| Complex mechatronic products are a kind of products that involve multi-disciplinary,multi-field and multi-factor and possess complex functions.As energy and signal transmission medium,cable harness is widely used in various kinds of complex mechatronic products in aviation,aerospace and shipbuilding,it is the "link" between the electronic device and the extension module.The complexity of the cable harness topological structure,the constraints of the product structure space,the flexible properties of cable harness,and the wiring quality guarantee mainly rely on the past experience,all these exist factors make the cable harness wiring becomes a technical problem.In this dissertation,some key technologies of cable harness wiring for complex mechatronic products are studied.It mainly includes the cable harness path planning technology,collision interference detection technology,physical characteristics modeling and simulation technology,and wiring quality assessment technology.Based on the above studies,a cable harness wiring system for complex mechatronic products is developed.The main contents and research achievements are as follows:(1)Path planning technology of three dimensional space for cable harness wiring is studied.For the cable harness wiring difficult problem of complex mechatronic products,a three dimensional space-wiring technology for cable harness based on multi-scale chaotic mutation particle swarm optimization algorithm is proposed in this paper.Firstly,the influence of cable harness wiring sequence on connecting result is analyzed,and the algorithm solve space is defined by abstract modeling of three dimensional wiring space environment.To realize the local solution escape of path optimization,the idea of chaotic mutation is introduced in the particle swarm optimization algorithm.To solve the problem of single mutation scale does not guarantee to obtain the optimal solution,and improve the overall and precise local optimization algorithm performance,the competitive mechanism among different mutation scales is used to make the whole population to search the solution space distributed.Finally,four kinds of standard Benchmark testing functions are chosen to test the proposed algorithm,and the proposed algorithm is successfully applied in the process of cable harness wiring for a certain phased array radar.(2)Collision detection technology of cable harness wiring for complex mechatronic products is studied.For the problem of collision detection difficulty caused by the cable harness with flexible and deformable characteristics,a collision detection method of cable harness based on distance fields and sweep-and-prune(Sa P)algorithm is proposed.The collision detection method based on distance fields is mainly used for detect the collisions among cable harnesses as well as cable harnesses and structural parts.In this phase,the spherical harmonics expression of cable harness with level of detail(LOD)is finished firstly based on the establishment of contour bounding sphere for cable harness;then,to acquire the collision feedback information from the surface normal vector and puncture depth of cable harness or structural parts,a distance fields mapping with three dimensions(3D)is generated.The collision detection method based on Sa P algorithm is mainly used for detect the cable harness self-collision.In this phase,a mathematical model of cable harness segments is constructed firstly;and then the discrete points Sa P algorithm is used to complete the cable harness self-collision.Finally,the algorithm presented is validated,and the results show that the algorithm has better accuracy and quickness to meet the requirements of engineering practice.(3)Physical characteristics modeling and deformation simulation technology of flexible cable harness for complex mechatronic products are studied.The spatial pose and shape of flexible cable harness are easy to change during the wiring in complex mechatronic products,thus lead to the sampling information of cable harness is inaccuracy in the process of wiring,and seriously affect the efficiency of wiring.This paper proposes a physical characteristics modeling and deformation simulation method for flexible cable harness based on exact Cosserat model.First,for the large deformation characteristics of cable harness,we build an activity frame and a parameterized model of cable harness,and analyze the spatial evolutionary process.Secondly,we describe the spatial pose and shape of cable harness,and establish a physical characteristics model of cable harness based on exact Cosserat model by comprehensive consideration the cable harness geometry and physical properties,and then construct the dynamic equilibrium equations of flexible cable harness.Finally,to simulate the deformation process in the process of wiring,we solve the physical characteristics model by using the numerical integration solution method.(4)Quality assessment technology of cable harness wiring for complex mechatronic products is studied.For the current cable harness wiring mainly rely on the assembly workers' experience and makes it difficult to get guaranteed quality problem,a variable precision rough set(VPRS)decision-making method based on attribute weighted similarity measurement for cable harness wiring quality assessment is proposed in this paper.Firstly,the influencing factors and composition of cable harness wiring quality are analyzed,and a quality assessment model for cable harness wiring is established by overall considering multiple attributes of assesses objects.Secondly,the cable harness wiring quality assessment rules are formulated combined with the theory of VPRS on the basis of quality assessment model.Finally,similarity degrees between the current cable harness wiring status and all objects from the decision-making system are compared based on attribute weighted similarity,which could obtain the decision results of wiring quality,and complete the quality assessment.Example results show that the method presented in this paper can provides more realistic decision-making results compared to the traditional quality assessment method.(5)A cable harness wiring system for complex mechatronic products based on the above studies is developed,and it has been implemented and validated in the cabinet wiring of a certain type phased array radar. |
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