Heavy load high-precision reconfigurable three-dimensional adjustment tool and control method

Abstract

The application relates to the technical field of component assembly, and provides a heavy-load high-precision reconfigurable three-dimensional adjustment tool. The heavy-load high-precision reconfigurable three-dimensional adjustment tool comprises a supporting base, an X-direction horizontal adjustment module arranged above the supporting base, a Y-direction horizontal adjustment module arranged above the X-direction horizontal adjustment module and capable of translating together with the X-direction horizontal adjustment module, a Z-direction lifting adjustment module arranged above the Y-direction horizontal adjustment module, and a bearing workbench arranged above the Z-direction lifting adjustment module and used for bearing a workpiece. The heavy-load high-precision reconfigurable three-dimensional adjustment tool has the advantages of high adaptability, large bearing capacity, high guiding precision and convenient maintenance, can eliminate the influence of elastic deformation of a piston rod on positioning precision through rod deformation compensation under heavy-load conditions, and meets the high-precision assembly requirement of heavy workpieces in the fields of large scientific experiment devices and ship manufacturing. In addition, the application further provides a control method applied to the tool.

Description

Technical Field

[0001] This application relates to the technical field of component assembly, and in particular to a heavy-duty, high-precision, reconfigurable three-dimensional adjustment fixture. Background Technology

[0002] In engineering practices such as the construction of large-scale scientific experimental facilities, shipbuilding, and the docking of aerospace components, it is often necessary to precisely assemble and join several large components in space. During the final assembly of these key components, their orientation and positioning need to be adjusted in multiple orthogonal directions to achieve precise docking between the parts. Existing technologies already possess various three-dimensional adjustment devices or tooling for assembling large components. These toolings are typically positioned below the workpiece and utilize adjustment mechanisms in multiple directions to change the spatial position of the workpiece.

[0003] Existing three-dimensional adjustment fixtures mainly employ the following implementation methods. One type is a dedicated fixture specifically designed for a particular workpiece or process; its structure is typically an integral welded construction, with the motion mechanisms for each adjustment direction integrated within the same frame. Another type uses a mechanical screw-type adjustment mechanism, achieving displacement adjustment in each direction through lead screw transmission. A third type uses a hydraulic drive scheme, using hydraulic cylinders to output thrust to achieve lifting or translation of the workpiece. In all these types of fixtures, horizontal guidance often uses ordinary sliding guides or linear guides, and a rigid support surface is usually provided on the worktable for placing the workpiece.

[0004] However, the existing three-dimensional adjustment fixtures have the following problems in use. Once the structure of a dedicated fixture is formed, it is difficult to adapt to the needs of different product types or different process stages. When the shape or specifications of the workpiece change, the original fixture often becomes unusable. When a part of an integral welded structure fails or wears out, it often requires complete disassembly or even replacement, resulting in long maintenance cycles and high costs. While mechanical screw-type adjustment mechanisms can achieve greater load-bearing capacity, their position control accuracy is limited. Ordinary sliding or linear guides tend to have reduced guiding accuracy under heavy and eccentric loads, affecting the straightness of horizontal movement and repeatability. More importantly, under heavy load conditions, the hydraulic cylinder piston rod is prone to elastic deformation under load, and traditional position control methods rely solely on displacement sensors for feedback, making it difficult to compensate for positioning errors caused by rod deformation. This problem is particularly prominent when the workpiece weight reaches tens or even hundreds of tons; the accumulation of positioning errors will directly affect the assembly quality of the mating surfaces, failing to meet the high-precision assembly requirements of large-scale projects. Summary of the Invention

[0005] In view of this, this application aims to propose a heavy-duty, high-precision, reconfigurable three-dimensional adjustment fixture to solve the above-mentioned technical problems.

[0006] To achieve the above objectives, the technical solution of this application is implemented as follows: Firstly, this application proposes a heavy-duty, high-precision, reconfigurable three-dimensional adjustment fixture, comprising: The support base is used to support the overall tooling and provide a stable installation reference. An X-axis horizontal adjustment module is disposed above the support base and is used to perform translational adjustment in the first horizontal direction; The Y-axis horizontal adjustment module is located above the X-axis horizontal adjustment module. It can move together with the X-axis horizontal adjustment module and is used to perform translation adjustment in a second horizontal direction orthogonal to the X-axis. The Z-axis lifting adjustment module is located above the Y-axis horizontal adjustment module and is used to perform vertical lifting adjustment. A support worktable is positioned above the Z-axis lifting adjustment module and is used to directly support the workpiece to be adjusted; The X-axis horizontal adjustment module, the Y-axis horizontal adjustment module, and the Z-axis lifting adjustment module are arranged in a three-layer stacked orthogonal layout in space. The support base and the X-axis horizontal adjustment module, the X-axis horizontal adjustment module and the Y-axis horizontal adjustment module, and the Y-axis horizontal adjustment module and the Z-axis lifting adjustment module are all provided with detachable standardized modular interfaces, which enable the three-dimensional adjustment fixture to select and reconfigure modules according to the size and weight requirements of the workpiece.

