Construction Method of Complex Product Repair Model for Process Execution End

The performance of complex products is directly related to their assembly quality, and as a result, the precision requirements for assembling complex products are becoming increasingly stringent. However, in the assembly process, precision deviations are inevitable, often leading to situations where the required accuracy cannot be met. In such cases, rework and adjustment methods are needed to modify certain geometric attributes of the product model to ensure assembly precision. Currently, most rework solutions rely on the personal experience of on-site workers and repeated disassembly and reassembly, lacking scientific guidance. Aiming to improve the accuracy of rework solutions, this paper proposes a rework model construction method tailored for the process execution phase. First, an error propagation function is established based on the Small Displacement Torsor (SDT) and homogeneous transformation matrices. High-precision measurement equipment is then used on-site to collect point cloud data of key features, which is processed to reconstruct the error model of critical features, thereby enabling a more accurate error propagation model. Subsequently, an optimization-based dynamic adjustment mechanism and an interval resampling mechanism are introduced to improve the particle swarm optimization (PSO) algorithm. Using the improved PSO algorithm, more accurate rework plans are generated to guide on-site rework operations. Finally, a case study is conducted using the rework process of a satellite product subassembly structure to validate the proposed method. The results demonstrate that the proposed approach can generate more reasonable and effective rework solutions, not only improving on-site rework efficiency but also increasing the first-time assembly success rate of complex products.