A bayesian based process monitoring and fixture fault diagnosis approach in the auto body assembly process

The auto body process monitoring and the root cause diagnosis based on data-driven approaches are vital ways to improve the dimension quality of sheet metal assemblies. However, during the launch time of the process mass production with an off-line measurement strategy, the traditional statistical methods are difficult to perform process control effectively. Based on the powerful abilities in information fusion, a systematic Bayesian based quality control approach is presented to solve the quality problems in condition of incomplete dataset. For the process monitoring, a Bayesian estimation method is used to give out-of-control signals in the process. With the abnormal evidence, the Bayesian network (BN) approach is employed to identify the fixture root causes. A novel BN structure and the conditional probability training methods based on process knowledge representation are proposed to obtain the diagnostic model. Furthermore, based on the diagnostic performance analysis, a case study is used to evaluate the effectiveness of the proposed approach. Results show that the Bayesian based method has a better diagnostic performance for multi-fault cases.     

Compliant assembly modeling and deformation analysis considering macro residual stress in engineering component

Based on the manufacturing history chain, a component's macro residual stress is introduced to the subsequent assembly model. In the simulated method, the simulation cost is saved via mapping the bulk stress profile directly to the component compared to our previous study. It thus facilitates the finite element analysis(FEA) which takes the component location in blank and the thickness of blank as two influence parameters. The methodology is proved to be feasible by the validation experiment designed for a typical assembly structure from the aerospace industry. The results show that the bulk stress originating from material preparation affects the downstream large-scale assembly deformation. The investigation of this research helps systematically to improve compliant assembly precision.     

FORMING FREEFORM SURFACE SHEET METAL USING INTEGRATED REVERSE ENGINEERING TECHNOLOGY

IntroductionReverse engineering in the manufacturing fieldis a process that people first measure an existentobject model or a part to obtain its data,then re-construct its CAD model. The CAD model repre-sents the geometric features and other propertiesoforiginal object and also can be used for many otherpurposes,such as analysis,modification,manu-facturing and test etc.The main difference be-tween conventional forward engineering and re-verse engineering is that the former is an explicitphys…     

Sensitivity Analysis of Effect Related with Material Process and Assembly Variations to Loads Deformation and Stress on HSS Stamping Die

During stamping process, the material properties, process design parameters and production environments inevitably have variation and noisy factors, which possibly affect the sheet metal formability and the deformation of the die structure.After gaining a success in applying sheet metal forming numerical simulation analysis to get the forming loads during stamping process, a methodology of die structure analysis based on sheet metal forming simulation was proposed and validated by experiments.Based on these results, the effect related with initial blank thickness, blank holder force, blank positioning error and die alignment error variations to a DP600 hyperbolic bottomed cup drawing die's forming loads(especially unbalanced loads), and deformation and stress was studied numerically.The influence level of these variations to the die's forming loads, deformation and stress was disclosed.The findings can guide die design, die tryout and process control for high-strength steel(HSS) stamping with increased forming load and decreased sheet metal formability.     

一种复杂诊断系统的多智能体协同求解算法

为适应故障诊断中动态变化的环境和满足求解复杂系统全部任务的要求,研究一种基于MAS的分布式智能监控系统.以诊断决策问题的结构及建模过程的层次性为基本思想,基于诊断任务的多层次混合分解策略,提出了融合不同表达方式和推理机制的多Agent并行诊断结构,分析了管理Agent,诊断Agent和决策Agent的基本职能.探讨了实时Agent的组织和演化机制,给出了并行推理过程中的冲突消解算法,建立了具有公共属性的智能体模块化层次结构,实现了基于MAS多层分布式黑板模型的智能监控系统.工程应用效果验证了该求解的可行性和有效性.     

