Design And Simulation Of An Automated Drill And Rivet System Based On Emr For Big Shells

With the development of China's large aircraft project and spaceflight project, the connection quality of aircraft and rocket body becomes increasingly demanding. Due to its unique advantages, electromagnetic riveting technology is widely used in the aircraft and rocket body. However, there are some shortcomings about manual EMR, such as instability of forming quality and poor reproducibility. Automated drill and rivet technology not only can improve the processing efficiency, but also can improve processing quality. Therefore, the development of automated drill and rivet technology becomes more and more essential and necessary.In this thesis, the program of an automated drill and rivet system based on EMR was designed aiming at a large shell, which can complete drilling and riveting anywhere in the workpiece. The shell is one quarter of a cylinder part, with the diameter 3350mm and the length 4000mm. CATIA and its motion simulation module were used to model and complete the motion simulation of the whole system, checking the dynamic and static interference and optimizing the program; ABAQUS software was used to analyze the stiffness and strength of the main bearing parts of the system; finally, the control system of the machine was designed ,which can guarantee its function and achieve flexible processing of cylindrical parts.In the aspect of modeling and motion simulation, four programs of an automated drill and rivet system based on EMR were modeled and simulated respectively. By comparison of simulations and optimization, the basic framework of the system was determined; then two programs of movement and conversion between electromagnetic riveter and drill bit were modeled and simulated respectively, then the structure of parts of the system was designed. The entire system was modeled and simulated to check the dynamic and static interference and observe the process of drilling and riveting at different required locations by machine.In terms of stiffness and strength analysis, the ABAQUS was used to analyze stiffness and strength of the main bearing parts of the system. The effect of the rotation of riveted piece on the stiffness and strength of rotating cylinder and column was also taken into account, and the stiffness and strength of the gear shaft, drilling and riveting rack, bracket, rotating cylinder, column and riveted piece was checked. As to control program, economic CNC system containing PLC was adopted. The control scheme of the system was designed, which is based on the SINUMERIK 802C base line and CS1W-MC421/MC221 motion control unit. Therefore, G code is avoided. As long as the location information of riveted piece is input from the operation board, they can be drilled and riveted as the designed order and quantitative feed by motion control units, which drive servo motors through decoding and interpolation.