[0007] Furthermore, the X-axis horizontal adjustment module includes an X-axis horizontal drive cylinder, an X-axis sliding base plate, and an X-axis dovetail guide mechanism; The Y-axis horizontal adjustment module includes a Y-axis horizontal drive cylinder, a Y-axis sliding base plate, and a Y-axis dovetail guide mechanism; the X-axis horizontal drive cylinder and the Y-axis horizontal drive cylinder are arranged horizontally at right angles to each other.

[0008] Furthermore, both the X-direction dovetail guide mechanism and the Y-direction dovetail guide mechanism are dovetail groove type guide structures; Dovetail-shaped guide rail pairs are provided between the X-axis sliding base and the support base, and between the Y-axis sliding base and the X-axis sliding base. The dovetail guide pair includes a convex dovetail guide rail and a concave dovetail groove that slide together along the guide direction.

[0009] Furthermore, it also includes a high-precision hydraulic control system; the high-precision hydraulic control system includes an electro-hydraulic power source, a valve island actuator, a signal processing unit, and multiple sensors; The electro-hydraulic power source includes an electro-hydraulic proportional control module, a pump motor unit, an oil tank, and hydraulic accessories. The electro-hydraulic proportional control module includes a proportional directional valve, a differential pressure reducing valve, and an accumulator. The valve island actuator includes multiple solenoid directional valves and connecting pipelines for each cylinder. The signal processing unit includes a programmable logic controller (PLC) and a proportional amplifier. The sensors include displacement sensors located at the cylinders of each adjustment module and force sensors located below the support worktable. The PLC controller is connected to each of the sensors to receive feedback signals from the displacement and force sensors and output control commands to the electro-hydraulic servo proportional valve to control the displacement and output force of each cylinder.

[0010] Furthermore, the PLC controller is also equipped with a rod deformation compensation module; The rod deformation compensation module calculates the elastic deformation compensation amount of the piston rod according to the elastic deformation formula based on the load force detected by the force sensor and the preset equivalent stiffness of the piston rod, and adds the elastic deformation compensation amount to the target value of displacement control to eliminate the influence of piston rod elastic deformation on positioning accuracy under heavy load conditions.

[0011] Furthermore, each of the modular interfaces includes a positioning pin hole and a quick-locking device. The positioning pin hole enables precise positioning between adjacent modules, and the quick-locking device enables detachable connection between modules.

[0012] Furthermore, the supporting worktable includes a worktable base plate and a plurality of adjustable ball joint support units disposed on the worktable base plate; The adjustable ball joint support unit includes a ball joint seat, a ball head support rod, and a locking mechanism. The ball head support rod can freely deflect in space relative to the ball joint seat. The height and deflection angle of each adjustable ball joint support unit can be adjusted independently.

[0013] Furthermore, it is also equipped with a pose monitoring system; The pose monitoring system includes a multi-station laser tracker target system or visual measurement markers, wherein the multi-station laser tracker target or the visual measurement markers are arranged at the four corners of the support worktable and at key measurement points of the workpiece; The posture monitoring system is connected to the PLC controller to collect the three-dimensional spatial posture data of the workpiece in real time and feed it back to the PLC controller to form workpiece posture control. The tooling includes at least two independent tooling units, each of which is arranged at different support points on the workpiece. Each tooling unit is connected to the PLC controller and is uniformly coordinated and controlled by the PLC controller.

[0014] Furthermore, the Z-axis lifting adjustment module includes a Z-axis lifting drive cylinder, and the hydraulic circuit of the Z-axis lifting drive cylinder is equipped with a booster system consisting of a cylinder booster and an ultra-high pressure relay.