KEY TECHNOLOGY IN INTELLIGENT CONTROL FOR SHEET METAL DEEP DRAWING

Introduction　　 With development of economics and furtheropening,competitions in market are intensive.The margin between the material cost and price ofproducts becomes small,which compels companiesto pursue higher rate of productivity and quality.The rate of productivity has been improvedthrough high pressing automation,but in order toget satisfactory quality of products under distur-bances,on- line measurement,identification,pre-diction and on- line control must be realized. Intel-ligentcont…     

面向装配和维修的动车组大模型实时可视化技术

针对动车组大模型实时绘制困难的问题,提出一种基于零件包围盒中心点的LOD自动生成方法与一种基于面向装配和维修重要性的实时自适应绘制方法.通过保留CAD装配树信息,以零件包围盒中心点为LOD中心点转换CAD大模型为虚拟装配、虚拟维修LOD模型,实现了大模型的LOD绘制.在上述LOD模型基础上,根据装配、维修对象的重要性,动态地调整LOD分辨率等级,实现了LOD实时自适应绘制.实验结果表明:采用文中方法生成的大型模型能完整保留CAD装配树,并可在普通计算机上实现实时的自适应绘制.     

机动车辆钣金件定损规范和修理与更换标准研究

改进传统的汽车保险理赔服务模式,提高工作效率,降低服务成本,已成为我国汽车保险业急需解决的问题,特别是车辆钣金件的定损规范和修理的更换标准更需要完善及细化。在机动车保险车辆钣金件定损规范的理论基础上,从定损工作流程入手,研究钣金件定损原则及方法。通过总结和分析,提出车身各覆盖件和结构件的更换与修理标准。     

基于微分变换的柔性体小变形装配精度分析

在产品设计阶段进行装配精度分析时通常以刚体假设为前提,往往忽略外部载荷、温度变化等载荷因素的影响.在已存在制造误差、装配误差的情况下,载荷因素引起的零件变形会进一步影响装配精度.因此,本文提出了一种同时考虑制造、装配误差和零件变形的装配精度分析模型.该模型首先沿尺寸链将变形的公差特征离散化,在每个节点处建立并固结节点坐标系;然后提取节点的变形信息,对目标特征上的每个节点坐标系进行微分变换,实现误差与变形的综合;最后建立了线性化的综合误差分析模型.研究结果表明:模型不仅克服了传统误差分析模型以刚体假设为前提的局限,得到了零件的局部变形对装配精度的影响,还可极大地减少装配系统几何建模与力学分析的难度和工作量.     

增材制造技术发展和在先进轨道交通装备中的应用展望

从增材制造技术的应用现状出发,概述了几种增材制造技术的特点和应用范围;介绍了典型的金属增材制造最新研究进展;考虑现有增材制件存在的固有缺陷、残余应力和裂纹等问题,总结了能有效改善成形增材制件质量的后处理工序;梳理了增材制件疲劳性能的影响因素,重点阐述了缺陷与增材制件疲劳损伤的关联性;探讨了增材制造技术广泛应用所涉及的关...     

Study on Dimension Chain Generation for Auto-body Tolerance Analysis

Introduction The construction of assembly function is oneof the keys to evaluate assembly dimensional quali-ty in the process of computer-aided product processconcurrent design. The assembly function mustrepresent the relationship among parts being as-sem…     

CAE-Based Robust Optimization for Deep-Drawing Process of Sheet Metal Forming Using Grey Relational Analysis Method

The theory of grey systems is a new technique for performing prediction, relational analysis and decision making in many areas. The grey relational analysis was used to optimize the deep-drawing process parameters with considerations of the multiple response (the wrinkle, crack and thinning variation). The deep-drawing parameters, such as the blank holding force (F_ bh ), the radii of punch and die (R_1,R_2), the coefficients of friction (μ_1,μ_2,μ_3) are considered. An orthogonal array is used for the experimental design. The multiple response values are obtained making use of finite element analysis (FEA). Optimal process parameters are determined by the grey relational grade obtained from the grey relational analysis for multi-performance characteristics (the wrinkle, crack and the thinning). The analysis of variance (ANOVA) for the grey relational grade is implemented. The results show that the quality of stamped parts can be improved effectively through the new approach. The grey relational analysis can be applied in sheet metal forming.     

