数字化制造系统规划与建模仿真研究

通过对离散制造系统规划、建模与仿真分析,研究数字化制造系统面向对象的仿真建模方法.利用仿真技术对制造系统的运行的性能进行分析与评价,可以在生产计划的早期,对制造系统进行规划设计、参数优化和结构调整,验证工艺,优化生产过程,提高生产效率.以实际生产系统缸盖加工生产线为例,建立生产线仿真模型,进行布局规划、瓶颈分析,对生产线设计方案进行验证,优化生产线的配置和布局.     

基于PCM/CAE集成的虚拟装配检测及工艺优化

开发了基于点云模型(PCM)/CAE集成的虚拟装配检测系统,将PCM与CAE模型进行了集成。聚焦虚拟装配检测过程中的误差分析问题,研究了基于仿真的零部件制造与装配误差分析方法。为了使一个存在各种变形与制造误差的零件达到理想或设计目标的装车状态,采用了多目标优化方法,实现了基于CAE仿真的虚拟装配分析与装配工艺优化。     

基于Internet／Intranet的汽车覆盖件冲压虚拟制造系统

提出基于Ｉｎｔｅｒｎｅｔ／Ｉｎｔｒａｎｅｔ汽车覆盖件冲压虚拟制造系统。在基于Ｉｎｔｅｒｎｅｔ／Ｉｎｔｒａｎｅｔ的信息系统集成的基础上,利用虚拟现实、科学可神化和多媒体的虚拟使用环境,在人工智能技术和基于事例的推理（ＣＢＲ）技术的支持下,通过集成地应用各种建模、仿真分析技术和工具以及控制技术实现集成的、并行的产品开发和制造系统,采用在虚拟环境下的基于黑板控制系统的分布式并行处理协同求解。最后给出了汽     

虚拟制造环境下焊接结构有限元分析体系的研究

介绍了将焊接有限元方法引入虚拟制造环境的新思路.将焊接过程的有限元分析集成到虚拟制造环境中,支持产品从机械加工到焊接成型全过程的设计,对需要进行焊接加工的产品实现虚拟设计过程,在实际焊接之前,设计焊接路径,规划焊接顺序,有效预测焊接应力场、温度场,焊件的变形情况,完善虚拟制造内涵,并指导实际生产.     

虚拟样机概念及体系结构研究

作为90年代才逐渐发展起来的以CAX/DFX为代表的先进系统建模仿真设计方法，虚拟样机（VP）技术已成为虚拟制造（VM）的关键使能技术。本文主要通过对其概念和体系结构发展的分析，结合当今CIMS技术和研究的进展，最终提出了基于集成产品和过程开发（IPPD）方法论、面向多领域复杂产品的新一代VP的概念和体系结构。     

CNC集成制造过程协同仿真模型及应用技术研究

针对CNC集成制造过程复杂、动态、迭代的特点,采用分层混合建模策略构建了CNC集成制造过程协同仿真模型,并设计了仿真单元;考虑到各过程之间的兼容性、集成性,采用基于模型字典和模型结构相结合的面向对象的模型表示方法对各仿真对象进行规范化表示。最后以曲轴工件为例,采用组态软件开发了曲轴CNC集成制造协同仿真系统,实现了曲轴工件加工过程、检测过程、质量监控的多模式窗口协同仿真运行,有效实现了各仿真单元模型及文档的共享和互操作,使用过程采样数据对仿真模型进行训练和测试,为工艺方案的寻优提出可供借鉴的依据,为集成制造过程的优化提供理论依据。     

加工过程物理仿真技术研究

加工过程仿真是虚拟制造的底层关键技术，同时也是数字化制造系统的重要组成部分，而物理仿真是其中的研究重点和难点。建模难，通用性和实用性差是目前物理仿真中存在的主要问题。文章总结了物理仿真的研究内容和方法，分析了研究中存在的问题及加工过程建模的常用方法。     

基于Roboguide平台的焊接机器人增材制造虚拟仿真研究与应用

为研究基于Roboguide平台的焊接机器人增材制造中的虚拟仿真技术,通过Roboguide平台进行焊接机器人离线编程,进行轨迹规划仿真的试验,应用于机器人增材制造过程中。研究表明,基于Roboguide平台的虚拟现实仿真技术方便可靠,避免了实际操作过程中的碰撞,优化了程序,有效缩短了机器人焊接时间,提高了机器人工作效率。     

基于Bezier曲线的焊缝成形计算机仿真技术

针对车间数字化制造的应用需要,提出了一种基于Bezier曲线的焊缝成形过程的计算机仿真建模技术. 通过对电弧焊焊缝成形规律的研究,建立了焊接工艺参数与焊缝几何特征之间的映射关系,并运用B-rep法开展了电弧焊焊缝的几何特征建模技术研究,采用OpenGL技术开发了电弧焊缝成形的计算机仿真原型. 仿真结果表明文中所提出的焊缝成形过程建模技术与计算机仿真系统可有效指导焊接工艺的数字化设计.     