[0015] Secondly, this application provides a control method applied to the heavy-duty, high-precision, reconfigurable three-dimensional adjustment fixture as proposed in the first aspect, comprising the following steps: Step S1, Pose Data Acquisition: The pose monitoring system collects real-time spatial pose data of the workpiece above each tooling unit. The real-time spatial pose data includes the three-dimensional coordinate values ​​of each measuring point. Step S2, Multi-objective optimization solution: Based on the target pose of each feature point, with the minimum sum of squared errors of feature points after the action of each tooling unit as the objective function, solve the optimal allocation scheme of motion of each degree of freedom of each tooling unit. Step S3, Coordination Command Issuance: The solved motion quantities are distributed to the corresponding adjustment modules of each tooling unit, and the motion commands are executed by the hydraulic control system of each adjustment module; Step S4, Real-time Feedback Correction: The pose monitoring system continuously collects real-time pose data and feeds it back to the PLC controller, repeating steps S2 to S3 until the error of each feature point is less than the preset threshold.

[0016] Compared with existing technologies, the heavy-duty, high-precision, reconfigurable three-dimensional adjustment fixture and control method proposed in this application have the following advantages: (1) This application sets the X-axis horizontal adjustment module, Y-axis horizontal adjustment module and Z-axis lifting adjustment module into a three-layer stacked orthogonal layout, and sets detachable standardized modular interfaces between the support base and the X-axis horizontal adjustment module, between the X-axis horizontal adjustment module and the Y-axis horizontal adjustment module, and between the Y-axis horizontal adjustment module and the Z-axis lifting adjustment module, so that the three-dimensional adjustment fixture can select and reconstruct modules according to the size and weight requirements of the workpiece; it also realizes the precise positioning between adjacent modules through the positioning pin holes in the modular interface, and realizes the detachable connection between modules through the quick locking device, so that the fixture can adapt to the assembly requirements of different specifications of workpieces and only needs to replace the corresponding module when there is a partial failure.

[0017] (2) This application achieves improved horizontal translational motion guidance accuracy and anti-overturning performance under heavy load conditions by using X-axis horizontal drive cylinders and Y-axis horizontal drive cylinders arranged at right angles to each other and independently controlled by a hydraulic control system. Combined with dovetail-shaped guide rail pairs between the X-axis sliding base and the support base, and between the Y-axis sliding base and the X-axis sliding base, feedback signals from displacement and force sensors are used to output control commands to the electro-hydraulic servo proportional valve via a PLC controller to control the cylinder displacement and output force. Furthermore, the rod deformation compensation module calculates the elastic deformation compensation amount based on the load force detected by the force sensor and the preset equivalent stiffness of the piston rod, and adds this compensation amount to the displacement control target value. This eliminates the influence of piston rod elastic deformation on positioning accuracy under heavy load conditions, thus improving positioning accuracy under heavy load conditions.

[0018] (3) This application achieves stable support and uniform force distribution for workpieces with different bottom shapes by using multiple adjustable ball joint support units set on the worktable base plate in the support worktable. The ball head support rod of each adjustable ball joint support unit can freely deflect in space relative to the ball joint seat, and the height and deflection angle can be adjusted independently. In addition, the three-dimensional spatial pose data of the workpiece is collected in real time by multi-station laser tracker targets or visual measurement markers arranged at the four corners of the support worktable and key measurement points of the workpiece in the pose monitoring system and fed back to the PLC controller. In addition, multiple independent tooling units are uniformly coordinated and controlled by the PLC controller, realizing the collaborative pose adjustment and docking positioning between multiple tooling units. Attached Figure Description

[0019] The accompanying drawings, which form part of this application, are used to provide a further understanding of this application. The illustrative embodiments and descriptions of this application are used to explain this application and do not constitute an undue limitation of this application. In the drawings: Figure 1 This is a schematic diagram of the heavy-duty, high-precision, reconfigurable three-dimensional adjustment fixture described in the embodiments of this application; Figure 2 This is a block diagram illustrating the high-precision hydraulic control system described in the embodiments of this application. Figure 3 This is a schematic diagram of the multi-tool collaborative control layout described in the embodiments of this application; Figure 4 This is a flowchart of the control method described in the embodiments of this application.

[0020] Explanation of reference numerals in the attached figures: 1. Supporting worktable; 2. X-axis horizontal drive cylinder; 3. Cylinder booster; 4. Proportional directional valve; 5. Filter; 6. X-axis sliding base plate; 7. Y-axis sliding base plate; 8. Support base; 9. Y-axis dovetail guide mechanism; 10. X-axis dovetail guide mechanism; 11. Z-axis lifting drive cylinder; 12. Displacement sensor; 13. Y-axis horizontal drive cylinder. Detailed Implementation

[0021] To make the technical solution and advantages of this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the scope of this application.

[0022] It should be noted that, unless otherwise specified, the embodiments and features described in this application can be combined with each other.

