Processing and assembling integrated tooling and processing method for composite star-sensing crossbeam

Abstract

This invention provides an integrated tooling and method for processing and assembling a composite star-type crossbeam, comprising: a base plate, a positioning plate, a pad, a cover plate, and a drilling jig; the positioning plate and the drilling jig are positioned and installed on the base plate, and the cover plate is installed on the top of the positioning plate; the base plate crossbeam of the base plate is used to connect the composite star-type crossbeam mounting surface of the composite star-type crossbeam, and the pad is installed between the base plate crossbeam and the composite star-type crossbeam mounting surface; the positioning plate mounting surface of the positioning plate is used to connect the star-type mounting surface of the composite star-type crossbeam. This application, by simultaneously designing the base plate and the cover plate, allows the composite star-type crossbeam to be positioned by the base plate, pad, and positioning plate during rough and fine machining, followed by the installation of the cover plate. After turning over, the base plate is removed, and the machining datum is transferred to the tooling, achieving unification of the machining datum with the subsequent assembly datum. This effectively reduces the number of rework and adjustments, and improves processing efficiency.

Description

Technical Field

[0001] This invention relates to the field of tooling design for processing and assembling composite structural components, and more specifically, to an integrated tooling and processing method for processing and assembling composite star-shaped crossbeams. Background Technology

[0002] A star sensor is an optical attitude control sensor that can accurately determine the location and attitude of a satellite in space, used for navigation and attitude control. The star sensor bracket is a key component in satellite assembly, used to connect the star sensor to the support structure and bear various loads throughout its lifespan from production to space mission. It needs to be lightweight, high rigidity, low creep, and high thermal stability. High-modulus carbon fiber composite material is usually used as the main material of the star sensor bracket.

[0003] The composite star-sensor beam integrates multiple star-sensor support heads onto the beam using an integrated molding method to improve the on-orbit pointing accuracy of the star sensor. The composite star-sensor beam is typically mounted on a support structure. Its beam mounting surface is the connection surface between the star-sensor beam and the support structure, while the star-sensor mounting surface is the connection surface between the star sensor and the beam. A specific spatial relationship must be maintained between the beam mounting surface and the star-sensor mounting surface. The star-sensor mounting surface of the composite star-sensor beam is planar, and the relative position of each star-sensor mounting surface can be ensured through adhesive bonding and assembly tools, such as adhesive scrapers. However, the beam mounting surface is generally L-shaped or U-shaped, with low raw precision, requiring post-processing of the cross-section cavity to ensure the spatial relationship between the beam mounting surface and the star-sensor mounting surface.

[0004] Currently, the assembly mold design is based on the crossbeam mounting surface being machined to the required position. The crossbeam mounting surface is used as a reference to glue and scrape the star sensor mounting surface. However, the composite star sensor crossbeam is machined separately without a corresponding reference and needs to be based on the star sensor mounting surface. There is a contradiction between the two requirements. The composite star sensor crossbeam needs to be repeatedly tested with the assembly mold and adjusted to meet the gap required for gluing the star sensor mounting surface scraper.

[0005] Therefore, it is necessary to design a tooling that simultaneously satisfies the processing and assembly of composite material star-shaped crossbeams, so that the processing state and the subsequent assembly state are consistent, thereby improving operability. Summary of the Invention

[0006] To address the shortcomings of existing technologies, the purpose of this invention is to provide an integrated tooling and processing method for machining and assembling composite star-shaped crossbeams.

[0007] According to the present invention, an integrated tooling for processing and assembling a composite material star-shaped crossbeam includes: a base plate, a positioning plate, a pad, a cover plate, and a drill jig;

[0008] A positioning plate and a drill jig are positioned and installed on the base plate, and a cover plate is installed on the top of the positioning plate;

[0009] The base plate crossbeam is used to connect the composite star-sensor beam mounting surface of the composite star-sensor beam, and a pad is installed between the base plate crossbeam and the composite star-sensor beam mounting surface;

[0010] The positioning plate mounting surface is used to connect to the star-sensor mounting surface of the composite material star-sensor beam.

[0011] Preferably, the positioning plate is positioned and connected to the base plate and the cover plate at both ends by positioning pins and screws.

[0012] Preferably, the drill jig is positioned and connected to the base plate by locating pins and screws, and the pad is connected to the base plate by screws.

[0013] Preferably, the base plate, the positioning plate, and the cover plate are welded from steel plates and cold-drawn seamless steel pipes.

[0014] Preferably, the pad is designed in two parts and includes various thickness specifications.

[0015] Preferably, a bonding gap is reserved between the mounting surface of the positioning plate and the mounting surface of the star sensor.

[0016] Preferably, the positioning plate is provided with reinforcing ribs.

