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Concentricity control for multistage rotor assembly based on contour vectorization

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Abstract

Rotor assembly is a core tache in the whole process of aero-engine manufacturing. It is critical to ensure the excellent concentric performance of the overall assembly to satisfy the requirements of vibration-free and noise-free. However, assembly deviation is unavoidable due to the parts’ geometrical error, and it is difficult to meet the target requirement by manual adjustments in practical production. Three-dimensional deviation modeling is a feasible means to analyze assembly precision and optimize assembly process. Existing methods can construct the position and pose of geometric deviations in space but unable to handle the problem of surface morphology expression. This will cause a great loss of physical constraints and deviation information to the reliability of the analysis results. This article focuses on two points: one is the deviation expression for morphology error, and the other is the deviation propagation for multistage rotational optimization. Firstly, vectorization method of non-line contour was introduced to characterize the morphology feature of mounting edge, the core idea of which was that multiple vectors were used to approximate the contour curve; secondly, the similarity of each group of corresponding vectors in source features and target features was calculated and evaluated, to realize morphology evaluation and matching; next, combining the multistage revolving characteristics of rotors, the deviation propagation model was established for optimum mounting angle searching. Finally, this contour vectorization-based assembly technique was demonstrated by an example application of four-stage rotors assembly. Experimental results show that compared with traditional deviation modeling method, the overall concentric performance has improved 26.6% by using the suggested method, and the optimal installation angles (2π/3 rad, πrad, and π/3 rad) can be easily solved. It proves that contour vectorization-based assembly technique is feasible and of high practicability. It can be integrated with computer systems to propose assistance for operators in assembling stage.

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Funding

This work was financially supported by grants from the National Natural Science Foundation of China under Grant Number 52105509, the Fundamental Research Funds for the Central Universities under Grant Number 2232023D-25, and the Beijing Postdoctoral Research Foundation. The authors are grateful for these financial supports.

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Authors and Affiliations

  1. Institute of Artificial Intelligence, Donghua University, Shanghai, 201600, China

    Siyi Ding & Jie Zhang

  2. Beijing Chonglee Machinery Engineering CO., LTD, Beijing, 101111, China

    Siyi Ding & Xinhua Mao

  3. College of Information Science and Technology, Donghua University, Shanghai, 201600, China

    Sen Wang & Huihui Tong

  4. College of Mechanical Engineering, Donghua University, 2999 North Renmin Road, Shanghai, 201600, China

    Jianguo Zhang

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  1. Siyi Ding
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  2. Sen Wang
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Correspondence to Jianguo Zhang.

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Ding, S., Wang, S., Tong, H. et al. Concentricity control for multistage rotor assembly based on contour vectorization. Int J Adv Manuf Technol 132, 147–166 (2024). https://doi.org/10.1007/s00170-024-13310-7

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