[0023] Furthermore, it should be noted that in the description of this application, if terms such as "upper," "lower," "inner," or "outer" appear, indicating orientation or positional relationship, these are based on the orientation or positional relationship shown in the accompanying drawings and 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, and therefore should not be construed as a limitation on this application. In addition, if terms such as "first" or "second" appear, they are also used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0024] Furthermore, in the description of this application, unless otherwise expressly defined, the terms "installation," "connection," "joining," and "connector" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection between two components. Those skilled in the art can understand the specific meaning of the above terms in this application in light of the specific circumstances.

[0025] In this application, the terms "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., refer to a specific feature, structure, material, or characteristic described in connection with that embodiment or example, which is included in at least one embodiment or example of this application. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0026] The present application will now be described in detail through exemplary embodiments. However, it should be understood that, without further description, elements, structures, and features in one embodiment may be advantageously incorporated into other embodiments.

[0027] Example 1 To achieve a balance between high load-bearing capacity and high adjustment accuracy, while simultaneously improving the adaptability and maintainability of the tooling, this embodiment provides a heavy-duty, high-precision, reconfigurable three-dimensional adjustment tooling, referring to... Figure 1 The fixture includes a support base 8, an X-axis horizontal adjustment module, a Y-axis horizontal adjustment module, a Z-axis lifting adjustment module, and a support worktable 1. The support base 8 supports the entire fixture and provides a stable installation reference. The X-axis horizontal adjustment module is positioned above the support base 8 and is used for translational adjustment in the first horizontal direction. The Y-axis horizontal adjustment module is positioned above the X-axis horizontal adjustment module and can move along with it, performing translational adjustment in the second horizontal direction orthogonal to the X-axis. The Z-axis lifting adjustment module is positioned above the Y-axis horizontal adjustment module and is used for vertical lifting adjustment. The support worktable 1 is positioned above the Z-axis lifting adjustment module and directly supports the workpiece to be adjusted. The X-axis horizontal adjustment module, Y-axis horizontal adjustment module, and Z-axis lifting adjustment module are arranged in a three-layer stacked orthogonal configuration in space. The support base 8 is equipped with detachable, standardized modular interfaces between itself and the X-axis horizontal adjustment module, between the X-axis horizontal adjustment module and the Y-axis horizontal adjustment module, and between the Y-axis horizontal adjustment module and the Z-axis lifting adjustment module. This allows the three-dimensional adjustment fixture to be selected and reconfigured according to the size and weight requirements of the workpiece. The support base 8 is made of high-strength steel plate and has leveling bolts and anchor holes at the bottom. It can be installed on the assembly platform and its horizontal reference can be adjusted to ensure the overall flatness and stability of the fixture.

[0028] To achieve independent translational adjustment in two orthogonal horizontal directions, the X-axis horizontal adjustment module in this embodiment includes an X-axis horizontal drive cylinder 2, an X-axis sliding base plate 6, and an X-axis dovetail guide mechanism 10. The Y-axis horizontal adjustment module includes a Y-axis horizontal drive cylinder 13, a Y-axis sliding base plate 7, and a Y-axis dovetail guide mechanism 9. The X-axis horizontal drive cylinder 2 and the Y-axis horizontal drive cylinder 13 are arranged horizontally at right angles to each other and are independently controlled by the hydraulic control system. Both the X-axis horizontal drive cylinder 2 and the Y-axis horizontal drive cylinder 13 are double-acting hydraulic cylinders, with a single cylinder stroke set to ±150mm and a single cylinder thrust set to 50 tons. This stroke parameter can cover the horizontal position deviation adjustment requirements during the docking process of most large components, and the 50-ton single cylinder thrust can meet the horizontal translational driving force requirements under heavy load conditions, while avoiding the increase in the length of the guide mechanism and the expansion of the overall tooling volume due to excessive stroke.

[0029] Based on the invention objective of improving the horizontal motion guidance accuracy and anti-eccentric load capability, in this embodiment, both the X-direction dovetail guide mechanism 10 and the Y-direction dovetail guide mechanism 9 are dovetail groove type guide structures. Between the X-direction sliding base plate 6 and the support base 8, and between the Y-direction sliding base plate 7 and the X-direction sliding base plate 6, mutually cooperating dovetail-shaped guide rail pairs are provided. The dovetail-shaped guide rail pairs include a convex dovetail guide rail and a concave dovetail groove that slide along the guiding direction. The guide rail surface is hardened and ground, with a surface roughness Ra not exceeding 0.4μm, and the fitting clearance is controlled within 0.02mm, ensuring a horizontal motion straightness better than 0.05mm per meter. The dovetail groove type guide structure possesses strong load-bearing capacity and anti-overturning moment performance, maintaining motion stability even under heavy load and eccentric load conditions. It eliminates the gap jitter problem easily occurring in ordinary sliding guide rails, effectively ensuring the straightness and repeatability of horizontal translational motion, meeting the requirements of high-precision fields for horizontal adjustment accuracy. Choosing a clearance of less than 0.02mm can avoid motion misalignment caused by excessive clearance, and prevent motion jamming and accelerated wear caused by insufficient clearance, thereby improving motion accuracy and service life.