高速列车开行方案研究

对高速列车停站影响进行了分析，建立了高速列车开行主案的多目标０－１规划数学模型，研究了一套有效可行的多层次０－１规划模型，这用有序组全树方法对问题求解。     

基于Simufact的焊接应力的对比分析

焊接部位要经历不均匀的加热和冷却历程,最终在焊接结构中产生应力,焊接应力会导致焊接接头产生冷、热裂纹等缺陷,焊接结构破坏事故许多是由焊接应力和变形所引起。因此,为了提高焊接结构的质量和使用性能,简化焊条电弧焊焊接的实验过程,本文运用Simufact-Welding软件对Q345钢的T形接头进行平焊仿真,对比分析了焊件不完全约束和完全约束两种方法下在焊接过程中和冷却过程中熔合线处的应力。结果表明：该仿真过程中,其它参数相同的情况下,不同的焊件装夹方法得到不同结果的焊接应力,焊接过程中,两种方法下大部分熔合线处的等效应力的最大值大于Q345的屈服强度,焊件不完全约束方法下大部分熔合线处的残余应力大于Q345的屈服强度,焊件完全约束方法下大部分熔合线处的残余应力小于Q345的屈服强度。     

面向自动装配的冲模装配建模与规划

通过对冲裁模设计过程中产生的零件之间装配关系的记录，建立了冲模装配体装配关系图。以装配图为基础，根据冲模生产过程中的设计惯例和零件之间的联接关系，对构成冲模结构的各零部件进行了子装配体的划分，形成了具有层次化结构的装配体结构树，并在此基础上，通过实例说明了子装配体的装配顺序规划方法。     

MULTI-AGENT APPROACH FOR DISTRIBUTED FLEXIBLE MANUFACTURING SYSTEMS

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A reconfigurable stamping die and its stamping process

A reconfigurable flexible poles die was developed. The die can be used to implement the process of “the multi-point pressing and forming sheet”. Sheet metal is restricted by the elastic pressing forces putting on the upper and lower surfaces of sheet in stamping process. The method is an effective way to enhance the buckling critical stresses and reduce wrinkling of sheet. The results of tests indicate that the die can achieve “one die brings multi-purpose” and suppress the wrinkle of sheet. The process of the multi-point pressing and forming sheet provides a practical and effective way for the curved sheet metal forming.     

Calibration for 3D Structured Light Measurement

A calibration procedure was developed for three-dimensional(3D) binocular structured light measurement systems. In virtue of a specially designed pattern, matching points in stereo images are extracted. And then sufficient 3D space points are obtained through pairs of images with the intrinsic and extrinsic parameters of each camera estimated prior and consequently some lights are calibrated by means of multi point fitting. Finally, a mathematical model is applied to interpolate and approximate all dynamic scanning lights based on geometry. The process of calibration method is successfully used in the binocular 3D measurement system based on structured lights and the 3D reconstruction results are satisfying.     

发动机滑动轴承故障定量诊断方法

应用振动监测技术,对EQ6100-1型发动机连杆轴瓦与曲柄销间隙故障进行模拟,分析振动响应与故障特征变化关系,从振动信号中提取反映偶件故障的特征参数,选择适当的数学模型描述特征参数随偶件状态的变化规律,实现对发动机滑动轴承间隙故障的定量诊断。试验结果表明:故障系数和连杆轴瓦与曲柄销间隙的关系是显著的,相关曲线为多项式回归曲线,其复相关系数接近1,说明采用振动信号进行发动机滑动轴承间隙故障诊断在实践上是可行的。     

Numerical analysis of unconventional forging process of hollowed shaft from Ti-6Al-4V alloy

This paper presents theoretical analysis of unconventional forging process of hollowed shaft from Ti-6Al-4V alloy in a three-slide forging press. This method in comparison with other metal forming methods allows for obtaining of hollowed products. The designed process is verified theoretically by means of numerical simulations based on finite element method with assumption of 3D state of strain. The following factors are considered in the analysis: material flow kinematics, strain distribution, temperature distribution and force of process. On the basis of results, it is stated that the application of designed technology allows for obtaining of a product of assumed quality. A comparison is made between material consumption in analyzed process and material consumption in typical metal forming methods, also in used at present technology of shaft manufacturing by machining only. It is stated that the application of forging in the three-slide forging press allows for a considerable decrease of manufacturing costs due to material savings and decrease of labor consumption of operations at finishing.