Framework and development of data-driven physics based model with application in dimensional accuracy prediction in pocket milling

In the manufacturing of thin wall components for aerospace industry, apart from the side wall contour error, the Remaining Bottom Thickness Error (RBTE) for the thin-wall pocket component (e.g. rocket shell) is of the same importance but overlooked in current research. If the RBTE reduces by 30%, the weight reduction of the entire component will reach up to tens of kilograms while improving the dynamic balance performance of the large component. Current RBTE control requires the off-process measurement of limited discrete points on the component bottom to provide the reference value for compensation. This leads to incompleteness in the remaining bottom thickness control and redundant measurement in manufacturing. In this paper, the framework of data-driven physics based model is proposed and developed for the real-time prediction of critical quality for large components, which enables accurate prediction and compensation of RBTE value for the thin wall components. The physics based model considers the primary root cause, in terms of tool deflection and clamping stiffness induced Axial Material Removal Thickness (AMRT) variation, for the RBTE formation. And to incorporate the dynamic and inherent coupling of the complicated manufacturing system, the multi-feature fusion and machine learning algorithm, i.e. kernel Principal Component Analysis (kPCA) and kernel Support Vector Regression (kSVR), are incorporated with the physics based model. Therefore, the proposed data-driven physics based model combines both process mechanism and the system disturbance to achieve better prediction accuracy. The final verification experiment is implemented to validate the effectiveness of the proposed method for dimensional accuracy prediction in pocket milling, and the prediction accuracy of AMRT achieves 0.014 mm and 0.019 mm for straight and corner milling, respectively.     

Influence of leading edge with real manufacturing error on aerodynamic performance of high subsonic compressor cascades

To investigate the influence of real leading-edge manufacturing error on aerodynamic performance of high subsonic compressor blades, a family of leading-edge manufacturing error data were obtained from measured compressor cascades. Considering the limited samples, the leading-edge angle and leading-edge radius distribution forms were evaluated by Shapiro-Wilk test and quantile–quantile plot. Their statistical characteristics provided can be introduced to later related researches. The parameterization design method B-spline and Bezier are adopted to create geometry models with manufacturing error based on leading-edge angle and leading-edge radius. The influence of real manufacturing error is quantified and analyzed by self-developed non-intrusive polynomial chaos and Sobol’ indices. The mechanism of leading-edge manufacturing error on aerodynamic performance is discussed. The results show that the total pressure loss coefficient is sensitive to the leading-edge manufacturing error compared with the static pressure ratio, especially at high incidence. Specifically, manufacturing error of the leading edge will influence the local flow acceleration and subsequently cause fluctuation of the downstream flow. The aerodynamic performance is sensitive to the manufacturing error of leading-edge radius at the design and negative incidences, while it is sensitive to the manufacturing error of leading-edge angle under the operation conditions with high incidences.     

Geometric error analysis of an over-constrained parallel tracking mechanism using the screw theory

This paper deals with geometric error modeling and sensitivity analysis of an overconstrained parallel tracking mechanism. The main contribution is the consideration of overconstrained features that are usually ignored in previous research. The reciprocal property between a motion and a force is applied to tackle this problem in the framework of the screw theory. First of all, a nominal kinematic model of the parallel tracking mechanism is formulated. On this basis, the actual twist of the moving platform is computed through the superposition of the joint twist and geometric errors. The actuation and constrained wrenches of each limb are applied to exclude the joint displacement. After eliminating repeated errors brought by the multiplication of wrenches, a geometric error model of the parallel tracking mechanism is built. Furthermore,two sensitivity indices are defined to select essential geometric errors for future kinematic calibration. Finally, the geometric error model with minimum geometric errors is verified by simulation with SolidWorks software. Two typical poses of the parallel tracking mechanism are selected, and the differences between simulation and calculation results are very small. The results confirm the correctness and accuracy of the geometric error modeling method for over-constrained parallel mechanisms.     

存储系统中两级纠错编码方案设计与验证

针对恶劣空间环境设计了一种两级存储编码方案，以应对航天系统中存储单元发生多个单粒子翻转（SEU）错误的问题。方案设计的主要思想是根据简单低纠错编码组合出高容错编码，通过编码组合，使用字间编码来纠正字内编码无法纠正的错误，从而使存储系统更加可靠；对两级编码方案提出若干优化策略，以提高编解码性能，使得两级冗余编码效率接近于原始字内编码。实验结果表明，提出的两级冗余编码方案能够较好解决存储系统中发生多个单粒子翻转错误的问题。即与单一的字内编码相比，两级纠错编码方案能够大大降低星上存储系统出现不可修复的概率，保证了星上存储系统的可靠运行。     

Experimental and numerical investigation on surface quality for two-point incremental sheet forming with interpolator

The unsatisfied surface quality seriously impedes the wide application of incremental sheet forming (ISF) in industrial field. As a novel approach, the interpolator method is a promising strategy to enhance the surface quality in ISF. However, the mechanism for the improvement of surface quality and the influence of interpolator properties on surface roughness are not well understood. In this paper, the influences of process variables (i.e. tool diameter, step size and thickness of interpolators) on the forming process (e.g. surface roughness, forming force and geometric error) are investigated through a systematic experimental approach of central composite design (CCD) in two-point incremental sheet forming (TPIF). It is obtained that the increase in thickness of interpolators decreases the surface roughness in direction vertical to the tool path while increases the surface roughness in direction horizontal to the tool path. Nevertheless, the combined influence between thickness of interpolators and process parameters (tool diameter and step size) is limited. Meanwhile, the placement of interpolator has little influence on the effective forming force of blank. In addition, the geometric error enlarges with the increase of step size and thickness of interpolator while decreases firstly and then increase with an increase in tool diameter. Finally, the influencing mechanism of the interpolator method on surface quality can be attributed to the decrease of the contact pressure due to the increase of contact area with the unchanged contact force. Meanwhile, the interpolator method eliminates the sliding friction on the surface of blank due to the stable relative position between the blank and the interpolator.     

