Modeling of Systematic Errors and Precision Optimization Methods for Workpiece Clamping and Alignment System in Aeroengine Gearbox Automated Line Machining

doi:10.16183/j.cnki.jsjtu.2023.511

Abstract

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

CLC Number:

V263.2

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.

Figures/Tables 20

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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