基于I-DEAS的虚拟数控加工中心的开发

设计研究开发一个分布式虚拟数控加工中心,利用I-DEAS软件进行虚拟数控机床的几何建模、运动控制和有限元分析。它的最终目的是为虚拟制造建立一个真实的加工环境,在计算机屏幕上实现加工过程的仿真,以增强制造过程的各级决策与控制能力,优化制造过程。论文系统地阐述了该研究对象的特点、功能、体系结构和开发流程。     

Virtual manufacturing for press line monitoring and diagnostics

Virtual manufacturing, or manufacturing simulation, can be divided into three domains: product domain, process domain, and resource domain. This paper focuses on the use of virtual manufacturing for press line monitoring and diagnostics. It contains an introduction to virtual manufacturing, divided into a general part on modelling and simulation, verification, validation and acceptance, and the division into the three domains, as well as a specific part on the use of simulation in these domains for sheet metal products, processes and processing equipment. The main software tools discussed in this paper are discrete event simulation and computer-aided robotics; the designed and implemented machine service support system is an example of advanced use of three-dimensional (3-D) graphical simulation in the resource domain. This system offers remote on-line monitoring and diagnostics functions as well as media player-type functions such as replay that allow a service and maintenance expert to analyse disturbances that occur at remote locations. A key feature of the system is 3-D graphical simulation with I/O synchronisation. This type of system is particularly useful for system integrators and machine builders that install press lines and press cells world-wide and need to guarantee a high level of availability of the installed machinery.     

弧焊机器人轨迹规划及应用研究

机器人弧焊技术,因焊接质量稳定、生产效率高等优势,在汽车工业中得到广泛的应用。在建立机器人弧焊工作单元的基础上,本文分析研究了弧焊工作站运动仿真、离线编程的实际应用及影响焊接质量的因素。通过使用轨迹优化仿真软件,指导焊接工装设计,降低投资成本;进一步的离线编程的使用使得虚拟轨迹与真实机器人运动轨迹挂钩,提高了工作效率和可靠性。通过实验对比及弧焊工作站的调试,讨论了焊接电流、焊接电压、机器人焊接速度对焊接质量的影响。     

Improved Accuracy of the Inherent Shrinkage Method for Fast and More Reliable Welding Distortion Calculations

This paper describes the implementation of a simple strategy adopted for the inherent shrinkage method (ISM) to predict welding-induced distortion. This strategy not only makes it possible for the ISM to reach accuracy levels similar to the detailed transient analysis method (considered the most reliable technique for calculating welding distortion) but also significantly reduces the time required for these types of calculations. This strategy is based on the sequential activation of welding blocks to account for welding direction and transient movement of the heat source. As a result, a significant improvement in distortion prediction is achieved. This is demonstrated by experimentally measuring and numerically analyzing distortions in two case studies: a vane segment subassembly of an aero-engine, represented with 3D-solid elements, and a car body component, represented with 3D-shell elements. The proposed strategy proves to be a good alternative for quickly estimating the correct behaviors of large welded components and may have important practical applications in the manufacturing industry.     

轨道式焊接机器人的虚拟样机设计与仿真

针对受损的水轮机叶片等具有空间复杂曲面结构,在其安装位置直接进行修复工作,设计了一种基于移动平台的焊接机器人虚拟样机。为确定焊枪末端与机器人6个关节之间的运动关系,建立虚拟样机DH坐标系,借助Matlab软件得到运动学方程正、逆解。将在Solid Works软件中建立的焊接机器人三维模型,导入ADAMS仿真软件进行运动学分析。仿真结果表明:机器人在狭窄空间启动时,由滑动、转动关节运动引起的焊枪末端空间位移变化小,速度、加速度曲线变化平缓,无任何突变,证明了该虚拟样机设计的有效性,满足基坑内的焊接工作要求。     

虚拟数控机床仿真系统的研究与实现

基于虚拟现实技术的虚拟制造是实际制造在计算机上的本质体现。本文基于虚拟制造的先进制造思想,讨论了虚拟数控机床仿真系统的结构及系统各模块实现的关键技术,并利用Visual C＋＋、Openlnventor为开发工具实现了虚拟数控机床仿真系统,该系统拥有虚拟装配、虚拟加工及刀具温度场的仿真等功能。以上海机床厂生产的CK6430数控机床为应用实例,验证了该仿真系统的正确性。最后提出了虚拟制造的发展方向。     

CAD model based virtual assembly simulation,planning and training

This paper reviews the state-of-the-art methodologies for developing computer-aided design (CAD) model based systems for assembly simulation, planning and training. Methods for CAD model generation from digital data acquisition, motion capture, assembly modeling, human–computer interface, and data exchange between a CAD system and a VR/AR system are described. Also presented is an integrated methodology for designing, planning, evaluating and testing assembly systems. The paper further describes the implementation of these methods and provides application examples of CAD model based simulation for virtual assembly prototyping, planning and training. Finally, the technology gaps and future research and development needs are discussed.     

高压往复泵虚拟装配系统的研究与开发

在对往复泵设计理论和虚拟制造技术进行系统分析和研究的基础上,结合为生产企业进行往复泵设计和改造的实际经验,研究与开发了往复泵虚拟装配系统。实现了往复泵设计的程序化,包括主要零部件的尺寸计算、强度校核;主要零部件的参数化绘图;往复泵的虚拟装配和动作仿真等,是一套集往复泵的设计、选型、分析、参数化绘图和虚拟装配为一体的,功能全面和实用的系统。文中详细介绍了往复泵虚拟装配系统的组成结构和功能。     

Digital manufacture of large-grade hydro turbine's blades

The blade is one of the vital components and the most difficulty in manufacturing of large hydro turbines. In order to cost-effectively and productively manufacture these kinds of blades, a series of innovative digital techniques have been developed. It includes the digital design of hydro turbine blades based on manufacturers’ requirements, computer-aided location and the machined error evaluation with three-dimensional digitized measure, tool path generation strategy for enhancing machining efficiency and controlling deviation in NC machining, tool path generation and NC machining simulation by means of a virtual NC machining environment for blades, and feasible strategy and the systematic scheme for manufacturing of large blades with 5-axis simultaneous CNC machining technology. The developed innovative digital manufacture techniques have been successfully applied in the manufacturing of both the large grade Kaplan and Francis hydraulic turbine blades. It has been shown that the higher efficiency and the better surfaces finish accuracy can be achieved in practical engineering.