考虑星历误差的天文测角/时间延迟量测组合导航方法

基于太阳震荡的时间延迟是一种新型天文导航量测量，可以提供探测器相对反射天体的距离信息，与星光角距量测量结合，可以提高导航性能。然而，星光角距量测模型与时间延迟量测模型均含有火卫一相对火星的位置矢量，火卫一的星历误差将影响导航精度。针对这一问题，提出了一种基于在线估计的天文测角/时间延迟量测组合导航方法，建立了包含火卫一位置及速度的状态模型，利用星光角距及时间延迟量测量同时对火卫一的位置和速度进行在线估计，仿真结果表明，提出的方法可以有效抑制火卫一星历误差对组合导航精度的影响，为探测器提供高精度的自主导航信息。     

低轨天基信息定向分发区域分割编码控制方法

为提高低轨指向性信息分发链路的频谱利用效率，从天基分发平台与地面用户的相对位置关系入手，建立了分发指向、编码增益与信道传输容量的量化关系。在此基础上，提出一种低轨天基信息定向分发区域分割编码控制方法，该方法针对不同信息分发区域，采用最小均方误差(MMSE)作为区域分割准则选择编码方式，既提升了信道传输效率也便于工程实现。最后，本文通过仿真分析了方法的效能和性能影响因素，并与现有自适应编码方法进行了对比，验证了本方法的有效性和可靠性。     

An empirical solar radiation pressure model for satellites moving in the orbit-normal mode

We present a family of empirical solar radiation pressure (SRP) models suited for satellites orbiting the Earth in the orbit normal (ON) mode. The proposed ECOM-TB model describes the SRP accelerations in the so-called terminator coordinate system. The choice of the coordinate system and the SRP parametrization is based on theoretical assumptions and on simulation results with a QZS-1-like box-wing model, where the SRP accelerations acting on the solar panels and on the box are assessed separately. The new SRP model takes into account that in ON-mode the incident angle of the solar radiation on the solar panels is not constant like in the yaw-steering (YS) attitude mode. It depends on the elevation angle of the Sun above the satellite’s orbital plane. The resulting SRP vector acts, therefore, not only in the Sun-satellite direction, but has also a component normal to it. Both components are changing as a function of the incident angle. ECOM-TB has been used for precise orbit determination (POD) for QZS-1 and BeiDou2 (BDS2) satellites in medium (MEO) and inclined geosynchronous Earth orbits (IGSO) based on IGS MGEX data from 2014 and 2015. The resulting orbits have been validated with SLR, long-arc orbit fits, orbit misclosures, and by the satellite clock corrections based on the orbits. The validation results confirm that—compared to ECOM2—ECOM-TB significantly (factor 3–4) improves the POD of QZS-1 in ON-mode for orbits with different arc lengths (one, three, and five days). Moderate orbit improvements are achieved for BDS2 MEO satellites—especially if ECOM-TB is supported by pseudo-stochastic pulses (the model is then called ECOM-TBP). For BDS2 IGSOs, ECOM-TB with its 9 SRP parameters appears to be over-parameterized. For use with BDS2 IGSO spacecraft we therefore developed a minimized model version called ECOM-TBMP, which is based on the same axis decomposition as ECOM-TB, but has only 2 SRP parameters and is supported by pseudo-stochastic parameters, as well. This model shows a similar performance as ECOM-TB with short arcs, but an improved performance with (3-day) long-arcs. The new SRP models have been activated in CODE’s IGS MGEX solution in Summer 2018. Like the other ECOM models the ECOM-TB derivatives might be used together with an a priori model.     

北斗空间信号误差统计特征及描述方法研究

通过对比北斗卫星导航系统(BeiDou Navigation Satellite System,BDS)广播星历与事后精密星历,提取了轨道和卫星时钟误差。基于北斗轨道误差及北斗卫星时钟误差统计特征分析,构建区别于全球定位系统(Global Positioning System,GPS)的BDS空间信号用户测距误差(Signal-In-Space User Range Error,SISRE)描述方法,对BDS广播星历中用户测距精度(User Range Accuracy,URA)进行了验证。6个月的北斗数据测试结果表明,北斗GEO、IGSO和MEO卫星的URA分别为3.0m、1.9m和1.6m。     

非接触转子振动位移采集系统测试误差

对基于叶尖定时测量原理开发的非接触转子振动位移采集系统(NRDMS)测试误差进行了研究分析。将模拟叶片振动标准信号作为采集系统测试的输入信号,研究了测试对象参数和采集系统时基信号对测试结果误差的影响,理论和测试结果分析表明:测试误差主要受采集系统时基信号和转速的影响,采集系统的最大引用误差为0.066%。