A novel algorithm of posture best fit based on key characteristics for large components assembly

Measurement and variation control of geometrical Key Characteristics (KCs), such as flatness and gap of joint faces, coaxiality of cabin sections, is the crucial issue in large components assembly from the aerospace industry. Aiming to control geometrical KCs and to attain the best fit of posture, an optimization algorithm based on KCs for large components assembly is proposed. This approach regards the posture best fit, which is a key activity in Measurement Aided Assembly (MAA), as a two-phase optimal problem. In the first phase, the global measurement coordinate system of digital model and shop floor is unified with minimum error based on singular value decomposition, and the current posture of components being assembly is optimally solved in terms of minimum variation of all reference points. In the second phase, the best posture of the movable component is optimally determined by minimizing multiple KCs' variation with the constraints that every KC respectively conforms to its product specification. The optimal models and the process procedures for these two-phase optimal problems based on Particle Swarm Optimization (PSO) are proposed. In each model, every posture to be calculated is modeled as a 6 dimensional particle (three movement and three rotation parameters). Finally, an example that two cabin sections of satellite mainframe structure are being assembled is selected to verify the effectiveness of the proposed approach, models and algorithms. The experiment result shows the approach is promising and will provide a foundation for further study and application. © 2013 The Authors.