Assembly precision greatly influences the performance of complex high-end equipment.The traditional industrial assembly process and deviation transfer are implicit and uncertain,causing problems like poor component fi...Assembly precision greatly influences the performance of complex high-end equipment.The traditional industrial assembly process and deviation transfer are implicit and uncertain,causing problems like poor component fit and hard-to-trace assembly stress concentration.Assemblers can only check whether the dimensional tolerance of the component design is exceeded step by step in combination with prior knowledge.Inversion in industrial assembly optimizes assembly and design by comparing real and theoretical results and doing inversion analysis to reduce assembly deviation.The digital twin(DT)technology visualizes and predicts the assembly process by mapping real and virtual model parameters and states simultaneously,expanding parameter range for inversion analysis and improving inversion result accuracy.Problems in improving industrial assembly precision and the significance and research status of DT-driven parametric inversion of assembly tools,processes and object precision are summarized.It analyzes vital technologies for assembly precision inversion such as multi-attribute assembly process parameter sensing,virtual modeling of high-fidelity assembly systems,twin synchronization of assembly process data models,multi-physical field simulation,and performance twin model construction of the assembly process.Combined with human-cyber-physical system,augmented reality,and generative intelligence,the outlook of DT-driven assembly precision inversion is proposed,providing support for DT's use in industrial assembly and precision improvement.展开更多
A novel approach is proposed to detect the normal vector to product surface in real time for the robotic precision drilling system in aircraft component assembly, and the auto-normalization algorithm is presented base...A novel approach is proposed to detect the normal vector to product surface in real time for the robotic precision drilling system in aircraft component assembly, and the auto-normalization algorithm is presented based on the detection system. Firstly, the deviation between the normal vector and the spindle axis is measured by the four laser displacement sensors installed at the head of the multi-function end effector. Then, the robot target attitude is inversely solved according to the auto-normalization algorithm. Finally, adjust the robot to the target attitude via pitch and yaw rotations about the tool center point and the spindle axis is corrected in line with the normal vector simultaneously. To test and verify the auto-normalization algorithm, an experimental platform is established in which the laser tracker is introduced for accurate measurement. The results show that the deviations between the corrected spindle axis and the normal vector are all reduced to less than 0.5°, with the mean value 0.32°. It is demonstrated the detection method and the autonormalization algorithm are feasible and reliable.展开更多
Microscopic vision has been widely applied in precision assembly.To achieve sufficiently high resolution in measurements for precision assembly when the sizes of the parts involved exceed the field of view of the visi...Microscopic vision has been widely applied in precision assembly.To achieve sufficiently high resolution in measurements for precision assembly when the sizes of the parts involved exceed the field of view of the vision system,an image mosaic technique must be used.In this paper,a method for constructing an image mosaic with non-overlapping areas with enhanced efficiency is proposed.First,an image mosaic model for the part is created using a geometric model of the measurement system installed on a X-Y-Z precision stages with high repeatability,and a path for image acquisition is established.Second,images are captured along the same path for a specified calibration plate,and an entire image is formed based on the given model.The measurement results obtained from the specified calibration plate are utilized to identify mosaic errors and apply compensation for the part requiring measurement.Experimental results show that the maximum error is less than 4μm for a camera with pixel equivalent 2.46μm,thereby demonstrating the accuracy of the proposed method.This image mosaic technique with non-overlapping regions can simplify image acquisition and reduce the workload involved in constructing an image mosaic.展开更多
Three-dimensional(3D)electrically conductive micro/nanostructures are now a key component in a broad range of research and industry fields.In this work,a novel method is developed to realize metallic 3D micro/nanostru...Three-dimensional(3D)electrically conductive micro/nanostructures are now a key component in a broad range of research and industry fields.In this work,a novel method is developed to realize metallic 3D micro/nanostructures with silver-thiol-acrylate composites via two-photon polymerization followed by femtosecond laser nanojoining.Complex 3D micro/nanoscale conductive structures have been successfully fabricated with∼200 nm resolution.The loading of silver nanowires(AgNWs)and joining of junctions successfully enhance the electrical conductivity of the composites from insulating to 92.9 Sm^−1 at room temperature.Moreover,for the first time,a reversible switching to a higher conductivity is observed,up to∼10^5Sm^−1 at 523 K.The temperature-dependent conductivity of the composite is analyzed following the variable range hopping and thermal activation models.The nanomaterial assembly and joining method demonstrated in this study pave a way towards a wide range of device applications,including 3D electronics,sensors,memristors,micro/nanoelectromechanical systems,and biomedical devices,etc.展开更多
