Evaluation of residual clearance after pre-joining and pre-joining scheme optimization in aircraft panel assembly

Purpose For the automatic drilling and riveting in panel assembly, gaps between the skin and strangers are inevitable and undesirable. At present, the determination of pre-joining schemes relies on workers’ experience, introducing excessive number and inappropriate locations of pre-joining. This paper aims to present a new method for the evaluation of residual clearances after pre-joining and the pre-joining scheme optimization, providing operation guidance for the workers in panel assembly workshop. Design/methodology/approach In this paper, an equivalent gap assembly model for pre-joining is proposed on the basis of the mechanism of variation. This model retains the essential elastic behavior of the key features during the pre-joining operation and calculates the residual clearances in the view of the potential energy. Subsequently, this method is embedded into a Pareto optimality-based genetic algorithm, and the optimal pre-joining schemes are achieved with the consideration of the total residual clearances and the permissive tolerances. Findings The equivalent gap assembly model has the capability to predict an acceptable degree of accuracy of the residual clearances and achieve the optimized pre-joining schemes with less number of pre-joining at the same level of residual clearances. Practical implications The optimized pre-joining schemes are given in the form of Pareto optimality set, and workers can select suitable results according to their inclination to the quality and efficiency. Originality/value The paper is the first to propose the equivalent gap assembly model for the pre-joining operation, which provides for the simplification of the calculation of residual clearances based on the constrained variation principles.

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