基于高斯过程的复合材料机身壁板力-形协同控制方法

Force-shape synchronous control method for composite fuselage panels based on Gaussian process

  • 摘要: 复合材料机身壁板在重力变形耦合制造偏差后,其外形精度难以满足装配要求,因此复合材料壁板的形状控制在飞机装配过程中至关重要。由于复合材料壁板脆性强、受力易损伤,在校正其外形的同时,还需兼顾装配力水平。然而,复杂的薄壁结构和装配过程中的不确定性,使得复合材料壁板的变形行为和载荷状态难以准确表征,外形调控难度大。本文提出了一种不确定性感知的力-形协同控制方法。方法以显式考虑不确定因素的高斯过程为预测核心,并与多目标优化(NSGA-II)结合,采用参考点方法选解并输出可执行的定位器最优位移。为评估有效性,在3 m × 2 m的复合材料机身壁板上进行验证,结果表明,与未考虑不确定性的高斯过程相比,所提出模型的变形与装配力的平均相对预测误差显著降低;外形调控后最大形状偏差从2.05 mm降低至0.29 mm,同时单自由度装配力/力矩分别控制在40 N和50 N·m以内。证明该方法能够有效降低复合材料机身壁板形状偏差并维持低水平的装配力,为薄壁复材件的低损伤、高精度装配提供了一种可复用的工程化框架。

     

    Abstract: After gravity-induced deformation is coupled with manufacturing deviations, the geometric accuracy of composite fuselage panels often fails to meet assembly requirements; therefore, shape control is essential in aircraft assembly. Given the high brittleness and vulnerability of composite panels under loading, assembly force levels must be constrained while correcting shape. However, the complex thin-walled structure and uncertainties in the assembly process make the deformation behavior and load state difficult to characterize, complicating shape regulation. This paper proposes an uncertainty aware force–shape synchronous control method. The method employs a Gaussian process that explicitly accounts for uncertainties as the predictive core, and couples it with multi-objective optimization (NSGA-II); a reference point selection scheme is used to output executable optimal displacements of the actuators. To evaluate effectiveness, validation is conducted on a 3 m × 2 m composite fuselage panel. The results show that, compared with a Gaussian process that does not consider uncertainties, the proposed model yields a significantly lower average relative prediction error for both deformation and assembly force; after shape regulation, the maximum deviation is reduced from 2.05 mm to 0.29 mm, while the per-axis assembly force/torque are controlled within 40 N and 50 N·m, respectively. These results demonstrate that the method effectively reduces shape deviations and maintains low assembly forces of composite fuselage panels, providing a reusable engineering framework for low-damage, high-precision assembly of thin-walled composite components.

     

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