CN112526916A - Airplane assembly fixture collision monitoring method - Google Patents
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- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/04—Programme control other than numerical control, i.e. in sequence controllers or logic controllers
- G05B19/048—Monitoring; Safety
- G—PHYSICS
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- G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
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Abstract
Description
Technical Field
The invention belongs to the technical field of aviation manufacturing, and particularly relates to a method for monitoring collision of an aircraft assembly fixture.
Background
The aircraft assembly fixture is an important manufacturing process device in the field of aviation manufacturing, and most of aircraft components, parts and complete machine assembly is completed on the assembly fixture. In the assembling process, the assembling fixture plays roles of positioning, clamping, supporting and the like on an assembling object, and in order to ensure that assembled parts and a complete machine meet various form and position precision requirements, the manufacturing precision requirement of the airplane assembling fixture is higher and the manufacturing cost is high. The situation that the positioning accuracy is reduced or even does not reach the standard and the like can occur due to improper use and maintenance of a set of manufactured qualified fixture, so that the service life of the assembly fixture is shortened at a low cost, the assembly quality of the airplane is directly influenced at a high cost, and great economic loss or potential safety hazards are caused. Workers mount and dismount airplane parts, fixture bolts and the like on an assembly fixture, often need to knock a mounting and dismounting object or a fixture structure related to the mounting and dismounting object by means of tools such as a wood hammer and the like, and the purposes of fine adjustment of positions, guarantee of attachment, auxiliary dismounting and the like are achieved. In order to not affect the surface quality of the parts of the aircraft and the performance of the assembly fixture, aircraft manufacturers usually have related requirements on the knocking tools and the operation modes used on the assembly fixture, and a mode of regular inspection is adopted to determine whether the technical state of the assembly fixture reaches the standard. However, in actual production, the situation that the performance of the assembly fixture does not reach the standard due to abnormal collision still exists, on one hand, measures on a management level are often difficult to implement completely, and workers cannot be guaranteed to work strictly by adopting correct tools and modes under any conditions, on the other hand, the problem that the accidental collision is lack of effective monitoring and identification, how much the impact of the collision on the fixture is caused is not clear when the accidental collision occurs, whether the detection and measurement are needed, and decision making is carried out due to lack of quantitative data is solved.
Disclosure of Invention
The invention provides a method for monitoring the collision condition of an aircraft assembly fixture in real time, which can judge whether the assembly fixture collides at a certain moment, determine the material type of a collision source and quantify the collision intensity.
In order to achieve the technical effects, the specific contents are as follows:
an aircraft assembly fixture collision monitoring method comprises the following steps:
firstly, detecting whether a collision monitoring system exists enough, if not, executingstep 1, and if the collision monitoring system exists, executingstep 2;
the collision monitoring system comprises a vibration sensor, a data acquisition device, a computer and a monitoring subsystem, wherein the vibration sensor is in signal connection with the data acquisition device, the data acquisition device is in signal connection with the computer, and the monitoring subsystem is arranged in the computer;
the monitoring subsystem comprises a data interface module, a noise reduction algorithm module, a Fourier transform module and a monitoring function module,
the data interface module is used for communicating the data acquisition device with a computer and transmitting acquired vibration signal data;
the noise reduction algorithm module adopts a wavelet threshold denoising algorithm to remove noise in original data, and the method comprises the following steps:
the original data is superimposed with white gaussian noise, and the superimposed signal can be represented as:
xt=yt+σzt (1)
in formula (1): x is the number oftThe signal to be processed after aliasing noise is obtained; y istThe signal is a denoised signal; σ is the noise level; z is a radical oftFor a standard Gaussian white noise signal, the step of eliminating zt in xt by the wavelet threshold method is as follows:
step 1: the decomposition of blasting vibration signal, selecting proper wavelet base to make noise signal xtAnd performing N-layer wavelet decomposition.
Step 2: selecting different thresholds for different layer coefficients to perform threshold quantization processing, wherein the threshold quantization processing is represented by ztThe derived coefficients are filtered out.
