A Digital Twin System for Adaptive Aligning of Large Cylindrical Components

Most large aerospace cylindrical components still adopt a manual aligning method with low automation, large manual intervention, and heavy dependence on operator workers, resulting in the low quality and efficiency of large component aligning, which seriously prolongs the manufacturing time of aerospace products. To cope with this issue, based on closed-loop adaptive control and digital twin (DT) technologies, an adaptive aligning system for large cylindrical components, i.e., the DT aligning system, is proposed in this study. For the DT aligning system, through the DT multi-dimensional modeling, i.e., geometric modeling, physical modeling, functional modeling, and data modeling, it can be divided into a physical space, a virtue space, and twin data. Note that the association, mapping, and interaction between physical space and virtual space of the aligning system can be realized via the twin data, thereby realizing real-time virtual display, monitoring, and control of the large component aligning. In addition, based on the measured pose data, aligning stress, and predicted aligning error, an adaptive force/position control method for large component aligning is proposed, and it can achieve real-time decision-making and precise execution of the aligning process. Finally, through application validation, the DT process system can realize the real-time status perception and process execution decision during the large component aligning. Finally, through experimental validation, it is found that the proposed system, i.e., the DT aligning system, can improve the quality and efficiency of the large aerospace cylindrical component aligning, as well as the automation and intelligent level of the aligning system.