[0030] To achieve precise control of the displacement and output force of each cylinder, the tooling in this embodiment also includes a high-precision hydraulic control system, as shown in the reference. Figure 2The high-precision hydraulic control system includes an electro-hydraulic power source, valve island actuators, a signal processing unit, and multiple sensors. The electro-hydraulic power source includes an electro-hydraulic proportional control module, a pump motor unit, an oil tank, and hydraulic accessories. The electro-hydraulic proportional control module includes a proportional directional valve 4, a differential pressure reducing valve, and an accumulator. The valve island actuator includes multiple solenoid directional valves and connecting pipelines for each cylinder. Filters 5 are installed on the pipelines to filter impurities in the hydraulic oil, ensuring the cleanliness and service life of the hydraulic components. The signal processing unit includes a programmable logic controller (PLC) and a proportional amplifier. Sensors include displacement sensors 12 located at each adjustment module cylinder and a force sensor located below the support platform 1. The PLC is connected to each sensor to receive feedback signals from the displacement sensors 12 and the force sensor, and outputs control commands to the electro-hydraulic servo proportional valve to control the displacement and output force of each cylinder. The differential pressure reducing valve ensures stable pressure difference across the proportional valve, improving control accuracy; the accumulator stabilizes system pressure, reduces pressure fluctuations, and improves motion smoothness. The displacement sensor 12 adopts a built-in structure with a resolution of 0.01mm, enabling real-time acquisition of the actual displacement data of the piston rod. The force sensor, located below the support table, has a measurement accuracy of 0.5%FS, accurately detecting the actual load force acting on each adjustment module. The programmable logic controller (PLC) uses the Siemens S7-1500 series with a control cycle of 1ms, possessing strong computing power and stability, suitable for the multi-axis control requirements of large tooling. The electro-hydraulic servo proportional valve uses the MOOGD633 series with a frequency response of no less than 100Hz, possessing high response speed and control accuracy, ensuring rapid response and execution of control commands, and improving the dynamic accuracy of the adjustment process. The selection of a 1ms control cycle and a 100Hz valve frequency response matches the motion control requirements of heavy-duty tooling, avoiding adjustment lag caused by excessively long control cycles and preventing system oscillation and increased hardware costs due to excessively high frequencies.

[0031] To eliminate the impact of piston rod elastic deformation on positioning accuracy under heavy loads, this embodiment includes a rod deformation compensation module in the programmable logic controller. Based on the load force detected by the force sensor and a preset equivalent stiffness of the piston rod, the rod deformation compensation module calculates the piston rod elastic deformation compensation amount according to the elastic deformation formula and adds this compensation amount to the target value of displacement control to eliminate the impact of piston rod elastic deformation on positioning accuracy under heavy loads. The elastic deformation amount can be calculated by dividing the load force by the equivalent stiffness of the piston rod. Adding this compensation amount to the original target displacement value offsets the compressive deformation of the piston rod under load, ensuring that the actual position of the workpiece matches the theoretical target position. Actual measurements show that under a 200-ton load, with rod deformation compensation, the vertical positioning error of the tooling can be controlled within ±0.1mm. Compared to the conventional control method without compensation, the positioning accuracy is significantly improved, meeting the requirements for high-precision docking of heavy workpieces.

[0032] Based on the invention's objective of improving the ease of tooling maintenance and adaptability, in this embodiment, each modular interface includes a positioning pin hole and a quick-locking device. The positioning pin hole enables precise positioning between adjacent modules, while the quick-locking device allows for detachable connection between modules. The positioning pin hole has a positioning accuracy of ±0.01mm, ensuring consistent positioning after module assembly. The quick-locking device can employ a quick-locking bolt structure, allowing for module connection and separation without complex disassembly tools. When a module malfunctions or wears out, only the corresponding module needs to be replaced to restore the tooling's functionality, eliminating the need for overall disassembly or scrapping. Single module replacement can be completed within 2 hours, effectively shortening maintenance downtime, reducing overall lifecycle costs, and adapting to the reliability and maintainability requirements of large-scale assembly projects.

