高精度陀螺仪装配应力形成机理与控制方法研究

One universal problem in gyro manufacturing is that the accuracy and performance of gyro cannot satisfy the design requirements after assembly, and poor consistency of assembly quality, although each part is machined perfectly. The main reasons for this is that the assembly stresses formed in the assembly process of subassembly structure will evolutes in working state, which results in structure deformation. And then the accuracy parameters of the gyro will change with deformation. Assembly stress in subassembly structure is affected by machining error and surface quality of parts, structure performance, and parameters of assembly process, but quantitative test and analysis of these effect factors is deficient in assembly process, formation mechanism and variation regularities of assembly stress is not clear. Therefore, considering the above-mentioned problem, the theory of the assemblage stress and the study of how to control it is the primary factor to the solution. In this project, analysis has been taken based on the high precision gyro, with regard to the formation mechanism of assembly stress, which aims to establish the model about the stress evolution and transfer. Based on the mentioned study, the monitoring method with measurable technical parameters can be carried out, which achieves the qualitative assemblage for exactitude configuration instead of quantificational analysis. By means of the theoretic analysis and product manufacturing process, this project contributes to improve the reliability of high accuracy gyro manufacturing process.

陀螺仪制造中的一个普遍问题是各零部件加工质量合格的情况下，装配后仪表精度和性能达不到设计要求，装配质量一致性差。主要原因是组件结构在装配过程中将形成装配应力，并且在工作状态下的应力分布状态将发生演变，从而影响组件结构稳定性，导致仪表精度参数发生变化。组件装配应力受到零部件加工误差、表面质量、结构特性以及装配工艺参数等因素的影响，然而目前的装配工艺对这些影响因素尚缺乏定量的测试和分析，装配应力的形成机理和影响规律从理论上尚不清楚，装配工艺具有很大的盲目性。因此，研究装配应力形成机理及其控制方法是解决上述问题的关键。本项目以高精度陀螺仪为典型研究对象，重点研究陀螺仪装配应力形成与演变机理，并建立陀螺仪关键组件应力演变与传递模型，提出装配工艺参数定量监控方法，实现精密结构装配从定性到定量的跨越，为提升高精度陀螺仪制造工艺水平提供理论分析依据和工艺方法。

本项目针对高精度陀螺仪制造过程中的装配精度差、装配质量一致性差和装配后性能的不稳定等关键问题，开展了陀螺仪浮子组件装配过程中由于零部件加工误差、结构特性以及装配工艺参数等因素的影响下，装配接触应力场的形成机理研究、装配应力时变特性分析以及装配工艺参数控制方法研究。建立了带有几何误差的装配应力场形成机理仿真模型，对带有几何误差的框架-马达轴-压块螺钉预紧结构进行了有限元分析，考虑了接触半圆孔的制造特性和装配参数，获得了装配应力场的分布与浮子质心稳定性的变化规律；提出了基于结构蠕变的装配应力场时变特性仿真分析方法，针对典型的胶接结构与浮子组件中浮筒-框架胶接结构和配重环-框架胶接结构进行了结构蠕变特性分析，获得了胶接参数对装配应力场演变以及浮子质心稳定性的变化规律；使用X射线衍射仪对装配应力场的分布进行了验证，获得实际装配中装配应力的分布与变化情况，验证了所提出的装配应力形成与时变特性仿真模型的准确性与有效性；最后探索了装配力与选配对装配应力的影响规律，提出了扭矩控制法与混合接触选配的方法对螺钉连接与胶接参数的控制，实现了陀螺仪螺钉装配和胶接装配从定性到定量、从经验到理论的跨越，为最终提升高精度陀螺仪制造工艺水平提供理论分析依据和工艺方法。