And 3, step 3: reconstructing the quantized wavelet coefficient to obtain the de-noisingThe latter signal yt。
The Fourier transform module is used for generating a frequency spectrum of vibration signal data, the frequency spectrum is solved for discrete vibration signals by adopting a fast Fourier transform function provided by MATLAB, and when the vibration amplitude value on the frequency spectrum is larger than a preset threshold value, collision is considered to occur;
the monitoring subsystem module is used for observing the frequency spectrum in real time to judge whether collision occurs or not, the monitoring subsystem extracts the maximum amplitude of each frequency band, compares the maximum amplitude with the threshold value of each frequency band, judges that collision occurs if the maximum amplitude is larger than the threshold value, and obtains the type of the collision object according to the frequency band range. The collision threshold value and the collision object material corresponding to each frequency band are obtained through experiments; the output is whether collision occurs or not, and the frequency band, intensity and collision source material corresponding to the collision.
firstly, arranging a vibration sensor on an assembly fixture for acquiring vibration signals generated by the assembly fixture, and mounting the vibration sensor on a structure with high precision requirement of the assembly fixture to complete the connection of a sensor cable and a data acquisition device and the communication between the data acquisition device and a monitoring subsystem.
Detecting whether a monitoring parameter is set or not, if not, executing thestep 3, and if the monitoring parameter is set, directly executing thestep 5;
determining a collision source which is possibly generated in the using process of the assembly jig, preparing a collision source material object or a typical test piece thereof as a collision test piece, and dividing the collision test piece into a legal collision object and an illegal collision object, wherein the legal collision object is an object which can collide with the assembly jig according to related process requirements; an illegal collision object is an object that is not allowed to collide with the mounting fixture under any circumstances.
Step 4, collision test and parameter setting;
performing collision test on the monitoring system by using a collision test piece to obtain vibration frequency bands and amplitude thresholds of different collision sources, and taking the data as input parameters of a monitoring subsystem; when in collision test, firstly, testing legal type collision objects, wherein each legal type collision object is knocked by two grades of force, namely the minimum knocking force for triggering collision recognition and the maximum allowable knocking force; then testing the illegal collision object, and only testing the minimum knocking force for triggering collision recognition, wherein the force can be determined by the comprehensive frame bearing capacity and the minimum amplitude which can be accurately recognized by a monitoring system; and inputting the amplitude threshold, the frequency band and the corresponding collision source material name obtained by all collision tests as parameters into the monitoring subsystem to enable the monitoring subsystem to take effect.
and (3) starting a collision monitoring system in the production process, and when collision occurs, prompting the collision by a monitoring subsystem, and displaying a collision source frequency band, a collision intensity and a collision source material.
The application has the advantages that:
the collision and the impact that this application received the aircraft type frame in the assembling process are quantified, and the frequency range and the threshold value that produce are collided to relevant instrument in reacing the aircraft assembling process through the experiment, have taken into account practical factors such as material, structure, the service mode of instrument comprehensively, and the judgement collision source that can be accurate has very strong practicality and guiding meaning.
Drawings
FIG. 1 is a flow chart of a method for collision monitoring of an aircraft assembly fixture
FIG. 2 is a schematic view of a monitoring system for a method of collision monitoring of an aircraft assembly fixture
The attached figure 2 marks: the method comprises the following steps of 1-vibration sensor, 2-data acquisition device, 3-computer, 4-connecting cable, 5-airplane assembly fixture structure and 6-airplane assembly fixture positioning device.
Detailed Description
In order to make the objects, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are some, but not all, embodiments of the present invention. The components of embodiments of the present invention generally described and illustrated in the figures herein may be arranged and designed in a wide variety of different configurations.
Thus, the following detailed description of the embodiments of the present invention, presented in the figures, is not intended to limit the scope of the invention, as claimed, but is merely representative of selected embodiments of the invention. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
It should be noted that: like reference numbers and letters refer to like items in the following figures, and thus, once an item is defined in one figure, it need not be further defined and explained in subsequent figures.
In the description of the present invention, it should be noted that the terms "upper", "vertical", "inside", "outside", and the like indicate orientations or positional relationships based on the orientations or positional relationships shown in the drawings, or orientations or positional relationships that are conventionally arranged when the products of the present invention are used, or orientations or positional relationships that are conventionally understood by those skilled in the art, and are used for convenience of description and simplification of description, but do not indicate or imply that the devices or elements that are referred to must have specific orientations, be constructed in specific orientations, and be operated, and thus, should not be construed as limiting the present invention. Furthermore, the terms "first," "second," and the like are used merely to distinguish one description from another, and are not to be construed as indicating or implying relative importance.