[0033] To accommodate workpieces with different bottom shapes, the supporting worktable 1 in this embodiment includes a worktable base plate and multiple adjustable ball joint support units disposed on the worktable base plate. Each adjustable ball joint support unit includes a ball joint seat, a ball head support rod, and a locking mechanism. The ball head support rod can freely deflect relative to the ball joint seat in space. The height and deflection angle of each adjustable ball joint support unit can be adjusted independently, accommodating a maximum workpiece bottom surface inclination angle of ±5°. This structure can conform to the bottom shape of large, irregularly shaped curved components, ensuring uniform stress distribution on the workpiece support, avoiding damage to the workpiece or tooling caused by localized stress concentration, and simultaneously improving the stability of workpiece placement.

[0034] Based on the invention objective of achieving full-process monitoring of workpiece pose and coordinated adjustment of multiple tooling fixtures, in this embodiment, the tooling fixture is also equipped with a pose monitoring system. The pose monitoring system includes a multi-station laser tracker target system or visual measurement markers, which are arranged at the four corners of the supporting worktable 1 and at key measurement points on the workpiece. The pose monitoring system is connected to a programmable logic controller (PLC) for real-time acquisition of the workpiece's three-dimensional spatial pose data and feedback to the PLC, forming workpiece pose control. The tooling fixture contains at least two independent tooling units, each arranged at different support points on the workpiece. Each tooling unit is connected to the PLC and is uniformly coordinated and controlled by the PLC. (Refer to...) Figure 3When multiple tooling units work collaboratively, they can each support different positions of the workpiece, and the overall pose of the workpiece can be changed through synchronous adjustment. The pose monitoring system uses a Leica AT960 laser tracker with a measurement accuracy of ±0.015mm and a sampling frequency of 20Hz. Pose data can be acquired and transmitted to the programmable logic controller via the analog input module of the ET200SP, ensuring the stability and real-time performance of data transmission and providing accurate pose feedback for collaborative adjustment. Choosing a sampling frequency of 20Hz ensures the real-time performance of pose data, meeting the feedback requirements of the dynamic adjustment process, while avoiding increased data processing pressure and system cost due to excessively high sampling frequencies.

[0035] To ensure long-term positional stability of the horizontal cylinders after they stop moving, both the X-axis horizontal drive cylinder 2 and the Y-axis horizontal drive cylinder 13 in this embodiment are equipped with bidirectional hydraulic locks on their hydraulic circuits. The bidirectional hydraulic locks are used to lock the oil circuits after the cylinders stop supplying oil, preventing displacement drift of the horizontal cylinders under workpiece loads. The bidirectional hydraulic locks can automatically lock the hydraulic oil in both chambers of the cylinders after the oil supply is cut off, keeping the piston rod in its current position, unaffected by external load fluctuations, ensuring long-term consistency of the workpiece position after assembly, and improving the reliability and safety of the assembly process.

[0036] To achieve high-tonnage lifting capacity within a limited volume, the Z-axis lifting adjustment module in this embodiment includes a Z-axis lifting drive cylinder 11. The hydraulic circuit of the Z-axis lifting drive cylinder 11 is equipped with a booster system consisting of a cylinder booster 3 and an ultra-high pressure relay. The booster system can increase the working pressure of a conventional hydraulic pump to an ultra-high pressure working pressure, thereby reducing the cylinder size and rotation radius of the vertical lifting cylinder and controlling the overall volume and weight of the tooling. The ultra-high pressure relay monitors the pressure in the ultra-high pressure circuit and controls the booster to stop working when the pressure reaches the set value, maintaining stable system pressure. The Z-axis lifting drive cylinder 11 has a cylinder diameter of 400mm, a piston rod diameter of 280mm, a rated working pressure of 28MPa, corresponding to a maximum lifting force of 300 tons, and a stroke of ±100mm. This parameter combination can meet the lifting and height adjustment requirements of 200-ton heavy workpieces. The ±100mm stroke covers the height deviation adjustment range during workpiece docking, while avoiding a decrease in piston rod stability due to excessive stroke. The hydraulic circuit of the Z-axis lifting drive cylinder 11 is also equipped with a balance valve, which can lock the vertical cylinder position when the oil supply stops, preventing the workpiece from falling due to its own weight, thereby improving the vertical position holding capability and operational safety.

[0037] Example 2 This embodiment provides a multi-tool collaborative control method, which is based on the aforementioned heavy-duty, high-precision, reconfigurable three-dimensional adjustment tooling, and refers to... Figure 4 The method includes the following steps.

[0038] The first step is to acquire pose data. The pose monitoring system collects real-time spatial pose data of the workpiece above each tooling unit, including the three-dimensional coordinate values ​​of each measuring point.

