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.

iGPS capability study

This report presents the results of testing of the Metris iGPS system performed by the National Physical Laboratory (NPL) and the University of Bath (UoB), with the assistance of Metris, and Airbus at Airbus, Broughton in March 2008. The aim of the test was to determine the performance capability of the iGPS coordinate metrology system by comparison with a reference measurement system based on multilateration implemented using laser trackers. A network of reference points was created using SMR nests fixed to the ground and above ground level on various stands. The reference points were spread out within the measurement volume of approximately 10 m ´ 10 m ´ 2 m. The coordinates of each reference point were determined by the laser tracker survey using multilateration. The expanded uncertainty (k=2) in the relative position of these reference coordinates was estimated to be of the order of 10 µm in x, y and z. A comparison between the iGPS system and the reference system showed that for the test setup, the iGPS system was able to determine lengths up to 12 m with an uncertainty of 170 µm (k=2) and coordinates with an uncertainty of 120 µm in x and y and 190 µm in z (k=2).