Research on combined tightening system for blind cavity of aero-engine rotors
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摘要:
传统的航空发动机转子盲腔螺栓拧紧机构采用一次展开的结构形式，并且能够承载的拧紧力矩较小，在可达性和结构强度方面无法适用于新一代转子盲腔螺栓的拧紧工况。为解决此问题，分析了盲腔螺栓拧紧的技术需求，在此基础上提出了大小力矩组合式拧紧的设计方案：通过齿轮传动形式的拧紧机构进行小力矩的螺栓拧靠与预加载，采用整体摆动形式的拧紧机构实现目标力矩的最终加载。基于多目标优化方法完成了大小力矩拧紧机构的设计，并通过运动学仿真进行了拧紧机构的运动轨迹规划。研究了基于全局定位的运动精度控制方法和基于预先校验的力矩精度控制方法，实现了机构-转子的几何位姿精准匹配与拧紧力矩的精准输出，并集成于转子盲腔自动化拧紧系统。该系统可实现目标拧紧力矩为48 N·m的螺栓拧紧操作，拧紧力矩精度为±2%，可以在70 min内完成所有螺栓拧紧工作。在转子盲腔模拟件上开展了试验验证，证明了上述指标的有效性，并基于拧紧系统研究了两步拧紧的工艺优化方法，有效提升了转子盲腔螺栓预紧力的一致性。
Abstract:The traditional rotor blind cavity bolt tightening mechanism adopts a one-time unfolding structural form, and the tightening torque is small, which cannot be applied to the tightening conditions of the new generation of aero-engine rotors in terms of accessibility and structural strength. To solve this problem, the technical requirements for tightening blind cavity bolts were first analyzed. Based on this, a design scheme for combined tightening of large and small torques was proposed: a tightening mechanism in the form of gear transmission was used to tighten and preload bolts with small torque, and a tightening mechanism in the form of an integral swing was used to achieve the final loading of the target torque. The design of the torque tightening mechanism was completed based on multi-objective optimization methods, and the motion trajectory planning of the tightening mechanism was carried out through kinematic simulation. The torque accuracy control method based on calibration method and the motion accuracy control method based on global positioning were both studied, achieving precise output of tightening torque and precise matching of geometric pose of the mechanism rotor, which were integrated into the blind cavity bolt automatic tightening system. This system can achieve a target tightening torque of 48 N·m for bolt tightening operations, with a tightening torque accuracy of ±2%, and it can also complete all bolt tightening work within 70 minutes. Based on this system, a two-step tightening process method was proposed and validated on the new generation of aero-engine, solving the problem of poor consistency in bolt preload and improving bolt tightening efficiency.
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图 4 齿轮传动拧紧机构迭代设计过程
Figure 4. Iterative design process of gear transmission tightening mechanism
图 6 小力矩拧紧机构模型示意图
Figure 6. Schematic diagram of small torque tightening mechanism model
图 7 小力矩拧紧机构有限元仿真模型
Figure 7. Finite element simulation model of small torque tightening mechanism
图 8 小力矩拧紧机构有限元仿真分析
Figure 8. Finite element simulation analysis of small torque tightening mechanism
图 10 连杆结构运动行程极限位置示意图
Figure 10. Schematic diagram of the limit position of the motion stroke of the connecting rod structure
图 11 连杆结构参数优化设计迭代过程
Figure 11. Iterative process of optimization design for connecting rod structure parameters
图 12 连杆结构参数目标函数值的变化率曲线
Figure 12. Objective function change rate of connecting rod parameters
图 13 大力矩拧紧机构模型示意图
Figure 13. Schematic diagram of high torque tightening mechanism model
图 14 大力矩拧紧机构有限元仿真分析
Figure 14. Finite element simulation analysis of high torque tightening mechanism
图 16 拧紧机构末端可达域仿真结果
Figure 16. Simulation results of reachable domain at the end of the tightening mechanism
图 17 拧紧机构末端轨迹规划仿真结果
Figure 17. Simulation results of end trajectory planning for tightening mechanism
图 18 闭环全局定位系统控制原理图
Figure 18. Control schematic diagram of closed-loop global positioning system
图 23 高压转子盲腔自动化拧紧系统示意图
Figure 23. Schematic diagram of high-pressure rotor blind cavity automatic tightening system
表 1 航空发动机盲腔螺栓拧紧特点变化
Table 1. Changes in tightening characteristics of blind cavity bolts in aeroengines
发动机型号 螺栓数量 螺栓规格 拧紧力矩/（N·m） 盘径比 螺栓分布圆直径/mm 转子最小内腔直径/mm 上一代 60 MJ6 15 1.4 290 200 新一代 24 MJ10 48 3.1 400 130 
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表 2 齿轮传动机构各设计变量含义
Table 2. Meaning of various design variables in gear transmission mechanism
变量 含义 取值范围 ${x_1}$ 齿轮的个数n n≥2 ${x_2}$ 传动齿轮的齿数z z≥17 ${x_3}$ 齿轮分布圆半径$ {r_3} $ ${r_2} \gt {r_3} \gt 0$ mm ${x_4}$ 从第i个齿轮开始展开 i≥2
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表 3 齿轮传动机构权重判断矩阵
Table 3. Weight judgment matrix of gear transmission mechanism
判断因素 拧紧精度 结构强度 拧紧效率 拧紧精度 1 2 9 结构强度 1/2 1 2 拧紧效率 1/9 1/2 1
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表 4 齿轮参数计算结果
Table 4. Calculation results of gear parameters
变量名称 计算结果 x1 7.6479 x2 23.1909 x3/mm 48.5057 x4 3.9471
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表 5 连杆尺寸计算结果
Table 5. Calculation results of connecting rod dimensions
mm 变量名称 计算结果 ${x_1}$ 51.0894 ${x_2}$ 43.7707 ${x_3}$ 92.1400 ${x_4}$ 26.3487
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表 6 拧紧机构的DH参数表
Table 6. DH parameter table for tightening mechanism
坐标变换 杆i−1 杆i ${\theta _i}$ ${d_i}$ ${\alpha _{i - 1}}$ ${\alpha _i}$ 基座→杆1 0 1 0 ${d_1}$ 0 π 杆1→杆2 1 2 ${\theta _2}$ 0 ${L_1}$ 0 杆2→杆3 2 3 ${\theta _3}$ ${L_{21}}$ ${L_{22}}$ 0 杆3→末端 3 4 π/2 0 ${L_3}$ π/2
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表 7 螺栓拧紧试验分组
Table 7. Grouping of bolt tightening test
组号 工艺参数 1 一步拧紧（步长为48 N·m） 2 两步拧紧（第1步步长为5 N·m） 3 两步拧紧（第1步步长为10 N·m） 4 两步拧紧（第1步步长为15 N·m） 5 两步拧紧（第1步步长为20 N·m） 6 两步拧紧（第1步步长为25 N·m）
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