[0017] Compared with the prior art, the present invention has the following beneficial effects:

[0018] 1. This application designs a base plate and a cover plate simultaneously. During rough and fine machining of the composite material star-sensor beam, the cover plate is installed after positioning by the base plate, pads, and positioning plates. After turning over, the base plate is removed, and the machining datum is transferred to the tooling. This achieves the unification of the machining datum with the subsequent assembly datum, which can effectively reduce the number of repeated machining and repairs and improve machining efficiency.

[0019] 2. This application avoids initial assembly interference by designing split pads of various thicknesses, and gradually meets the requirements of roughing, finishing and final assembly of composite star-sensor beams, thereby reducing the amount of repairs. Attached Figure Description

[0020] Other features, objects, and advantages of the present invention will become more apparent from the following detailed description of non-limiting embodiments with reference to the accompanying drawings:

[0021] Figure 1 The main view of the integrated tooling;

[0022] Figure 2 A top view of the integrated tooling;

[0023] Figure 3 This is a schematic diagram showing the positional relationship between the base plate and the pad blocks;

[0024] Figure 4 A schematic diagram of a composite material star-shaped crossbeam mounted on a base plate;

[0025] Figure 5 A schematic diagram showing the installation of a positioning plate after the composite star-shaped crossbeam is mounted on the base plate.

[0026] Figure 6 This is a schematic diagram of the composite material star-shaped crossbeam, along with the positioning plate and cover plate, when inverted.

[0027] Figure 7 A 3D view of the integrated tooling;

[0028] Figure 8 This is a schematic diagram showing the location of the star sensor mounting surface;

[0029] As shown in the figure:

[0030] Detailed Implementation

[0031] The present invention will now be described in detail with reference to specific embodiments. These embodiments will help those skilled in the art to further understand the present invention, but do not limit the invention in any way. It should be noted that those skilled in the art can make several changes and improvements without departing from the concept of the present invention. These all fall within the protection scope of the present invention.

[0032] Example 1

[0033] like Figure 1-3 As shown, this embodiment includes: a base plate 1, a positioning plate 2, a pad 3, a cover plate 4, and a drill jig 5. The positioning plate 2 and the drill jig 5 are positioned and installed on the base plate 1. The drill jig 5 is positioned and connected to the base plate 1 by positioning pins and screws. The two ends of the positioning plate 2 are positioned and connected to the base plate 1 and the cover plate 4 by positioning pins and screws. The base plate crossbeam 101 of the base plate 1 is used to connect the composite material star-sensor crossbeam 6 to the composite material star-sensor crossbeam 6. The pad 3 is installed between the base plate crossbeam 101 and the composite material star-sensor crossbeam 611. The pad 3 is connected to the base plate 1 by screws. The positioning plate mounting surface 201 of the positioning plate 2 is used to connect the star-sensor mounting surface 621 of the composite material star-sensor crossbeam 6. A pre-reserved adhesive gap is provided between the positioning plate mounting surface 201 and the star-sensor mounting surface 621.

[0034] In one embodiment, the pad 3 adopts a split design and includes various thickness specifications.

[0035] In one embodiment, the base plate 1, the positioning plate 2, and the cover plate 4 are made of steel plates welded together with cold-drawn seamless steel pipes.

[0036] In one embodiment, the positioning plate 2 is provided with reinforcing ribs.

[0037] Combination Figure 4-8 As shown in the figure, this embodiment also provides a method for processing composite star-shaped crossbeams using an integrated tooling for processing and assembling composite star-shaped crossbeams, including the following steps:

[0038] Step S1: Install pad 3 on the base plate crossbeam 101, and install the composite star-sensor crossbeam mounting surface 611 of the composite star-sensor crossbeam 6 onto the base plate crossbeam 101; if the composite star-sensor crossbeam mounting surface 611 causes interference during the initial assembly due to unevenness after molding, rough machine the interference area until the interference is eliminated; Step S2: Install positioning plate 2 on the base plate 1, and place carbon sheet or aluminum sheet between the star-sensor mounting surface 621 of the composite star-sensor crossbeam 6 and the positioning plate mounting surface 201 of the positioning plate 2 to reserve a gap. At the same time, fill the gap between the pad 3 at the base plate crossbeam 101 and the composite star-sensor crossbeam mounting surface 611 with carbon sheet or aluminum sheet, and then use C-clamps to clamp and fix the star-sensor mounting surface 621 and the positioning plate mounting surface 201; Step S3: Install cover plate 4 on positioning plate 2, then flip the entire fixture and remove the base plate 1 and pad 3. Place the fixture on the milling machine platform, and... Figure 6 After the reference planes formed by H and K are leveled with the milling machine coordinate axes using dial indicators, the dimensions and positional accuracy of the composite star-sensor beam mounting surface 611 are machined using the reference planes formed by H and K as references. In step S4, the C-clamp and carbon or aluminum sheet are removed, the composite star-sensor beam 6 is moved away, the base plate 1 is reassembled, the tooling is flipped over as a whole and the positioning plate 2 and cover plate 4 are removed, the pad block 3 is installed on the base plate beam 101, and then the composite star-sensor beam 6 is installed on the base plate beam 101 and the positioning plate 2 is installed. The gap requirements between the star-sensor mounting surface 621 and the positioning plate mounting surface 201 are checked. If they meet the requirements, the hole positions are machined on the composite star-sensor beam 6 using the drill jig 5. Otherwise, the machining needs to be re-adjusted.

