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Article
Publication date: 15 July 2022

Lulu Huang, Xiang Huang and Shuang-Gao Li

The size of the aircraft tooling structure is huge, and the ambient temperature is difficult to maintain a constant state. Aiming at the influence of current temperature…

Abstract

Purpose

The size of the aircraft tooling structure is huge, and the ambient temperature is difficult to maintain a constant state. Aiming at the influence of current temperature, this paper aims to propose a compensation method for registration error of large-scale measurement fields based on multi-temperature sensors.

Design/methodology/approach

In this method, an enhanced reference points (ERS)–temperature regression model is constructed from ERS and temperature data. The ERS offsets compensation model is established by solving the offset through the regression model, and the ERS offset compensation analysis is carried out.

Findings

The experimental results show that the proposed registration error compensation algorithm has obvious advantages over traditional methods in reducing the influence of ambient temperature and improving the measurement accuracy by reducing the registration error.

Originality/value

This method reduces registration error caused by the influence of ambient temperature and is used for aircraft measurements in different temperature environments.

Details

Sensor Review, vol. 42 no. 5
Type: Research Article
ISSN: 0260-2288

Keywords

Open Access
Article
Publication date: 13 April 2022

Shuanggao Li, Zhichao Huang, Qi Zeng and Xiang Huang

Aircraft assembly is the crucial part of aircraft manufacturing, and to meet the high-precision and high-efficiency requirements, cooperative measurement consisting of…

Abstract

Purpose

Aircraft assembly is the crucial part of aircraft manufacturing, and to meet the high-precision and high-efficiency requirements, cooperative measurement consisting of multiple measurement instruments and automatic assisted devices is being adopted. To achieve the complete data of all assembly features, measurement devices need to be placed at different positions, and the flexible and efficient transfer relies on Automated Guided Vehicles (AGVs) and robots in the large-size space and close range. This paper aims to improve the automatic station transfer in accuracy and flexibility.

Design/methodology/approach

A transferring system with Light Detection and Ranging (LiDAR) and markers is established. The map coupling for navigation is optimized. Markers are distributed according to the accumulated uncertainties. The path planning method applied to the collaborative measurement is proposed for better accuracy. The motion planning method is optimized for better positioning accuracy.

Findings

A transferring system is constructed and the system is verified in the laboratory. Experimental results show that the proposed system effectively improves positioning accuracy and efficiency, which improves the station transfer for the cooperative measurement.

Originality/value

A Transferring system for collaborative measurement is proposed. The optimized navigation method extends the application of visual markers. With this system, AGV is capable of the cooperative measurement of large aircraft structural parts.

Details

Journal of Intelligent Manufacturing and Special Equipment, vol. 3 no. 1
Type: Research Article
ISSN: 2633-6596

Keywords

Article
Publication date: 1 March 2018

Zhengping Deng, Shuanggao Li and Xiang Huang

For the measurement of large-scale components in aircraft assembly, the evaluation of coordinate transformation parameters between the coordinate frames of individual…

Abstract

Purpose

For the measurement of large-scale components in aircraft assembly, the evaluation of coordinate transformation parameters between the coordinate frames of individual measurement systems to the assembly frame is an essential task, which is usually completed by registration of the enhanced reference system (ERS) points. This paper aims to propose an analytical method to evaluate the uncertainties of transformation parameters considering both the measurement error and the deployment error of ERS points.

Design/methodology/approach

For each measuring station, the measured coordinates of ERS points are first roughly registered to the assembly coordinate system using the singular value decomposition method. Then, a linear transformation model considering the measurement error and deployment error of ERS points is developed, and the analytical solution of transformation parameters’ uncertainties is derived. Moreover, the covariance matrix of each ERS points in the transformation evaluation is calculated based on a new uncertainty ellipsoid model and variance-covariance propagation law.

Findings

For the transformation of both single and multiple measuring stations, the derived uncertainties of transformation parameters by the proposed analytical method are identical to that obtained by the state-of-the-art iterative method, but the solution process is simpler, and the computation expenses are much less.

