机匣组线加工装夹找正系统误差建模与精度优化方法

doi:10.16183/j.cnki.jsjtu.2023.511

摘要/Abstract

摘要：

在航空发动机机匣类零件自动化组线升级改造中,零点定位系统和辅助找正台等新设备的引入显著提升了生产效率,但同时也加剧了多工序加工中的系统误差累积.为降低新系统误差对加工精度的不利影响,研究了不确定性输入条件下找正系统的误差建模与精度优化方法.研究方法主要包括:首先,建立考虑零点定位系统子母盘装配差异的偏差分析模型,并采用K-S检验方法验证模型准确性;基于该模型,系统分析了多子盘-母盘互换过程中的精度损失规律.其次,创新性地提出基于输出分布差异与超差率差异的精度损失量化函数,通过对找正系统的基座结构进行优化,将系统精度损失由原先的11.53%降低至2.33%.同时,有效改善了由加工基准和定位基准不一致导致的工件径跳分布问题,其分布差异由 0.117 15 降至 0.039 54.本研究实现了零点装夹找正系统性能的显著提升,为产线的装夹定位精度分析和优化提供了理论支撑和实践指导.

关键词: 航发机匣, 零点定位系统, 误差建模, 精度优化

Abstract:

In the upgrading and automation of aeroengine gearbox assembly line, the introduction of new equipment such as zero-point positioning systems and auxiliary alignment systems has significantly improved production efficiency. However, it has also brought about an increase in systematic errors during multi-process machining. To mitigate the adverse impact of these new systematic errors on machining accuracy, this paper investigates error modeling and precision optimization methods for the alignment system under uncertainty. First, it develops an assembly deviation analysis model, considering the differences between the master and sub-discs in the zero-point positioning system. It then designs a Kolmogorov-Smirnov (K-S) test to verify the accuracy of the model, based on which, the accuracy loss patterns during multi-sub-master disc to master disc interchange processes is analyzed. Afterwards, it defines a precision loss quantification function, incorporating both output distribution deviations and tolerance violation rates. By optimizing the bases structure of the alignment system, the precision loss is reduced from 11.53% to 2.33%. Additionally, the difference in radial runout distribution caused by misalignment between machining and positioning references is reduced from 0.117 to 0.039. These improvements significantly improve the performance of the zero-point clamping and alignment system, providing essential theoretical support for the analysis and optimization of clamping and positioning precision in automated production lines.

Key words: aircraft gearbox, zero-point positioning system, error modeling, accuracy optimization

中图分类号:

V263.2

杜雪明, 向洋, 刘顺, 金隼. 机匣组线加工装夹找正系统误差建模与精度优化方法[J]. 上海交通大学学报, 2025, 59(8): 1156-1168.

DU Xueming, XIANG Yang, LIU Shun, JIN Sun. Modeling of Systematic Errors and Precision Optimization Methods for Workpiece Clamping and Alignment System in Aeroengine Gearbox Automated Line Machining[J]. Journal of Shanghai Jiao Tong University, 2025, 59(8): 1156-1168.

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公差等级	公差范围
公差等级	标称尺寸 0.5~3 mm	标称尺寸 3~6 mm	标称尺寸 6~30 mm	标称尺寸 30~120 mm	标称尺寸 120~400 mm	标称尺寸 400~1 000 mm
f	±0.05	±0.05	±0.10	±0.15	±0.20	±0.30
m	±0.10	±0.10	±0.20	±0.30	±0.50	±0.80
c	±0.15	±0.20	±0.50	±0.80	±1.20	±2.00
v	-	±0.50	±1.00	±1.50	±2.50	±4.00

公差等级	公差范围
公差等级	标称尺寸 0~10 mm	标称尺寸 10~30 mm	标称尺寸 30~100 mm	标称尺寸 100~300 mm	标称尺寸 300~1 000 mm	标称尺寸 1 000~3 000 mm
H	0.02	0.05	0.1	0.2	0.3	0.4
K	0.05	0.1	0.2	0.4	0.6	0.8
L	0.1	0.2	0.4	0.8	1.2	1.6

序号	测量值	序号	测量值	序号	测量值	序号	测量值	序号	测量值
1	0.52	21	0.46	41	0.40	61	0.35	81	0.30
2	0.46	22	0.49	42	0.47	62	0.34	82	0.49
3	0.22	23	0.48	43	0.51	63	0.38	83	0.46
4	0.34	24	0.40	44	0.46	64	0.38	84	0.46
5	0.37	25	0.50	45	0.40	65	0.37	85	0.47
6	0.37	26	0.46	46	0.51	66	0.30	86	0.37
7	0.50	27	0.39	47	0.50	67	0.34	87	0.15
8	0.49	28	0.24	48	0.22	68	0.31	88	0.14
9	0.49	29	0.46	49	0.47	69	0.33	89	0.36
10	0.49	30	0.46	50	0.33	70	0.30	90	0.36
11	0.46	31	0.45	51	0.33	71	0.29	91	0.36
12	0.16	32	0.45	52	0.32	72	0.24	92	0.36
13	0.46	33	0.36	53	0.31	73	0.26	93	0.32
14	0.50	34	0.35	54	0.31	74	0.28	94	0.19
15	0.39	35	0.35	55	0.31	75	0.27	95	0.51
16	0.39	36	0.43	56	0.28	76	0.24	96	0.34
17	0.30	37	0.42	57	0.30	77	0.48	97	0.34
18	0.45	38	0.42	58	0.30	78	0.16	98	0.47
19	0.44	39	0.40	59	0.28	79	0.28	99	0.50
20	0.43	40	0.40	60	0.30	80	0.47	100	0.11

序号	数值	分布	序号	数值	分布	序号	数值	分布
e₁	0.5	Normal	t₁	⌀0.4	Normal	t₆	⌀0.2	Normal
e₂	0.3	Normal	t₂	0.012	Normal	t₇	0.01	Normal
e₃	0.3	Normal	t₃	0.012	Normal	t₈	0.005	Normal
e₄	0.01	Normal	t₄	⌀0.2	Normal	t₉	⌀0.2	Normal
e₅	0.3	Normal	t₅	⌀0.2	Normal

序号	名义值	μ	σ	OOT/%	CP	CPK	LSL	USL	L₃_σ	H₃_σ
FR1/${t}_{3}^{\mathrm{F}\mathrm{R}}$	0	0.012	0.002 9	46.32	0.670	-0.005	0	0.012	0.004 7	0.031 8
FR2/${t}_{4}^{\mathrm{F}\mathrm{R}}$	0	0.001	0.007 6	4.98	0.869	0.588	0	0.012	0.000 7	0.016 1