[0039] The second step is multi-objective optimization. Based on the target pose of each feature point, the objective function is to minimize the sum of squared errors of the feature points after the actions of each tooling unit. The optimal allocation scheme for the motion of each degree of freedom of each tooling unit is then solved. The solution process can employ a sequential quadratic programming algorithm, with constraints including stroke and speed limits for each cylinder, ensuring that the solution results conform to the actual operating parameter range of the tooling.

[0040] The third step involves issuing coordination commands, distributing the motion quantities obtained in the second step to the corresponding adjustment modules of each tooling unit, and then having the hydraulic control system of each adjustment module execute the motion commands. The command issuance process can employ a feedforward plus proportional-integral control strategy to improve the speed and stability of motion execution.

[0041] The fourth step involves real-time feedback correction. The pose monitoring system continuously collects real-time pose data and feeds it back to the controller, repeating steps two and three until the error of each feature point is less than a preset threshold. The preset threshold can be set according to the assembly accuracy requirements; in this embodiment, it is set to ±0.1mm. When the position error of all measuring points is less than this threshold, the docking and positioning are completed.

[0042] To verify the practical effect of this collaborative control method, a field test was conducted on a 200-ton large component docking scenario. Four tooling units were used to support the workpiece, and the above-mentioned method was used for collaborative attitude adjustment. The test results showed that the final positioning error of each feature point of the workpiece was less than ±0.1mm, and the overall docking time was reduced by 60% compared with the traditional manual step-by-step adjustment method, effectively improving the work efficiency and docking quality of large component assembly.

[0043] In actual operation, the workpiece is first lifted to near the docking height using the Z-axis lifting adjustment module, leaving a 10mm margin. Then, horizontal fine adjustments are made sequentially in the X and Y axes. Simultaneously, the posture monitoring system displays the posture deviation in real time, and the control program corrects the deviation based on the data. After docking is completed, the horizontal cylinder is locked by a two-way hydraulic lock, and the vertical cylinder is locked by a balance valve to ensure long-term stability of the workpiece.

[0044] The above descriptions are merely some embodiments of this application and are not intended to limit this application. The technical features or structures in the foregoing different embodiments can be arbitrarily combined to form other specific technical solutions as needed. For those skilled in the art, this application can have various modifications and variations. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the scope of protection of the claims of this application.

Claims

1. A heavy-duty, high-precision, reconfigurable three-dimensional adjustment fixture, characterized in that, include: The support base (8) is used to support the overall tooling and provide a stable installation reference; The X-axis horizontal adjustment module is located above the support base (8) and is used to perform translational adjustment in the first horizontal direction; The Y-axis horizontal adjustment module is located above the X-axis horizontal adjustment module. It can move together with the X-axis horizontal adjustment module and is used to perform translation adjustment in a second horizontal direction orthogonal to the X-axis. The Z-axis lifting adjustment module is located above the Y-axis horizontal adjustment module and is used to perform vertical lifting adjustment. The support worktable (1) is located above the Z-axis lifting adjustment module and is used to directly support the workpiece to be adjusted; The X-axis horizontal adjustment module, the Y-axis horizontal adjustment module, and the Z-axis lifting adjustment module are arranged in a three-layer stacked orthogonal layout in space. The support base (8) and the X-axis horizontal adjustment module, the X-axis horizontal adjustment module and the Y-axis horizontal adjustment module, and the Y-axis horizontal adjustment module and the Z-axis lifting adjustment module are all provided with detachable standardized modular interfaces, so that the three-dimensional adjustment fixture can select and reconstruct modules according to the size and weight requirements of the workpiece.

2. The heavy-duty, high-precision, reconfigurable three-dimensional adjustment fixture according to claim 1, characterized in that, The X-direction horizontal adjustment module includes an X-direction horizontal drive cylinder (2), an X-direction sliding base plate (6), and an X-direction dovetail guide mechanism (10). The Y-axis horizontal adjustment module includes a Y-axis horizontal drive cylinder (13), a Y-axis sliding base plate (7), and a Y-axis dovetail guide mechanism (9); the X-axis horizontal drive cylinder (2) and the Y-axis horizontal drive cylinder (13) are arranged horizontally at right angles to each other.

3. The heavy-duty, high-precision, reconfigurable three-dimensional adjustment fixture according to claim 2, characterized in that, Both the X-direction dovetail guide mechanism (10) and the Y-direction dovetail guide mechanism (9) are dovetail groove type guide structures; Dovetail-shaped guide rail pairs are provided between the X-axis sliding base plate (6) and the support base (8), and between the Y-axis sliding base plate (7) and the X-axis sliding base plate (6). The dovetail guide pair includes a convex dovetail guide rail and a concave dovetail groove that slide together along the guide direction.

