Measurements error propagation and its sensitivity analysis in the aero-engine multistage rotor assembling process.

Area of Science:

• Mechanical Engineering
• Aerospace Engineering
• Metrology

Background:

• Accurate measurement and assembly are critical for aero engine multistage rotors.
• Existing methods may not fully capture error propagation in complex measurement equipment.
• Understanding error sources is vital for enhancing assembly precision.

Purpose of the Study:

• To research the principle of measurement error propagation in aero engine multistage rotor measurement-assembly equipment.
• To analyze the influence of linear and rotational motion on final alignment errors.
• To improve the measurement and assembly accuracy of aero engine multistage rotors.

Main Methods:

• Established measurement equipment topology using multibody system theory.
• Constructed error propagation paths via low-order body sorting.
• Developed error transfer models for linear and rotational motion using homogeneous coordinate transformation matrices.
• Calculated total measurement terminal errors and performed numerical simulations.
• Conducted sensitivity analysis to identify key error sources.

Main Results:

• Quantified measurement terminal offset errors through numerical simulation.
• Demonstrated that linearity and angular errors significantly impact cumulative offset displacement.
• Identified linear guide alignment error and verticality error as primary error sources.
• Simulation showed a 97% probability of a -0.1002 μm to -0.0998 μm cumulative offset displacement error with 0.1 μm linearity and 0.1″ angular errors.

Conclusions:

• Measurement accuracy is dependent on both sensor accuracy and measurement-assembly equipment precision.
• Linear guide alignment and verticality errors are the most significant contributors to final alignment errors.
• Improvements in the angular accuracy of the turntable are necessary to enhance overall measurement and assembly accuracy.