In the description of the present invention, it should also be noted that, unless otherwise explicitly specified or limited, the terms "disposed," "mounted," and "connected" are to be construed broadly, e.g., as meaning fixedly connected, detachably connected, or integrally connected; can be mechanically or electrically connected; they may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meanings of the above terms in the present invention can be understood in specific cases to those skilled in the art.
Example 1
Step 1: a collision monitoring system is constructed, an acceleration vibration sensor, a data acquisition device with an Ethernet interface and a computer are selected, monitoring software is developed in the computer, and the monitoring software consists of a data interface, a noise reduction algorithm, Fourier transform and a monitoring function. The data interface is used for communicating with the data acquisition device to acquire vibration signal data; adopting Gaussian filtering as a noise reduction algorithm; generating a frequency spectrum of the vibration signal data using fourier transform; the monitoring function is used for observing whether the amplitude of each frequency band in the frequency spectrum is larger than a preset threshold value or not in real time, determining the material type of the collision source according to the frequency band range, setting different amplitude threshold values for different frequency bands for monitoring, and monitoring a plurality of threshold values in one frequency band. The input of the monitoring function is a collision recognition threshold value and a collision source material corresponding to each frequency band, and the input data are software parameters and are set by a user; the output is whether collision occurs or not, the frequency band and intensity of the collision and the material of the collision source. Wherein, the quantitative indexes of the intensity of collision are as follows: (actually measured amplitude value-threshold)/threshold value x 100%, and this index positively correlates with the severity of collision.
Step 2: and installing a collision monitoring system, installing an acceleration vibration sensor on a positioner base body structure of the assembly fixture, connecting a sensor cable with a data acquisition device, connecting the data acquisition device with a microcomputer through an Ethernet cable, and establishing software communication.
And step 3: preparing a collision test piece, and taking a wooden hammer, a wrench and a screwdriver as legal collision objects, and taking a transport trolley and the like as illegal collision objects.
And 4, step 4: and performing collision test and parameter setting, performing collision test on the monitoring system by using a collision test piece to obtain frequency bands and amplitude thresholds of different collision sources, and taking the data as input parameters of monitoring software. When in collision test, firstly, a legal collision object is tested, and the legal collision object is knocked by two forces, namely the minimum knocking force for triggering collision recognition and the maximum allowable knocking force; and then testing the illegal collision objects, and only testing the minimum knocking force for triggering collision recognition. And inputting the amplitude threshold, the frequency band and the corresponding collision source material name obtained by all collision tests as parameters into the monitoring software and enabling the monitoring software to take effect.
And 5: and carrying out collision monitoring on the assembly fixture, prompting the occurrence of collision by monitoring software when the collision occurs, and displaying a collision source frequency band, a collision degree and a collision source material. A set of monitoring system with good application effect and set parameters thereof can be directly applied to the same type or similar assembly jig.
Example 2
An aircraft assembly fixture collision monitoring method comprises the following steps:
firstly, detecting whether a collision monitoring system exists enough, if not, executingstep 1, and if the collision monitoring system exists, executingstep 2;
the collision monitoring system comprises a vibration sensor, a data acquisition device, a computer and a monitoring subsystem, wherein the vibration sensor is in signal connection with the data acquisition device, the data acquisition device is in signal connection with the computer, and the monitoring subsystem is arranged in the computer;
the monitoring subsystem comprises a data interface module, a noise reduction algorithm module, a Fourier transform module and a monitoring function module,
the data interface module is used for communicating the data acquisition device with a computer and transmitting acquired vibration signal data;
the noise reduction algorithm module adopts a wavelet threshold denoising algorithm to remove noise in original data, and the method comprises the following steps:
the original data is superimposed with white gaussian noise, and the superimposed signal can be represented as:
xt=yt+σzt (1)
in formula (1): x is the number oftThe signal to be processed after aliasing noise is obtained; y istThe signal is a denoised signal; σ is the noise level; z is a radical oftFor a standard Gaussian white noise signal, the step of eliminating zt in xt by the wavelet threshold method is as follows:
step 1: the decomposition of blasting vibration signal, selecting proper wavelet base to make noise signal xtPerforming N-layer wavelet decomposition, wherein wavelet base and layerThe selection of N may be calculated or empirically derived.
Step 2: selecting different thresholds for different layer coefficients to perform threshold quantization processing, wherein the threshold quantization processing is represented by ztThe derived coefficients are filtered out.
