero-margin precision assembly through sample process control.

[0027] Virtual simulation technology based on measured data can simulate the assembly process of large components, thereby guiding the actual assembly process. However, in practical applications, it often suffers from "simulation without realism," because it is difficult to perfectly simulate the actual assembly process in a virtual environment. By performing three-dimensional measurements on large component parts and then conducting virtual simulation based on the measured data, the confidence level of the simulation is significantly improved, effectively solving the problem of "simulation without realism" and enhancing the guiding nature of the simulation results. Moreover, virtual simulation technology based on measured data achieves a "1+1>2" effect.

[0028] The assembly system of this invention mainly comprises the following modules:

[0029] 1. Data Management Module

[0030] First, a database needs to be established, which organizes and manages data using a three-level structure of batch, individual, and part.

[0031] A batch manages all design models, assembly sequences, assembly requirements, assembly clearances, etc., of individual assembly components. The design models of individuals within the same batch all originate from this batch. Different assembly process cards can be created within a batch to store the assembly sequences, requirements, clearances, etc., of different processes. Users can select different assembly processes for assembly according to actual conditions. That is, a batch can create multiple assembly schemes; when creating an individual component, the required assembly scheme is selected, and the measurement data of each assembly part (design model) is stored under the individual component.

[0032] 2. Assembly scheme module

[0033] The assembly scheme module (i.e., process card) stores the assembly sequence, requirements, clearances, etc., for different processes. Users can select different assembly processes based on their actual situation. When designing this software system, users have already stored a certain number of assembly scheme templates according to their needs. Users can call up assembly scheme templates and customize them when using the system.

[0034] The specific method is as follows: Right-click on "Assembly Scheme," open the right-click menu, select "New Scheme," and enter the new assembly scheme interface; when creating an assembly scheme, you can set the scheme name and adjust the assembly order; after creation, each assembly scheme will automatically obtain all design models under this batch, and different assembly process cards can be created, such as... Figure 2 As shown:

[0035] The design model under the assembly scheme is accessed through the virtual assembly interface. The software displays the design models assembled in the correct order. For example, double-clicking MX2 in ZPFA1 will display design models MX1 and MX2 in the virtual assembly 3D view. During model assembly, gaps and overall tolerance requirements are displayed in real time. Users can adjust the model or replace part models as needed. Figure 3 As shown:

[0036] 3. Individual Management Module

[0037] A batch can create any number of assembly individuals. When creating an assembly individual, the corresponding assembly scheme is selected. The theoretical data of the design model and the actual measurement data of each assembly part are stored under the individual.

[0038] There are two methods to create assembly individuals: through batch nodes or through individual nodes. Taking batch node creation as an example, right-click the batch name "Batch 1", select "New Individual" from the context menu, set the individual name, select the assembly scheme, and the creation time will be displayed. After the individual is created, the individual node includes parts, scan data, and bolt hole positions. The parts will automatically retrieve measurement data with the same filename, such as... Figure 4 As shown:

[0039] Methods for obtaining measurement data, such as Figure 6 As shown, the parts to be assembled are scanned and measured to obtain point cloud data. After the scan is completed, the data is imported into the assembly system, and assembly simulation is performed based on the measured point cloud data.

[0040] Welding positioning can be determined based on the final assembly coordinates and gap values; for example, after the reference plate is positioned, the components assembled in sequence can be assembled according to the gap.

[0041] The welding gap volume can be obtained by fitting a spatial polyhedron to the measured points of the gap positioning in the virtual assembly, and then obtaining the volume of the polyhedron, such as... Figure 5 As shown:

[0042] This invention does not require physical assembly and supports virtual assembly simulation of large structural components for various special vehicles. It also features on-site assembly control, automatically adjusting each component to the expected position based on the data of all positioned parts collected by the laser tracker and the final assembly result, thus achieving a matching assembly effect.

[0043] This invention is the first to propose an integrated technology for the measurement, simulation and assembly of large components, and constructs a closed-loop control mode for the precise welding of large components based on measured data.

[0044] This invention proposes a method for detecting multidimensional heterogeneous parts based on three-dimensional laser measurement, which significantly improves the measurement accuracy and efficiency of complex parts, lays the foundation for virtual assembly based on actual measurement data, and provides basic data for the precise welding of large components.