Macroscopic supramolecular assembly(MSA)has been a recent progress in supramolecular chemistry.MSA mainly focuses on studies of the building blocks with a size beyond ten micrometers and the non-covalent interactions ...Macroscopic supramolecular assembly(MSA)has been a recent progress in supramolecular chemistry.MSA mainly focuses on studies of the building blocks with a size beyond ten micrometers and the non-covalent interactions between these interactive building blocks to form ordered structures.MSA is essential to realize the concept of"self-assembly at all scales"by bridging most supramolecular researches at molecular level and at macroscopic scale.This review summaries the development of MSA,the basic design principle and related strategies to achieve MSA and potential applications.Correspondingly,we try to elucidate the correlations and differences between"macroscopic assembly"and MSA based on intermolecular interactions;the design principle and the underlying assembly mechanism of MSA are proposed to understand the reported MSA behaviors;to demonstrate further applications of MSA,we introduce some methods to improve the ordered degree of the assembled structures from the point of precise assembly and thus envision some possible fields for the use of MSA.展开更多
Due to the excellent self-centering and load-carrying capability,curvic couplings have been widely used in advanced aero-engine rotors.However,curvic tooth surface errors lead to poor assembly precision.Traditional ph...Due to the excellent self-centering and load-carrying capability,curvic couplings have been widely used in advanced aero-engine rotors.However,curvic tooth surface errors lead to poor assembly precision.Traditional physical-master-gauge-based indirect tooth surface error measurement and circumferential assembly angle optimization methods have the disadvantages of high cost and weak generality.The unknown tooth surface fitting mechanism is a big barrier to assembly precision prediction and improvement.Therefore,this work puts forward a data-driven assembly simulation and optimization approach for aero-engine rotors connected by curvic couplings.The origin of curvic tooth surface error is deeply investigated.Using 5-axis sweep scan method,a large amount of high-precision curvic tooth surface data are acquired efficiently.Based on geometric models of parts,the fitting mechanism of curvic couplings is uncovered for assembly precision simulation and prediction.A circumferential assembly angle optimization model is developed to decrease axial and radial assembly runouts.Experimental results show that the assembly precision can be predicted accurately and improved dramatically.By uncovering the essential principle of the assembly precision formation and proposing circumferential assembly angle optimization model,this work is meaningful for assembly quality,efficiency and economy improvement of multistage aero-engine rotors connected by curvic couplings.展开更多
In this paper, the main effective factors of engine assembly quality have been analyzed in detail. It provided a mathematical model of engine life span based on the laws of the changirng of friction pairs gap and runn...In this paper, the main effective factors of engine assembly quality have been analyzed in detail. It provided a mathematical model of engine life span based on the laws of the changirng of friction pairs gap and running-in analysis. On the basis of a EQ6100 engine test, the applied spectral analysis technique, it gained efficient technique measures to enhance the engine 's life span, and provided a proposal value and an allowed value of integrated position precision error.展开更多
This paper presents a multi-joint desensitization design(MDD)-based assembly distribution and precision evolution for industrial parallel robots.The optimization of a-UPS/S parallel robot is demonstrated through the o...This paper presents a multi-joint desensitization design(MDD)-based assembly distribution and precision evolution for industrial parallel robots.The optimization of a-UPS/S parallel robot is demonstrated through the optimization of its performance index and precision performance,achieved through the construction of a global error sensitivity.The precision degradation law for independent sources of uncertainty is introduced,and the accelerated degradation after multiple repairs is considered to establish a source-split maintenance yield model to formulate an optimized operation and maintenance strategy.Experiment demonstrates that the MDD method significantly enhances the precision and reliability of the equipment.Compared with that in the pre-optimization stage,the lifetime of the equipment is extended by 38.88%,while the cost remains unchanged.In addition,the effectiveness of MDD in additive manufacturing is demonstrated through an industrial bending pipe case.展开更多