4. The heavy-duty, high-precision, reconfigurable three-dimensional adjustment fixture according to claim 1, characterized in that, It also includes a high-precision hydraulic control system; the high-precision hydraulic control system includes an electro-hydraulic power source, a valve island actuator, a signal processing unit, and multiple sensors; The electro-hydraulic power source includes an electro-hydraulic proportional control module, a pump motor unit, an oil tank, and hydraulic accessories. The electro-hydraulic proportional control module includes a proportional directional valve (4), a differential pressure reducing valve, and an accumulator. The valve island actuator includes multiple electromagnetic directional valves and connecting pipelines for each oil cylinder. The signal processing unit includes a programmable logic controller (PLC) and a proportional amplifier. The sensors include displacement sensors (12) installed at each adjustment module oil cylinder and force sensors installed below the bearing worktable (1). The PLC controller is connected to each of the sensors to receive feedback signals from the displacement sensor (12) and the force sensor, and outputs control commands to the electro-hydraulic servo proportional valve to control the displacement and output force of each cylinder.

5. The heavy-duty, high-precision, reconfigurable three-dimensional adjustment fixture according to claim 4, characterized in that, The PLC controller is also equipped with a rod deformation compensation module; The rod deformation compensation module calculates the elastic deformation compensation amount of the piston rod according to the elastic deformation formula based on the load force detected by the force sensor and the preset equivalent stiffness of the piston rod, and adds the elastic deformation compensation amount to the target value of displacement control to eliminate the influence of piston rod elastic deformation on positioning accuracy under heavy load conditions.

6. The heavy-duty, high-precision, reconfigurable three-dimensional adjustment fixture according to claim 1, characterized in that, Each of the modular interfaces includes a positioning pin hole and a quick-locking device. The positioning pin hole enables precise positioning between adjacent modules, and the quick-locking device enables detachable connection between modules.

7. The heavy-duty, high-precision, reconfigurable three-dimensional adjustment fixture according to claim 1, characterized in that, The supporting worktable (1) includes a worktable base plate and a plurality of adjustable ball joint support units disposed on the worktable base plate; The adjustable ball joint support unit includes a ball joint seat, a ball head support rod, and a locking mechanism. The ball head support rod can freely deflect in space relative to the ball joint seat. The height and deflection angle of each adjustable ball joint support unit can be adjusted independently.

8. The heavy-duty, high-precision, reconfigurable three-dimensional adjustment fixture according to claim 7, characterized in that, It is also equipped with a pose monitoring system; The pose monitoring system includes a multi-station laser tracker target system or a visual measurement marker point. The multi-station laser tracker target or the visual measurement marker point is arranged at the four corners of the bearing worktable (1) and at the key measurement points of the workpiece. The pose monitoring system is connected to the PLC controller to collect the three-dimensional spatial pose data of the workpiece in real time and feed it back to the PLC controller to form workpiece pose control. The tooling includes at least two independent tooling units, each of which is arranged at different support points on the workpiece. Each tooling unit is connected to the PLC controller and is uniformly coordinated and controlled by the PLC controller.

9. The heavy-duty, high-precision, reconfigurable three-dimensional adjustment fixture according to claim 1, characterized in that, The Z-axis lifting adjustment module includes a Z-axis lifting drive cylinder (11), and the hydraulic circuit of the Z-axis lifting drive cylinder (11) is equipped with a booster system consisting of a cylinder booster (3) and an ultra-high pressure relay.

10. A control method applied to the heavy-duty, high-precision, reconfigurable three-dimensional adjustment fixture as described in any one of claims 1-9, characterized in that, Includes the following steps: Step S1, Pose Data Acquisition: The pose monitoring system collects real-time spatial pose data of the workpiece above each tooling unit. The real-time spatial pose data includes the three-dimensional coordinate values ​​of each measuring point. Step S2, Multi-objective optimization solution: Based on the target pose of each feature point, with the minimum sum of squared errors of feature points after the action of each tooling unit as the objective function, solve the optimal allocation scheme of motion of each degree of freedom of each tooling unit. Step S3, Coordination Command Issuance: The solved motion quantities are distributed to the corresponding adjustment modules of each tooling unit, and the motion commands are executed by the hydraulic control system of each adjustment module; Step S4, Real-time Feedback Correction: The pose monitoring system continuously collects real-time pose data and feeds it back to the PLC controller, repeating steps S2 to S3 until the error of each feature point is less than the preset threshold.

Images