And 3, step 3: reconstructing the quantized wavelet coefficient to obtain a denoised signal yt。
The Fourier transform module is used for generating a frequency spectrum of vibration signal data, the frequency spectrum is solved for discrete vibration signals by adopting a fast Fourier transform function provided by MATLAB, when a vibration amplitude value on the frequency spectrum is larger than a preset threshold value, collision is considered to occur, and due to the fact that vibration frequencies generated by collision objects made of different materials are different, the material type of a vibration source can be determined according to a frequency band range;
the monitoring subsystem module is used for observing the frequency spectrum in real time to judge whether collision occurs or not, different collision amplitude threshold values can be set for different frequency bands to monitor, and a plurality of threshold values can also be monitored in one frequency band. The monitoring subsystem extracts the maximum amplitude of each frequency band, compares the maximum amplitude with the threshold value of each frequency band, judges that collision occurs if the maximum amplitude is larger than the threshold value, and obtains the type of the collision object according to the frequency band range. Wherein, the collision threshold and the collision object material corresponding to each frequency band are obtained by experiments, are parameters of the monitoring subsystem and are set by a user; the output is whether collision occurs or not, and the frequency band, intensity and collision source material corresponding to the collision.
The severity of collision may be expressed as an amplitude value as it is, or the amplitude value may be converted into an index, and the severity of collision may be quantified, for example, by "(measured amplitude value-threshold)/threshold value × 100%", and a larger percentage indicates a higher severity of collision.
firstly, arranging a vibration sensor on an assembly fixture for acquiring vibration signals generated by the assembly fixture, wherein the type, specification and installation position of the sensor are determined according to the structure, material and monitoring target point of the assembly fixture, the arrangement principle is that the sensor is directly installed on a structure with high precision requirement of the assembly fixture as far as possible, and a part which is directly connected with the structure is selected for being close to the structure as far as possible and cannot be realized. And finally, completing the connection between the sensor cable and the data acquisition device and the communication between the data acquisition device and the monitoring subsystem.
Detecting whether a monitoring parameter is set or not, if not, executing thestep 3, and if the monitoring parameter is set, directly executing thestep 5;
determining a collision source which may occur in the use process of the assembly type frame, and preparing a collision source substance or a typical test piece thereof as a collision test piece, wherein the collision source substance is a possible collision source, and the collision test piece comprises a wood hammer, a wrench, a screwdriver, a transportation trolley and the like. The collision test piece is divided into a legal collision object and an illegal collision object, wherein the legal collision object is an object which can collide with the assembly jig according to related process requirements, for example, a wooden hammer can be used for knocking the assembly jig; an illegal collision object is an object that is not allowed to collide with the assembly jig in any case, such as a transportation cart or the like.
Step 4, collision test and parameter setting;
performing collision test on the monitoring system by using a collision test piece to obtain vibration frequency bands and amplitude thresholds of different collision sources, and taking the data as input parameters of a monitoring subsystem; when in collision test, firstly, testing legal type collision objects, wherein each legal type collision object is knocked by two grades of force, namely the minimum knocking force for triggering collision recognition and the maximum allowable knocking force; then testing the illegal collision object, and only testing the minimum knocking force for triggering collision recognition, wherein the force can be determined by the comprehensive frame bearing capacity and the minimum amplitude which can be accurately recognized by a monitoring system; and inputting the amplitude threshold, the frequency band and the corresponding collision source material name obtained by all collision tests as parameters into the monitoring subsystem to enable the monitoring subsystem to take effect. The monitoring system can be tested repeatedly by using the test piece so as to adjust and obtain the optimal parameter setting.
and (3) starting a collision monitoring system in the production process, and when collision occurs, prompting the collision by a monitoring subsystem, and displaying a collision source frequency band, a collision intensity and a collision source material.
The fourier transform in the monitoring subsystem can be replaced by other signal processing algorithms, such as wavelet analysis, and the monitored object of the monitoring function can be replaced by a power spectrum, an energy spectrum and the like.