Originality/value

The proposed uncertainty evaluation method would be useful for in-site measurement and optimization of the configuration of ERS points in the design of fixture and large assembly field. It could also be applied to other registration applications with errors on both sides of registration points.

Details

Sensor Review, vol. 38 no. 4
Type: Research Article
ISSN: 0260-2288

Keywords

Article
Publication date: 7 February 2020

Wenmin Chu and Xiang Huang

Flexible tooling for adjusting the posture of large components of aircraft (LCA) is composed of several numerical control locators (NCLs). Because of the manufacture and…

Abstract

Purpose

Flexible tooling for adjusting the posture of large components of aircraft (LCA) is composed of several numerical control locators (NCLs). Because of the manufacture and installation errors of NCL, the traditional control method of NCL may cause great interaction force between NCLs and form the internal force of LCA during the process of posture adjustment. Aiming at this problem, the purpose of this paper is to propose a control method for posture adjustment system based on hybrid force-position control (HFPC) to reduce the internal force of posture adjustment.

Design/methodology/approach

First of all, the causes of internal force of posture adjustment were analyzed by using homogeneous transformation matrix and inverse kinematics. Then, axles of NCLs were divided into position control axle and force control axle based on the screw theory, and the dynamic characteristics of each axle were simulated by MATLAB. Finally, a simulated posture adjustment system was built in the laboratory to carry out HFPC experiment and was compared with the other two traditional control methods for posture adjustment.

Findings

The experiment results show that HFPC method for redundant actuated parallel mechanism (RAPM) can significantly reduce the interaction force between NCLs.

Originality/value

In this paper, HFPC is applied to the control of the posture adjustment system, which reduces the internal force of LCA and improves the assembly quality of aircraft parts.

Details

Industrial Robot: the international journal of robotics research and application, vol. 47 no. 3
Type: Research Article
ISSN: 0143-991X

Keywords

Article
Publication date: 23 March 2022

Wenmin Chu and Xiang Huang

Large gear components widely exist in the transmission system of helicopters, ships, etc. Due to the small assembly clearance of large gear components, using an automatic…

Abstract

Purpose

Large gear components widely exist in the transmission system of helicopters, ships, etc. Due to the small assembly clearance of large gear components, using an automatic docking system based on position control will lead to forced assembly. The purpose of this paper is to reduce the assembly stress of large gear components by an active compliant docking technology based on distributed force sensors.

Design/methodology/approach

Firstly, aiming at the noise interference in three-dimensional force sensor (TDFS), Kalman filter and Savitzky–Golay filter are used to process the sensor’s output signal. Secondly, the active compliant docking control model is constructed according to the principle of impedance control. Thirdly, the contact force is calculated based on the Euler equation, and the impedance control parameters are tuned by the particle swarm optimization algorithm. Finally, an active compliant docking system of a large gear structure based on distributed force sensor is built in the laboratory to verify the proposed method.

Findings

The experimental results show that the contact force and contact torque gradually decrease in all directions and are always in the safe range during the docking process. The feasibility of this method in practical application is preliminarily demonstrated.

Originality/value

The distributed TDFSs are used to replace the traditional six-dimensional force sensor in the active compliant docking system of gear components, which solves the problem of the small bearing capacity of the conventional active compliant docking system. This method can also be used for the docking of other large components.

Details

Sensor Review, vol. 42 no. 3
Type: Research Article
ISSN: 0260-2288

Keywords

Article
Publication date: 8 April 2021

Wenmin Chu, Xiang Huang and Shuanggao Li

With the improvement of modern aircraft requirements for safety, long life and economy, higher quality aircraft assembly is needed. However, due to the manufacturing and…

Abstract

Purpose

With the improvement of modern aircraft requirements for safety, long life and economy, higher quality aircraft assembly is needed. However, due to the manufacturing and assembly errors of the posture adjustment mechanism (PAM) used in the digital assembly of aircraft large component (ALC), the posture alignment accuracy of ALC is difficult to be guaranteed, and the posture adjustment stress is easy to be generated. Aiming at these problems, this paper aims to propose a calibration method of redundant actuated parallel mechanism (RAPM) for posture adjustment.

