A Displacement Field Perception Method for Component Digital Twin in Aircraft Assembly.

Full-field displacement perception and digital twins for core components play a crucial role in the precision manufacturing industry, such as aviation manufacturing. This paper presents a real-time full-field displacement perception method for the combination of online multipoint displacement monitoring and matrix completion theory. Firstly, a conceptual full-field displacement perception model based on the observed information of the multi-points is established. To obtain the full-field displacements of a core component, the component is divided into plentiful discrete points, including observed and unobserved points, based on which the relationship between the observed points and the full-field displacements is established. Then, the solution method of the full-field displacement perception model is proposed. Based on the matrix completion principle and the big data of the simulation, the optimization problem is employed to work out the model and, meanwhile, the pseudo-code is put forward. Finally, the full-field displacement perception experiments are performed. Repeated experiments show that the max error of the displacements calculated by the proposed method can be less than 0.094 mm and the median error can be less than 0.054 mm, while the average time frame can be less than 0.48 s, which is promising considering the high precision and efficiency requirements of the assembly of large aircraft.

A Decoupled Unified Observation Method of Stochastic Multidimensional Vibration for Wind Tunnel Models.

Active vibration control is the most effective method for stochastic multidimensional vibration in wind tunnel tests, in which vibration monitoring is the core foundation. Vibrations are induced by the disturbances of several complex air flow instabilities under extreme test conditions with high attack angles. Here, a decoupled unified observation method is proposed in order to fully monitor stochastic multidimensional vibration. First, stochastic multidimensional vibration is explained using the Cartesian coordinate system. Then, the multidimensional vibration decoupling of the pitch plane and the yaw plane is realized according to the proposed decoupling design principle of the long cantilever sting. A unified observation method is presented, based on inertial force theory, to observe multidimensional vibration due to acceleration in each decoupling plane. Verification experiments were conducted in lab and a transonic wind tunnel, using an established real-time monitoring system. The results of lab experiments indicate that, in the frequency region of 0-120 Hz, three vibration modes of a selected stochastic vibration can be decoupled and observed through the vibration components in pitch plane and yaw plane. In addition, wind tunnel tests were carried out according to the working conditions (α = -4~10° with γ = 45°) at Ma = 0.6 and Ma = 0.7, respectively. The results show that six vibration modes of two selected stochastic vibrations can be decoupled and observed through the vibration components in pitch plane and yaw plane. The experimental results prove that stochastic vibration can be fully monitored in multiple dimensions through the vibration components in pitch plane and yaw plane using the proposed decoupled unified observation method. Therefore, these results lay the foundation for active vibration control.

Multidimensional Vibration Suppression Method with Piezoelectric Control for Wind Tunnel Models.

In wind tunnel tests, the low-frequency and large-amplitude vibration of the cantilever sting result in poor test data in pitch plane and yaw plane, more seriously, even threatens the safety of wind tunnel tests. To ensure the test data quality, a multidimensional vibration suppression method is proposed to withstand the vibration from any direction, which is based on a system with stackable piezoelectric actuators and velocity feedback employing accelerometers. Firstly, the motion equation of the cantilever sting system is obtained by Hamilton's principle with the assumed mode method. Then, the multidimensional active control mechanism is qualitatively analyzed and a negative velocity feedback control algorithm combined with a root mean square (RMS) evaluation method is introduced to realize active mass and active damping effect, meanwhile, a weight modification method is performed to determine the sequence number of the stacked piezoelectric actuators and the weight of control voltages in real time. Finally, a multidimensional vibration suppression system was established and verification experiments were carried out in lab and a transonic wind tunnel. The results of lab experiments indicate that the damping ratio of the system is improved more than 4.3 times and the spectrum analyses show reductions of more than 23 dB. In addition, wind tunnel test results have shown that for the working conditions (α = -4~10° with γ = 0° or α = -4~10° with γ = 45°) respectively at 0.6 Ma and 0.7 Ma, the remainder vibration is less than 1.53 g, which proves that the multidimensional vibration suppression method has the ability to resist vibration from any direction to ensure the smooth process of wind tunnel tests.

High-Accuracy Calibration Based on Linearity Adjustment for Eddy Current Displacement Sensor.

High precision position control is essential in the process of parts manufacturing and assembling, where eddy current displacement sensors (ECDSs) are widely used owing to the advantages of non-contact sensing, compact volume, and resistance to harsh conditions. To solve the nonlinear characteristics of the sensors, a high-accuracy calibration method based on linearity adjustment is proposed for ECDSs in this paper, which markedly improves the calibration accuracy and then the measurement accuracy. After matching the displacement value and the output voltage of the sensors, firstly, the sensitivity is adjusted according to the specified output range. Then, the weighted support vector adjustment models with the optimal weight of the zero-scale, mid-scale and full-scale are established respectively to cyclically adjust the linearity of the output characteristic curve. Finally, the final linearity adjustment model is obtained, and both the calibration accuracy and precision are verified by the established calibration system. Experimental results show that the linearity of the output characteristic curve of ECDS adjusted by the calibration method reaches over 99.9%, increasing by 1.9⁻5.0% more than the one of the original. In addition, the measurement accuracy improves from 11⁻25 µ m to 1⁻10 µ m in the range of 6mm, which provides a reliable guarantee for high accuracy displacement measurement.