Claims (4)
1. An aircraft assembly fixture collision monitoring method is characterized in that: the method comprises the following steps:
firstly, detecting whether a collision monitoring system exists enough, if not, executing step 1, and if the collision monitoring system exists, executing step 2;
step 1, constructing a collision monitoring system;
the collision monitoring system comprises a vibration sensor, a data acquisition device, a computer and a monitoring subsystem, wherein the vibration sensor is in signal connection with the data acquisition device, the data acquisition device is in signal connection with the computer, and the monitoring subsystem is arranged in the computer;
the monitoring subsystem comprises a data interface module, a noise reduction algorithm module, a Fourier transform module and a monitoring function module,
the data interface module is used for communicating the data acquisition device with a computer and transmitting acquired vibration signal data;
the noise reduction algorithm module adopts a wavelet threshold denoising algorithm to remove noise in original data, and the method comprises the following steps:
the original data is superimposed with white gaussian noise, and the superimposed signal can be represented as:
xt=yt+σzt (1)
in formula (1): x is the number oftThe signal to be processed after aliasing noise is obtained; y istThe signal is a denoised signal; σ is the noise level; z is a radical oftIs a standard white gaussian noise signal;
the Fourier transform module is used for generating a frequency spectrum of vibration signal data, the frequency spectrum is solved for discrete vibration signals by adopting a fast Fourier transform function provided by MATLAB, and when the vibration amplitude value on the frequency spectrum is larger than a preset threshold value, collision is considered to occur;
the monitoring subsystem module is used for observing the frequency spectrum in real time to judge whether collision occurs or not, the monitoring subsystem extracts the maximum amplitude of each frequency band, compares the maximum amplitude with the threshold value of each frequency band, judges that collision occurs if the maximum amplitude is larger than the threshold value, and obtains the type of a collision object according to the frequency band range, and the collision threshold value and the material of the collision object corresponding to each frequency band are obtained through experiments; the output is whether collision occurs or not, and the frequency band, the intensity and the collision source material corresponding to the collision;
step 2, installing a collision monitoring system;
firstly, arranging a vibration sensor on an assembly jig, wherein the vibration sensor is used for acquiring vibration signals generated by the assembly jig, and is arranged on a structure with high precision requirement of the assembly jig to complete the connection of a sensor cable and a data acquisition device and the communication between the data acquisition device and a monitoring subsystem;
detecting whether a monitoring parameter is set or not, if not, executing the step 3, and if the monitoring parameter is set, directly executing the step 5;
step 3, preparing a collision test piece;
determining a collision source which is possibly generated in the using process of the assembly jig, preparing a collision source material object or a typical test piece thereof as a collision test piece, and dividing the collision test piece into a legal collision object and an illegal collision object, wherein the legal collision object is an object which can collide with the assembly jig according to related process requirements, and the illegal collision object is an object which is not allowed to collide with the assembly jig under any condition;
step 4, collision test and parameter setting;
performing collision test on the monitoring system by using a collision test piece to obtain vibration frequency bands and amplitude thresholds of different collision sources, and taking the data as input parameters of a monitoring subsystem; when in collision test, firstly, testing legal type collision objects, wherein each legal type collision object is knocked by two grades of force, namely the minimum knocking force for triggering collision recognition and the maximum allowable knocking force; then testing the illegal collision object, and only testing the minimum knocking force for triggering collision recognition, wherein the force can be determined by the comprehensive frame bearing capacity and the minimum amplitude which can be accurately recognized by a monitoring system; inputting the amplitude threshold, the frequency band and the corresponding collision source material name obtained by all collision tests as parameters into a monitoring subsystem to enable the monitoring subsystem to take effect;
step 5, performing collision monitoring on the assembly fixture;
and (3) starting a collision monitoring system in the production process, and when collision occurs, prompting the collision by a monitoring subsystem, and displaying a collision source frequency band, a collision intensity and a collision source material.
2. An aircraft assembly fixture collision monitoring method according to claim 1, wherein:
in the step 1, the denoising algorithm module eliminates zt in xt by using a wavelet threshold method as follows:
step 1: the decomposition of blasting vibration signal, selecting proper wavelet base to make noise signal xtPerforming N-layer wavelet decomposition;
step 2: selecting different thresholds for different layer coefficients to perform threshold quantization processing, wherein the threshold quantization processing is represented by ztFiltering out the derived coefficients;
and 3, step 3: reconstructing the quantized wavelet coefficient to obtain a denoised signal yt。
3. An aircraft assembly fixture collision monitoring method according to claim 1, wherein: in step 1, the severity of the collision is directly expressed by an amplitude value or the amplitude value is converted into an index.
4. An aircraft assembly fixture collision monitoring method according to claim 1, wherein: the collision source comprises a wooden hammer, a wrench, a screwdriver and a transport trolley.
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