Design/methodology/approach

First, the kinematics model of the PAM is established, and the influence of the coupling relationship between the axes of the numerical control locators (NCL) is analyzed. Second, the calibration method based on force closed-loop feedback is used to calibrate each branch chain (BC) of the PAM, and the solution of kinematic parameters is optimized by Random Sample Consensus (RANSAC). Third, the uncertainty of kinematic calibration is analyzed by Monte Carlo method. Finally, a simulated posture adjustment system was built to calibrate the kinematics parameters of PAM, and the posture adjustment experiment was carried out according to the calibration results.

Findings

The experiment results show that the proposed calibration method can significantly improve the posture adjustment accuracy and greatly reduce the posture adjustment stress.

Originality/value

In this paper, a calibration method based on force feedback is proposed to avoid the deformation of NCL and bracket caused by redundant driving during the calibration process, and RANSAC method is used to reduce the influence of large random error on the calibration accuracy.

Details

Industrial Robot: the international journal of robotics research and application, vol. 48 no. 4
Type: Research Article
ISSN: 0143-991X

Keywords

Article
Publication date: 17 October 2016

Yifan Jiang, Xiang Huang and Shuanggao Li

The purpose of this paper is to propose an on-line iterative compensation method combining with a feed-forward compensation method to enhance the assembly accuracy of a…

Abstract

Purpose

The purpose of this paper is to propose an on-line iterative compensation method combining with a feed-forward compensation method to enhance the assembly accuracy of a metrology-integrated robot system (MIRS).

Design/methodology/approach

By the integration of a six degrees of freedom (6DoF) measurement system (T-Mac), the robot’ movement can be tracked with real-time measurement. With the on-line measured data, the proposed iterative compensation for absolute positioning and the feed-forward compensation for relative linear motion are integrated into the assembly process to improve the assembly accuracy.

Findings

It is found that the MIRS exhibits good performance in both accuracy and efficiency with the application of the proposed compensation method. With the proposed assembly process, a component can be automatically aligned to the target in seconds, and the assembly error can be decreased to 0.021 mm for position and 0.008° for orientation on average.

Originality/value

This paper presents a 6DoF MIRS for high-precision assembly. Based on the system, a novel on-line compensation method is proposed to enhance the assembly accuracy. In this paper, the assembly accuracy and the corresponding distance parameter are given by a series of experiments as reference for assembly applications.

Details

Industrial Robot: An International Journal, vol. 43 no. 6
Type: Research Article
ISSN: 0143-991X

Keywords

Article
Publication date: 19 October 2018

Shuanggao Li, Zhengping Deng, Qi Zeng and Xiang Huang

The assembly of large component in out-field is an important part for the usage and maintenance of aircrafts, which is mostly manually accomplished at present, as the…

Abstract

Purpose

The assembly of large component in out-field is an important part for the usage and maintenance of aircrafts, which is mostly manually accomplished at present, as the commonly used large-volume measurement systems are usually inapplicable. This paper aims to propose a novel coaxial alignment method for large aircraft component assembly using distributed monocular vision.

Design/methodology/approach

For each of the mating holes on the components, a monocular vision module is applied to measure the poses of holes, which together shape a distributed monocular vision system. A new unconstrained hole pose optimization model is developed considering the complicated wearing on hole edges, and it is solved by a iterative reweighted particle swarm optimization (IR-PSO) method. Based on the obtained poses of holes, a Plücker line coordinates-based method is proposed for the relative posture evaluation between the components, and the analytical solution of posture parameters is derived. The required movements for coaxial alignment are finally calculated using the kinematics model of parallel mechanism.