基金Supported by National Key Research and Development Program of China(Grant No.2022YFB3304200)National Natural Science Foundation of China(Grant No.52205288)+1 种基金China Postdoctoral Science Foundation(Grant Nos.2024T170795,2024M762815)Zhejiang Provincial Key Research and Development Program(Grant No.2024C01029)。
文摘Assembly precision greatly influences the performance of complex high-end equipment.The traditional industrial assembly process and deviation transfer are implicit and uncertain,causing problems like poor component fit and hard-to-trace assembly stress concentration.Assemblers can only check whether the dimensional tolerance of the component design is exceeded step by step in combination with prior knowledge.Inversion in industrial assembly optimizes assembly and design by comparing real and theoretical results and doing inversion analysis to reduce assembly deviation.The digital twin(DT)technology visualizes and predicts the assembly process by mapping real and virtual model parameters and states simultaneously,expanding parameter range for inversion analysis and improving inversion result accuracy.Problems in improving industrial assembly precision and the significance and research status of DT-driven parametric inversion of assembly tools,processes and object precision are summarized.It analyzes vital technologies for assembly precision inversion such as multi-attribute assembly process parameter sensing,virtual modeling of high-fidelity assembly systems,twin synchronization of assembly process data models,multi-physical field simulation,and performance twin model construction of the assembly process.Combined with human-cyber-physical system,augmented reality,and generative intelligence,the outlook of DT-driven assembly precision inversion is proposed,providing support for DT's use in industrial assembly and precision improvement.
基金co-supported by Key Technology Research and Development Program of Jiangsu Province, China (No. BE2011178)the Aviation Industry Innovation Fund (No. AC2011214)
文摘A novel approach is proposed to detect the normal vector to product surface in real time for the robotic precision drilling system in aircraft component assembly, and the auto-normalization algorithm is presented based on the detection system. Firstly, the deviation between the normal vector and the spindle axis is measured by the four laser displacement sensors installed at the head of the multi-function end effector. Then, the robot target attitude is inversely solved according to the auto-normalization algorithm. Finally, adjust the robot to the target attitude via pitch and yaw rotations about the tool center point and the spindle axis is corrected in line with the normal vector simultaneously. To test and verify the auto-normalization algorithm, an experimental platform is established in which the laser tracker is introduced for accurate measurement. The results show that the deviations between the corrected spindle axis and the normal vector are all reduced to less than 0.5°, with the mean value 0.32°. It is demonstrated the detection method and the autonormalization algorithm are feasible and reliable.
基金supported by the Liaoning Revitalization Talents Program(Grant No.XLYC2002020)the Major Project of Basic Scientific Research of Chinese Ministry(Grant No.JCYK2016205A003).
文摘Microscopic vision has been widely applied in precision assembly.To achieve sufficiently high resolution in measurements for precision assembly when the sizes of the parts involved exceed the field of view of the vision system,an image mosaic technique must be used.In this paper,a method for constructing an image mosaic with non-overlapping areas with enhanced efficiency is proposed.First,an image mosaic model for the part is created using a geometric model of the measurement system installed on a X-Y-Z precision stages with high repeatability,and a path for image acquisition is established.Second,images are captured along the same path for a specified calibration plate,and an entire image is formed based on the given model.The measurement results obtained from the specified calibration plate are utilized to identify mosaic errors and apply compensation for the part requiring measurement.Experimental results show that the maximum error is less than 4μm for a camera with pixel equivalent 2.46μm,thereby demonstrating the accuracy of the proposed method.This image mosaic technique with non-overlapping regions can simplify image acquisition and reduce the workload involved in constructing an image mosaic.
基金This research was financially supported by the National Key R&D Program of China(2017YFB1104300)the National Science Foundation(CMMI 1825608)Nebraska Center for Energy Sciences Research,and National Natural Science Foundation of China(61774067).The authors would like to thank Professor Stephen Ducharme for valuable discussions regarding the electrical conductivity analysis of this work and Joel Brehm for figure improvement.