[0045] This invention proposes a method for detecting multidimensional heterogeneous parts based on three-dimensional laser measurement, which significantly improves the measurement accuracy and efficiency of complex parts, lays the foundation for virtual assembly based on actual measurement data, and provides basic data for the precise welding of large components.

[0046] At the same time, an integrated equipment system was built, which integrates key equipment such as measurement system, simulation system and positioning adjustment system, and solved the bottleneck problem of interference and excessive gap in the welding process of large and complex components.

[0047] This invention obtains actual data of actual parts through a laser tracker, and performs virtual assembly using virtual assembly technology based on the measurement data, including gap adjustment, interference error reporting, etc., to ensure that the optimal gap is obtained, prompts are given for interfering parts, and they are dealt with or replaced in advance, thereby ensuring the success rate of assembly on the first attempt.

[0048] This invention strengthens the control of the assembly and welding process. It utilizes 3D laser scanning measurement technology to scan and measure the turret body after spot welding, obtaining its external dimensions. These dimensions are then compared with a standard digital model to obtain the deformation value. Similarly, the assembled turret body is scanned and compared to obtain the welding deformation. The large-scale 3D measurement, virtual simulation, and adjustment of turret body parts have accumulated a wealth of manufacturing process data. Through statistical analysis based on this big data, the impact of factors such as processing errors and clearance requirements on the final assembly accuracy can be obtained, laying the foundation for optimizing the assembly process.

[0049] The above description is only a preferred embodiment of the present invention. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the technical principles of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A structural component assembly system based on measured data from a laser tracker, characterized in that, The system includes: a data management module, an assembly scheme module, and an individual management module; The data management module is used to establish a database. The database organizes and manages data in a three-level structure of batch, individual, and part. Under the batch, all design models, assembly sequence, assembly requirements, and assembly gaps of the assembly individual are managed. The design models of individuals under the same batch all come from this batch. Different assembly process cards can be created under the batch to store the assembly sequence, requirements, and gaps of different processes. Users can select different assembly processes for assembly according to the actual situation. That is, a batch can create multiple assembly schemes. The assembly scheme module stores the assembly sequence, requirements, and clearances for different processes. Users can select different assembly processes for assembly based on the actual situation. A batch can create any number of assembly individuals. When creating an assembly individual, the corresponding assembly scheme is selected. The theoretical data of the design model and the actual measurement data of each assembly part are stored under the individual. in, The method for acquiring measurement data is as follows: scan and measure the parts to be assembled to obtain point cloud data, import the data into the assembly system after scanning, and perform assembly simulation based on the measured point cloud data.

2. The structural component assembly system based on laser tracker measured data as described in claim 1, characterized in that, When designing the system, users have already stored a certain number of assembly scheme templates according to their needs. When using the system, users can call up the assembly scheme templates and customize them.

3. The structural component assembly system based on laser tracker measured data as described in claim 1, characterized in that, The method for creating an assembly scheme is as follows: Right-click "Assembly Scheme", open the right-click menu, select "New Scheme", and enter the new assembly scheme interface; when creating an assembly scheme, set the scheme name and adjust the assembly order; after creation, each assembly scheme will automatically obtain all design models under this batch and create different assembly process cards.

4. The structural component assembly system based on laser tracker measured data as described in claim 3, characterized in that, The design model under the assembly scheme is entered into the virtual assembly interface, where the software displays the design model assembled in the assembly sequence.

5. The structural component assembly system based on laser tracker measured data as described in claim 4, characterized in that, During the model assembly process, the gap and overall tolerance requirements are displayed in real time, allowing users to adjust the model or replace part models as needed.

6. The structural component assembly system based on laser tracker measured data as described in claim 1, characterized in that, To create an assembly individual using a batch node, right-click the batch name "Batch 1", select "New Individual" from the right-click menu, set the individual name, select the assembly scheme, and the creation time will be displayed. After the individual is created, the individual node includes parts, scan data, and bolt hole positions. The parts will automatically retrieve measurement data with the same file name.

7. The structural component assembly system based on laser tracker measured data as described in claim 1, characterized in that, The method for creating an assembly individual is: through individual nodes.

8. The structural component assembly system based on laser tracker measured data as described in claim 1, characterized in that, Welding positioning is determined based on the final assembly coordinates and gap values.

9. The structural component assembly system based on laser tracker measured data as described in claim 1, characterized in that, The welding gap volume is obtained by fitting a spatial polyhedron through the measured points of the gap positioning of the virtual assembly, and then obtaining the volume of the polyhedron.

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