Findings

The IR-PSO method derived more accurate hole pose arguments than the state-of-the-art method under complicated wearing situation of holes, and is much more efficient due to the elimination of constraints. The accuracy of the Plücker line coordinates-based relative posture evaluation (PRPE) method is competitive with the singular value decomposition (SVD) method, but it does not rely on the corresponding of point set; thus, it is more appropriate for coaxial alignment.

Practical implications

An automatic coaxial alignment system (ACAS) has been developed for the assembly of a large pilotless aircraft, and a coaxial error of 0.04 mm is realized.

Originality/value

The IR-PSO method can be applied for pose optimization of other cylindrical object, and the analytical solution of Plücker line coordinates-based axes registration is derived for the first time.

Details

Assembly Automation, vol. 38 no. 4
Type: Research Article
ISSN: 0144-5154

Keywords

Article
Publication date: 27 March 2020

Shuanggao Li, Wenmin Chu and Xiang Huang

The measurement of aircraft barycenter is a verification of theoretical barycenter and is an important step of aircraft development. In the traditional measurement method…

Abstract

Purpose

The measurement of aircraft barycenter is a verification of theoretical barycenter and is an important step of aircraft development. In the traditional measurement method of aircraft barycenter, the posture of the aircraft needs to be adjusted manually and is measured by optical instruments. The efficiency of posture adjustment depends on the proficiency of workers, and the accuracy of measurement is not high. In view of these problems of the current barycenter measurement method, this paper aims to propose an aircraft barycenter measurement method based on multi-posture.

Design/methodology/approach

In this method, the numerical control locator is used as a supporting part to fix and adjust the aircraft, and the calculation model of aircraft barycenter is established according to the principle of rigid body rotation and the principle of moment balance. Then, the influence of the main error sources on the measurement accuracy of aircraft barycenter is analyzed by Monte Carlo simulation, and the measurement accuracy is compared with that of the barycenter measurement method based on horizontal posture. Finally, the experiment platform of barycenter measurement was built in the laboratory and the experiments were carried out.

Findings

The experimental results show that the barycenter measurement method proposed in this paper has obvious advantages in measurement accuracy and efficiency compared with the traditional method.

Originality/value

This method can be used to measure the barycenter of different types of aircraft quickly and automatically.

Details

Sensor Review, vol. 40 no. 2
Type: Research Article
ISSN: 0260-2288

Keywords

Article
Publication date: 3 June 2019

Yifan Jiang, Xiang Huang, Shuanggao Li and Zhengping Deng

The purpose of this paper is to propose an assembly coordination modelling approach based on measured data for assembly quality control of multi-constrained objects in…

Abstract

Purpose

The purpose of this paper is to propose an assembly coordination modelling approach based on measured data for assembly quality control of multi-constrained objects in aircraft assembly. This approach aims to establish a high-precision digital mirror of physical assembly system in the virtual environment, with which the assembly process in the virtual environment can be performed synchronously with that in the physical world.

Design/methodology/approach

This paper presents a realistic geometrical representation model based on measured point cloud, as well as the multiple constraints modelling methods for local and global constraints with the proposed representation model. For the assembly target optimization, a novel optimization method based on the evaluation of multi-dimensional tolerance zone is proposed, where the particle swarm optimization and simulated annealing algorithm are combined to calculate the optimal solutions.

Findings

As shown in the validation results, the minimum easiness value for easiness model in global optimization is 3.01, while the best value for weighting model by adjusting weights for more than 10 times is 1.94. The results verify that the proposed coordination modelling approach is effective to the assembly of multi-constrained objects, and the optimization model has an obvious advantage over the traditional weighting method.

Originality/value

This paper provides a new idea for the fine control of assembly quality of non-ideal components by introducing the measured data into the on-line assembly process. Besides, a novel optimization method based on the evaluation of multi-dimensional tolerance zone is proposed, which overcomes the problem of traditional weighting model wherein the weightings are difficult to determine.

Details

Assembly Automation, vol. 39 no. 2
Type: Research Article
ISSN: 0144-5154

Keywords

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