A rapid reconstruction method of simulation model based on point cloud and design model

doi:10.3785/j.issn.1008-973X.2021.05.011

Journal of ZheJiang University (Engineering Science)

2021, Vol. 55

Issue (5): 905-916 DOI: 10.3785/j.issn.1008-973X.2021.05.011

A rapid reconstruction method of simulation model based on point cloud and design model

Jun CAI1(

),Gang ZHAO1,2,Yong YU1,3,*(

),Qiang-wei BAO1,Sheng DAI1

1. School of Mechanics and Automation, Beihang University, Beijing 100191, China
2. Key Laboratory of Aeronautics Smart Manufacturing, Beihang University, Beijing 100191, China
3. Beijing Engineering Technological Research Center of High-Efficient and Green CNC Machining Process, Beijing 100191, China

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Abstract

The high fidelity of CAD model in simulation test has been unsatisfied with the continuous improvement of product assembly quality requirements. A rapid reconstruction method of simulation model based on point cloud and design model was proposed in order to express the actual machining quality of parts quickly and accurately in the simulation experiment. The method of "one-plane and two-hole registration" was adopted to register the measured point cloud data to the design model. The control vertices in the boundary of the design model were extracted for surface reconstruction. Non-uniform rational B-spline (NURBS) method was used to fit the surface. The partial and efficient replacement of the model surface was realized, which combined boundary representation (BREP) and constructive solid geometry (CSG), with the simulation requirements. A rapid reconstruction module based on actual measured point cloud and design model, and a digital preinstalled module based on extensible markup language (XML) and fully features matched, were developed in CATIA. The reconstruction accuracy and efficiency of the proposed method, as well as its high efficiency and accuracy in the simulation of preassembly, were verified by taking a typical part of an aviation enterprise and assembly of aircraft door as examples.

Key words： point cloud refactoring point cloud registration point cloud extraction non-uniform?rational?B-spline?(NURBS) surface replacement

Received: 29 April 2020 Published: 10 June 2021

CLC:

TP 391

Fund: 工信部2017民用飞机专项科研技术资助项目

Corresponding Authors: Yong YU E-mail: 15600260806@163.com;yuyong@buaa.edu.cn

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Cite this article:

Jun CAI,Gang ZHAO,Yong YU,Qiang-wei BAO,Sheng DAI. A rapid reconstruction method of simulation model based on point cloud and design model. Journal of ZheJiang University (Engineering Science), 2021, 55(5): 905-916.

URL:

http://www.zjujournals.com/eng/10.3785/j.issn.1008-973X.2021.05.011 OR http://www.zjujournals.com/eng/Y2021/V55/I5/905

基于点云和设计模型的仿真模型快速重构方法

随着产品装配质量要求的不断提高，为了在CAD模型仿真试验中快速且准确地表达零件实际加工质量，提出基于点云和设计模型的仿真模型快速重构方法. 采用“一面两孔配准”方法，将零件实测点云数据配准到设计模型上；根据设计模型边界提取出曲面重构所需的控制顶点；采用非均匀有理B样条（NURBS）方法对控制顶点进行曲面拟合；根据仿真需求，结合边界表示法（BREP）和构造实体表示法（CSG）实现模型表面的局部和快速替换. 在CATIA中开发基于实测点云数据和设计模型的仿真模型快速重构模块，和基于可拓展标记语言（XML）和特征完全匹配的数字预装配模块. 以某航空企业典型零件和舱门预装配为例，验证该方法的重构精度和效率及其在预装配仿真中的高效性和准确性.

关键词： 点云重构, 点云配准, 点云提取, 非均匀有理 B 样条（NURBS）, 曲面替换

Fig.1 Point cloud registration flow chart based on one plane and two holes

Fig.2 Local coordinates creating on point cloud and model

Fig.3 Transformation of coordinate system of target point

Fig.4 Uniform grid boxes creation on NUV plane

Fig.5 Flow of surface replacement based on BREP/CSG

Fig.6 Flow of simulation for digital preassembly

Tab.1 Extraction of assembly information

Fig.7 XML document recording assembly information

Tab.2 Shape features and matching parameters

Tab.3 Development environment and tools for component

Fig.8 Interface of design model reconstruction based on CAA development

Fig.9 Measured point cloud data of test part

Tab.4 Technical parameters of PTS-HS717 handheld 3D laser scanner

Fig.10 Schematic diagram of ane-plane and two-hole registration

Fig.11 Results of point cloud segmentation

Fig.12 Comparison of point cloud simplification effect

Fig.13 Reconstructed NURBS surface

Fig.14 Substitution of NURBS surface

Fig.15 Traditional flow of model reconstruction

Fig.16 Improved flow of model reconstruction

Tab.5 Time table for different refactoring methods

Fig.17 Deviation analysis of different reconstruction methods

Tab.6 Key parts accuracy requirements for aircraft door assembly

Fig.18 Model of aircraft door assembly

Fig.19 XML document lightweighted

Fig.20 Model comparison diagram before and after reconstruction

Fig.21 XML document after replacement of part

Fig.22 Aircraft door assembly with side wall reconstruction

Fig.23 Interference analysis of aircraft door assembly

Tab.7 Data of aircraft door pre-installation


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