FEA model based cautious automatic optimal shape control for fuselage assembly

In a half fuselage assembly process, shape control is vital for achieving ultra-high precision assembly. To achieve better shape adjustment, we need to determine the optimal location and force of each actuator to push and pull a fuselage to compensate for its initial shape distortion. The current practice achieves this goal by solving a surrogate model based optimization problem. However, there are two limitations of this surrogate model based method: (1) Low efficiency: Collecting training data for surrogate modeling from many FEA replications is time-consuming. (2) Non-optimality: The required number of FEA replications for building an accurate surrogate model will increase as the potential number of actuator locations increases. Therefore, the surrogate model can only be built on a limited number of prespecified potential actuator locations, which will lead to sub-optimal control results. To address these issues, this paper proposes an FEA model based automatic optimal shape control (AOSC) framework. This method directly loads the system equation from the FEA simulation platform to determine the optimal location and force of each actuator. Moreover, the proposed method further integrates the cautious control concept into the AOSC system to address model uncertainties in practice. The case study with industrial settings shows that the proposed Cautious AOSC method achieves higher control accuracy compared to the current industrial practice.

Selection of Existing Sail Designs for Multi-Fidelity Surrogate Models

Velocity Prediction Programs (VPPs) are commonly used to help predict and compare the performance of different sail designs. A VPP requires an aerodynamic input force matrix which can be computationally expensive to calculate, limiting its application in industrial sail design projects. The use of multi-fidelity kriging surrogate models has previously been presented by the authors to reduce this cost, with high-fidelity data for a new sail being modelled and the low-fidelity data provided by data from existing, but different, sail designs. The difference in fidelity is not due to the simulation method used to obtain the data, but instead how similar the sail’s geometry is to the new sail design. An important consideration for the construction of these models is the choice of low-fidelity data points, which provide information about the trend of the model curve between the high-fidelity data. A method is required to select the best existing sail design to use for the low-fidelity data when constructing a multi-fidelity model. The suitability of an existing sail design as a low fidelity model could be evaluated based on the similarity of its geometric parameters with the new sail. It is shown here that for upwind jib sails, the similarity of the broadseam between the two sails best indicates the ability of a design to be used as low-fidelity data for a lift coefficient surrogate model. The lift coefficient surrogate model error predicted by the regression is shown to be close to 1% of the lift coefficient surrogate error for most points. Larger discrepancies are observed for a drag coefficient surrogate error regression.