A Displacement Field Perception Method for Component Digital Twin in Aircraft Assembly

Abstract

Full-field displacement perception and digital twins for core components play a crucial role in the precision manufacturing industry, such as aviation manufacturing. This paper presents a real-time full-field displacement perception method for the combination of online multipoint displacement monitoring and matrix completion theory. Firstly, a conceptual full-field displacement perception model based on the observed information of the multi-points is established. To obtain the full-field displacements of a core component, the component is divided into plentiful discrete points, including observed and unobserved points, based on which the relationship between the observed points and the full-field displacements is established. Then, the solution method of the full-field displacement perception model is proposed. Based on the matrix completion principle and the big data of the simulation, the optimization problem is employed to work out the model and, meanwhile, the pseudo-code is put forward. Finally, the full-field displacement perception experiments are performed. Repeated experiments show that the max error of the displacements calculated by the proposed method can be less than 0.094 mm and the median error can be less than 0.054 mm, while the average time frame can be less than 0.48 s, which is promising considering the high precision and efficiency requirements of the assembly of large aircraft.

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“…As highly accurate measurements become increasingly affordable, measurement technology has become a bridge connecting the real world and the digital world. Liang et al [42] presented a realtime full-field displacement perception method for a component digital twin in aircraft assembly by the combination of online multi-point displacement monitoring and matrix completion theory. MAA generates new chances for the automation of fitting processes and the active closed-loop control of onsite assembly processes.…”

Towards Safe and Efficient Unmanned Aircraft System Operations: Literature Review of Digital Twins’ Applications and European Union Regulatory Compliance

“…Strelets et al [57] created a DT in a uniform information environment of the product life cycle, which, as the virtual copy of a product, is convenient to use at all stages of the life cycle. Liang et al [58] presented a real-time displacement detection DT in aircraft assembly. Zhang et al [59] proposed an effective simulation and optimization containing heuristic algorithms and applied them to a DT-based aircraft part production workshop.…”

“…In parallel with the establishment of regulatory frameworks, the potential of [5,[8][9][10][11]] DT utilization in the aviation industry has been explored and documented in numerous pieces of the scientific literature [44][45][46][47][48][49]. DTs can be used in any stage of the aircraft life cycle [50][51][52][53][54][55][56][57][58][59][60], such as design, manufacturing, operations, and maintenance. DTs can also be implemented on components as well as systems [61][62][63][64][65][66][67][68][69][70] that provide a comprehensive view of an aircraft and its individual parts.…”

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“…Meanwhile, new sensor types are emerging and already prove their value in specific tasks, such as RFID [58], [66], intelligent sensors (e.g. light sensor monitoring label, current monitoring label and industrial sensor), laser sensor [80] and camera based visual sensor [137], [138]. However, different from manufacturing and ground maintenance, on-flight aircraft has stricter requirement on sensor selection.…”