Measurements error propagation and its sensitivity analysis in the aero-engine multistage rotor assembling process

Abstract

The purpose of this paper is to research the measurements error propagation principle about the measurement-assembly equipment of aero engine multistage rotor, besides analyze the effect of guide linear motion and turntable rotational motion on the final alignment error. Furthermore, we can improve the measurement and assembly accuracy of the aero engine multistage rotor. In this paper, a novel error analysis method related to measurement-assembly equipment was proposed. First, the topology of the measuring equipment was established based on the multibody system theory, the error propagation path was constructed by using the low order body sorting method. Second, the error transfer model of the linear motion and the rotational motion were established by using the homogeneous coordinate transformation matrix, and the total measurement terminal errors introduced by the equipment were calculated. Finally, through numerical simulation, the magnitude of the measurement terminal offset error was obtained, sensitivity analysis was performed to calculate key error sources. Measurement accuracy not only depended on the accuracy of the sensor but also closely related to the accuracy of the measurement-assembly equipment. Through the simulation verification, when the linearity error is 0.1 μm and the angular error is 0.1″, the final cumulative offset displacement error is about −0.1002 μm to −0.0998 μm with a probability of 97%. Different type errors have different effects on the results. We can give a conclusion that linear guide alignment error and verticality error are the primary error sources, and the angle error of the turntable need to be improved.

Measuring Point Planning and Fitting Optimization of the Flange and Spigot Structures of Aeroengine Rotors

“…Automated systems have gradually been applied in the measurement of aeroengine rotors [11][12][13][14][15]. Among these, the multi-axis precision mechanical contact measurement system and laser measurement system have the advantages of high reliability and automation [16][17][18]. A large number of point cloud coordinates are generated after measurement.…”

Decoupling method for four-degree-of-freedom automatic centering and tilting worktable

“…Aero-engine assembly is the last part of the aero-engine manufacturing process, and its assembly quality will directly affect the performance, reliability, and life of the aero-engine [1][2][3][4][5], and the poor assembly may lead to serious vibration or even collision when the rotor rotates at high speed, which is related to the stable operation and safety of the aviation system [6][7][8][9]. The multi-stage rotors in aero-engines are cylindrical components of the rotary symmetry class, and there is a problem of gradual accumulation of machining errors of rotors at all levels during the assembly process [10][11][12], so the precision measurement of single-stage rotor circular contours is a prerequisite and basis for ensuring the rationality of the assembly process.…”

An Assembly Method for the Multistage Rotor of An Aero-Engine Based on the Dual Objective Synchronous Optimization for the Coaxality and Unbalance

“…Assembly is the ultimate technical link during the manufacturing process of an aeroengine. Especially for the multistage stacking rotors typically represented by the highpressure compressor of an aero-engine, their assembly quality may have a direct effect on the stability of an aero-engine in high-speed operation [1][2][3]. Excessive misalignment and unbalance of a multistage rotor caused by improper assembly may give rise to complicated vibration and noise during rotating [4][5][6].…”