Updating assembly parameters for spacecraft assembly process state changes: based on data fusion method

Thermal protection systems (TPSs) are important components of reusable spacecraft, and their assembly quality has a crucial impact on flight safety. Owing to the complex assembly process and variable states of spacecraft thermal protection systems, assembly parameters may vary under different assembly states. Therefore, to obtain assembly parameters accurately and efficiently under different assembly states, in this study, 3D point cloud data and fiber optic sensor data were fused to develop an assembly parameter update method for assembly process state changes. Firstly, based on the measured data of thermal protection components and load-bearing structure, the gap, flush and matching parameters solution model are proposed. Secondly, to address the deformation problem of the load-bearing structure caused by changes in assembly status, a fusion method based on laser scanning and sensor detection was devised to achieve deformation prediction of the assembly structure during the assembly process. Thirdly, based on the assembly parameter solution model and point cloud prediction model, a constraint-based assembly parameter optimisation model was established, and an improved quantum particle swarm optimisation (LQPSO) algorithm was employed to achieve assembly parameter updates oriented toward changes in assembly status. Finally, an experimental system for array-based thermal protection structure simulation was established to validate the proposed method. The results show that the proposed parameter update method can achieve ideal results for different assembly state simulation components.