文摘Three-dimensional(3D)electrically conductive micro/nanostructures are now a key component in a broad range of research and industry fields.In this work,a novel method is developed to realize metallic 3D micro/nanostructures with silver-thiol-acrylate composites via two-photon polymerization followed by femtosecond laser nanojoining.Complex 3D micro/nanoscale conductive structures have been successfully fabricated with∼200 nm resolution.The loading of silver nanowires(AgNWs)and joining of junctions successfully enhance the electrical conductivity of the composites from insulating to 92.9 Sm^−1 at room temperature.Moreover,for the first time,a reversible switching to a higher conductivity is observed,up to∼10^5Sm^−1 at 523 K.The temperature-dependent conductivity of the composite is analyzed following the variable range hopping and thermal activation models.The nanomaterial assembly and joining method demonstrated in this study pave a way towards a wide range of device applications,including 3D electronics,sensors,memristors,micro/nanoelectromechanical systems,and biomedical devices,etc.
文摘Macroscopic supramolecular assembly(MSA)has been a recent progress in supramolecular chemistry.MSA mainly focuses on studies of the building blocks with a size beyond ten micrometers and the non-covalent interactions between these interactive building blocks to form ordered structures.MSA is essential to realize the concept of"self-assembly at all scales"by bridging most supramolecular researches at molecular level and at macroscopic scale.This review summaries the development of MSA,the basic design principle and related strategies to achieve MSA and potential applications.Correspondingly,we try to elucidate the correlations and differences between"macroscopic assembly"and MSA based on intermolecular interactions;the design principle and the underlying assembly mechanism of MSA are proposed to understand the reported MSA behaviors;to demonstrate further applications of MSA,we introduce some methods to improve the ordered degree of the assembled structures from the point of precise assembly and thus envision some possible fields for the use of MSA.
基金co-supported by the National Basic Research Project(Nos.J2022-VII-0001-0043 and 2017-VII-0010-0104)the Fundamental Research Funds for the Central Universities,and the National Natural Science Foundation of China(No.72231008)。
文摘Due to the excellent self-centering and load-carrying capability,curvic couplings have been widely used in advanced aero-engine rotors.However,curvic tooth surface errors lead to poor assembly precision.Traditional physical-master-gauge-based indirect tooth surface error measurement and circumferential assembly angle optimization methods have the disadvantages of high cost and weak generality.The unknown tooth surface fitting mechanism is a big barrier to assembly precision prediction and improvement.Therefore,this work puts forward a data-driven assembly simulation and optimization approach for aero-engine rotors connected by curvic couplings.The origin of curvic tooth surface error is deeply investigated.Using 5-axis sweep scan method,a large amount of high-precision curvic tooth surface data are acquired efficiently.Based on geometric models of parts,the fitting mechanism of curvic couplings is uncovered for assembly precision simulation and prediction.A circumferential assembly angle optimization model is developed to decrease axial and radial assembly runouts.Experimental results show that the assembly precision can be predicted accurately and improved dramatically.By uncovering the essential principle of the assembly precision formation and proposing circumferential assembly angle optimization model,this work is meaningful for assembly quality,efficiency and economy improvement of multistage aero-engine rotors connected by curvic couplings.
文摘In this paper, the main effective factors of engine assembly quality have been analyzed in detail. It provided a mathematical model of engine life span based on the laws of the changirng of friction pairs gap and running-in analysis. On the basis of a EQ6100 engine test, the applied spectral analysis technique, it gained efficient technique measures to enhance the engine 's life span, and provided a proposal value and an allowed value of integrated position precision error.
基金funded by the China National Key Research and Development Project(Grant No.2022YFB3303303)Key Project of Zhejiang Provincial Natural Science Foundation(Grant No.Z26E050041)State Key Laboratory of Materials Processing and Die and Mold Technology Key Open Fund,China(Grant No.P2024-001).
文摘This paper presents a multi-joint desensitization design(MDD)-based assembly distribution and precision evolution for industrial parallel robots.The optimization of a-UPS/S parallel robot is demonstrated through the optimization of its performance index and precision performance,achieved through the construction of a global error sensitivity.The precision degradation law for independent sources of uncertainty is introduced,and the accelerated degradation after multiple repairs is considered to establish a source-split maintenance yield model to formulate an optimized operation and maintenance strategy.Experiment demonstrates that the MDD method significantly enhances the precision and reliability of the equipment.Compared with that in the pre-optimization stage,the lifetime of the equipment is extended by 38.88%,while the cost remains unchanged.In addition,the effectiveness of MDD in additive manufacturing is demonstrated through an industrial bending pipe case.
