Abstract
Strict quality requirements in aircraft manufacturing demand high accuracy concerning pose alignments of aircraft structures. However, even though a pose adjustment system does pass the accuracy verification, the pose of the large complex structure has difficulty in smoothly and efficiently converging on the desired pose in large aircraft assembly. To solve this problem, we developed a pose adjustment system enhanced by integrating physical simulation for the wing-box assembly of a large aircraft. First, the development of the pose adjustment system, which is the base of the digital pose alignment of a large aircraft’s outer wing panel, is demonstrated. Then, the pose alignment principles of duplex and multiple assembly objects based on the best-fit strategy are successively explored. After that, the contributor analysis is conducted for nonideal pose alignment, in which the influences of thermal and gravity deformations on the pose alignment are discussed. Finally, a physical simulation-assisted pose alignment method considering multisource errors, which uses the Finite Element Analysis (FEA) to integrate temperature fluctuation and gravity field effects, is developed. Compared with a conventional digital pose adjustment system driven by the classical best-fit, the deviations of the Key Characteristic Points (KCPs) significantly decreased despite the impacts of thermal and gravity deformations. The developed pose alignment system has been applied to large aircraft wing-box assembly in Aviation Industry Corporation of China, Ltd. It provides an improved understanding of the pose alignment of large-scale complex structures.