Abstract

In a half fuselage assembly process, shape control is vital for achieving ultra-high-precision assembly. To achieve better shape adjustment, we need to determine the optimal location and force of each actuator to push or pull a fuselage to compensate for its initial shape distortion. The current practice achieves this goal by solving a surrogate model-based optimization problem. However, there are two limitations of this surrogate model-based method: (1) low efficiency: collecting training data for surrogate modeling from many finite element analysis (FEA) replications is time-consuming; (2) non-optimality: The required number of FEA replications for building an accurate surrogate model will increase as the potential number of actuator locations increases. Therefore, the surrogate model can only be built on a limited number of prespecified potential actuator locations, which will lead to suboptimal control results. To address these issues, this paper proposes an FEA model-based automatic optimal shape control (AOSC) framework. This method directly loads the system equation from the FEA simulation platform to determine the optimal location and force of each actuator. Moreover, the proposed method further integrates the cautious control concept into the AOSC system to address model uncertainties in practice. The case study with industrial settings shows that the proposed Cautious AOSC method achieves higher control accuracy compared to the current industrial practice.

References

1.
Gates
,
D.
,
2007
, “
Boeing Finds 787 Pieces Aren’t Quite a Perfect Fit
,”
Seattle Times Aerospace Report, Seattle Times
, Seattle, WA, https://www.seattletimes.com/business/boeing-finds-787-pieces-arent-quite-a-perfect-fit/, Accessed January 19, 2022.
2.
Wen
,
Y.
,
Yue
,
X.
,
Hunt
,
J. H.
, and
Shi
,
J.
,
2018
, “
Feasibility Analysis of Composite Fuselage Shape Control via Finite Element Analysis
,”
J. Manuf. Syst.
,
46
, pp.
272
281
.
3.
Yue
,
X.
,
Wen
,
Y.
,
Hunt
,
J. H.
, and
Shi
,
J.
,
2018
, “
Surrogate Model-Based Control Considering Uncertainties for Composite Fuselage Assembly
,”
ASME J. Manuf. Sci. Eng.
,
140
(
4
), p. 041017.
4.
Du
,
J.
,
Yue
,
X.
,
Hunt
,
J. H.
, and
Shi
,
J.
,
2019
, “
Optimal Placement of Actuators via Sparse Learning for Composite Fuselage Shape Control
,”
ASME J. Manuf. Sci. Eng.
,
141
(
10
), p. 101004.
5.
Zhong
,
J.
,
Liu
,
J.
, and
Shi
,
J.
,
2010
, “
Predictive Control Considering Model Uncertainty for Variation Reduction in Multistage Assembly Processes
,”
IEEE Trans. Autom. Sci. Eng.
,
7
(
4
), pp.
724
735
.
6.
Maciejowski
,
J. M.
,
2002
,
Predictive Control: With Constraints
,
Prentice Hall
,
New York
.
7.
Grant
,
M.
,
Boyd
,
S.
, and
Ye
,
Y.
,
2008
, CVX: Matlab Software for Disciplined Convex Programming, CVX Research, Inc., Austin, TX.
8.
Natarajan
,
B. K.
,
1995
, “
Sparse Approximate Solutions to Linear Systems
,”
SIAM J. Comput.
,
24
(
2
), pp.
227
234
.
9.
Haftka
,
R. T.
, and
Adelman
,
H. M.
,
1985
, “
An Analytical Investigation of Shape Control of Large Space Structures by Applied Temperatures
,”
AIAA J.
,
23
(
3
), pp.
450
457
.
10.
Chee
,
C. Y.
,
Tong
,
L.
, and
Steven
,
G. P.
,
2002
, “
Static Shape Control of Composite Plates Using a Slope-Displacement-Based Algorithm
,”
AIAA J.
,
40
(
8
), pp.
1611
1618
.
11.
Burdisso
,
R. A.
, and
Haftka
,
R. T.
,
1990
, “
Statistical Analysis of Static Shape Control in Space Structures
,”
AIAA J.
,
28
(
8
), pp.
1504
1508
.
12.
Hakim
,
S.
, and
Fuchs
,
M. B.
,
1996
, “
Quasistatic Optimal Actuator Placement With Minimum Worst Case Distortion Criterion
,”
AIAA J.
,
34
(
7
), pp.
1505
1511
.
13.
Burdisso
,
R. A.
, and
Haftka
,
R. T.
,
1989
, “
Optimal Location of Actuators for Correcting Distortions in Large Truss Structures
,”
AIAA J.
,
27
(
10
), pp.
1406
1411
.
14.
Ponslet
,
E.
,
Haftka
,
R.
, and
Cudney
,
H.
,
1993
, “
Optimal Placement of Tuning Masses on Truss Structures by Genetic Algorithms
,”
Proceedings of the 34th Structures, Structural Dynamics and Materials Conference
,
La Jolla, CA
,
Apr. 19–22
, p.
1586
.
15.
Haftka
,
R. T.
, and
Adelman
,
H. M.
,
1985
, “Selection of Actuator Locations for Static Shape Control of Large Space Structures by Heuristic Integer Programing,”
Advances and Trends in Structures and Dynamics
,
Elsevier
,
New York
, pp.
575
582
.
16.
Plumbridge
,
W.
,
Matela
,
R. J.
, and
Westwater
,
A.
,
2007
, “Nonlinear Finite Element Analysis,”
Structural Integrity and Reliability in Electronics: Enhancing Performance in a Lead-Free Environment
,
Springer Science & Business Media
,
Berlin, Germany
.
17.
Kohnke
,
P.
,
2013
,
ANSYS Mechanical APDL Theory Reference
,
ANSYS
,
Canonsburg, PA
.
18.
Reddy
,
J. N.
,
2019
,
Introduction to the Finite Element Method
,
McGraw-Hill Education,
New York
.
19.
Du
,
J.
,
Liu
,
C.
,
Liu
,
J.
,
Zhang
,
Y.
, and
Shi
,
J.
,
2021
, “
Optimal Design of Fixture Location for Compliant Part With Application in Ship Curved Panel Assembly
,”
ASME J. Manuf. Sci. Eng.
,
143
(
6
), p.
061007
.
You do not currently have access to this content.