[0039] Example 2

[0040] Example 2 is a preferred example of Example 1.

[0041] like Figure 1-8 As shown, this embodiment includes: a base plate 1, a positioning plate 2, a pad 3, a cover plate 4, and a drill jig 5. The base plate 1 and positioning plate 2, and the cover plate 4 and positioning plate 2 are positioned and connected using positioning pins and screws. The pad 3 is connected to the base plate 1 using screws. The drill jig 5 and base plate 1 are positioned and connected using positioning pins and screws. After the star-sensor mounting surface 621 is installed, the drill jig 5 is used to machine the relevant holes. The pins, screws, positioning pins, and screws are designed and configured with different specifications according to assembly requirements.

[0042] To prevent interference with the mounting surface 611 of the composite star-type crossbeam at the base plate crossbeam 101, the spacer block 3 is designed as a separate piece, and the spacer block 3 has multiple thickness specifications to meet the roughing, finishing and final assembly requirements of the composite star-type crossbeam 6. In this embodiment, the spacer block 3 is designed with three thickness specifications: 9mm, 9.5mm and 10mm, which respectively meet the roughing, finishing and final assembly requirements of the composite star-type crossbeam 6.

[0043] In this embodiment, the machining datum for the composite star-shaped crossbeam 6 is designed on the integrated tooling. The machining datum is obtained by overall machining after assembly. After the positioning plate 2 is installed on the cover plate 4, the coplanar datum K is obtained by machining the positioning plate 2 as a whole, that is, the coplanarity formed by the sides of multiple positioning plates 2. At the same time, the mounting surface of the positioning plate 2 and the base plate 1 can be used as the coplanar datum H. The coplanar datums K and H can be used as the machining datum for the composite star-shaped crossbeam 6.

[0044] In one embodiment, a 0.3mm adhesive gap is reserved between the positioning plate mounting surface 201 and the star sensor mounting surface 621.

[0045] In one embodiment, the base plate 1, positioning plate 2, and cover plate 4 are made of steel plate and cold-drawn seamless steel pipe welded together. Welding stress should be eliminated before machining after welding.

[0046] In one embodiment, the flatness of the base plate beam 101 is better than 0.05, and the verticality is better than 0.05.

[0047] The processing method in this embodiment includes:

[0048] Step 1: Install 9mm or 9.5mm thick pads 3 on the base plate crossbeam 101, then... Figures 4-5 As shown, the composite star-sensor beam 6 is installed on the base plate beam 101 and the positioning plate 2 is installed. If the mounting surface 611 of the composite star-sensor beam is uneven after molding, causing interference during the initial assembly, the interference part needs to be rough machined until the assembly requirements are met.

[0049] Step 2: Place carbon or aluminum sheets between the star sensor mounting surface 621 and the positioning plate mounting surface 201 to ensure a gap of 0.3mm. Similarly, use aluminum sheets to fill the gap between the pad 3 at the bottom plate beam 101 and the composite material star sensor beam mounting surface 611. Then, use C-clamps to clamp and fix the star sensor mounting surface 621 and the positioning plate mounting surface 201.

[0050] Step 3: Install cover plate 4, flip the entire fixture over, remove base plate 1 and pad block 3, and place it on the milling machine platform. Figure 5 The coplanar reference points H and K are used as reference planes, and the surface dimensions and dimensional accuracy of the composite material star-sensor beam mounting surface 611 are machined respectively.

[0051] Step 4: Remove the C-shaped clamps and aluminum sheets, and move the composite material star-sensor beam 6; reassemble the base plate 1 into the tooling, flip it over, remove the cover plate 4 and positioning plate 2, and install 10mm pads 3 on the base plate beam 101, then proceed as follows. Figure 4 As shown, the composite material star-sensor beam 6 is installed on the base plate beam 101 and the positioning plate 2 is installed. The star-sensor mounting surface 621 and the positioning plate mounting surface 201 are checked to ensure that the gap requirement of 0.3mm is met. If they meet the requirement, the hole position is machined using the drill jig 5. Otherwise, the machining needs to be re-adjusted.

[0052] In the description of this application, it should be understood that the terms "upper", "lower", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this application and simplifying the description, and 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. Therefore, they should not be construed as limitations on this application.

[0053] Specific embodiments of the present invention have been described above. It should be understood that the present invention is not limited to the specific embodiments described above, and those skilled in the art can make various changes or modifications within the scope of the claims, which do not affect the essence of the present invention. Unless otherwise specified, the embodiments and features described in this application can be arbitrarily combined with each other.

Claims

1. A method for processing composite star-shaped crossbeams, comprising an integrated tooling for processing and assembling composite star-shaped crossbeams, characterized in that, include: Base plate (1), positioning plate (2), pad block (3), cover plate (4) and drilling jig (5); Positioning plate (2) and drill jig (5) are positioned and installed on the base plate (1), and cover plate (4) is installed on the top of positioning plate (2). The bottom plate crossbeam (101) of the bottom plate (1) is used to connect the composite star-sensor crossbeam mounting surface (611) of the composite star-sensor crossbeam (6), and a pad (3) is installed between the bottom plate crossbeam (101) and the composite star-sensor crossbeam mounting surface (611). The positioning plate mounting surface (201) of the positioning plate (2) is used to connect the star-sensor mounting surface (621) of the composite star-sensor beam (6). Includes the following steps: Step S1: Install pads (3) on the bottom plate crossbeam (101) and install the composite material star-sensor crossbeam mounting surface (611) of the composite material star-sensor crossbeam (6) onto the bottom plate crossbeam (101); Step S2: Install the positioning plate (2) on the base plate (1), and place carbon or aluminum sheets between the star sensor mounting surface (621) of the composite star sensor beam (6) and the positioning plate mounting surface (201) of the positioning plate (2) to reserve a gap. At the same time, fill the gap between the pad (3) at the base plate beam (101) and the composite star sensor beam mounting surface (611) with carbon or aluminum sheets. Then use C-clamps to clamp and fix the star sensor mounting surface (621) and the positioning plate mounting surface (201). Step S3: Install the cover plate (4) on the positioning plate (2), then flip the tooling over as a whole and remove the bottom plate (1) and pad (3). Place the tooling on the milling machine platform, and after leveling it with the milling machine coordinate axis by referring to the reference plane H and reference plane K, process the surface dimensions and shape and position accuracy of the composite material star-sensor crossbeam mounting surface (611) based on the reference plane composed of the reference plane H and reference plane K. Among them, the reference surface K is the coplanar surface formed by the sides of multiple positioning plates (2), and the reference surface H is the mounting surface of the positioning plate (2) and the base plate (1); Step S4: Remove the C-clamp and carbon or aluminum sheet, remove the composite star sensor beam (6), reassemble the base plate (1), flip the tooling over and remove the positioning plate (2) and cover plate (4), install the pad (3) on the base plate beam (101), then install the composite star sensor beam (6) on the base plate beam (101) and install the positioning plate (2), check the gap requirements for clamping and fixing the star sensor mounting surface (621) and the positioning plate mounting surface (201). If it meets the requirements, use the drill jig (5) to process the hole on the composite star sensor beam (6); otherwise, it needs to be re-processed.

2. The method for processing composite star-shaped crossbeams according to claim 1, characterized in that: The positioning plate (2) is positioned and connected to the base plate (1) and the cover plate (4) by positioning pins and screws at both ends.

3. The method for processing composite star-shaped crossbeams according to claim 1, characterized in that: The drill jig (5) is positioned and connected to the base plate (1) by positioning pins and screws, and the pad (3) is connected to the base plate (1) by screws.

4. The method for processing composite star-shaped crossbeams according to claim 1, characterized in that: The base plate (1), the positioning plate (2), and the cover plate (4) are made of steel plate and cold-drawn seamless steel pipe welded together.

5. The method for processing composite star-shaped crossbeams according to claim 1, characterized in that: The pad (3) adopts a split design and includes various thickness specifications.

6. The method for processing composite star-shaped crossbeams according to claim 1, characterized in that: A pre-reserved adhesive gap is provided between the positioning plate mounting surface (201) and the star sensor mounting surface (621).

7. The method for processing composite star-shaped crossbeams according to claim 1, characterized in that: The positioning plate (2) is provided with reinforcing ribs.

8. The method for processing composite star-shaped crossbeams according to claim 1, characterized in that: In step S1, if the composite material star-sensor beam mounting surface (611) causes interference during the initial assembly due to unevenness after molding, the interference area is rough-machined until the interference is eliminated.

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