大型光电集成的机械结构外文文献翻译.docx
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大型光电集成的机械结构外文文献翻译
附录A
Integrateddesignforlarge-scaleopto-mechanicalstructure
ChrisLucky,JamesLee,BruceKing.
AppliedThermalEngineering,2016,8(6):
556-568.
Abstract:
Anintegrateddesignmethodisdiscussedwhichthoroughlyconsidersrelatedparametersofthevarioussubsystemsinordertooptimizetheoverallsystemthatmainlyconsistsofopto--mechanicalstructureCAD,CAEandtheintegratedinformationplatformPDM.Basedontheparameterdriveofthevirtualmainmodel,themethodfocusesonthemodeltransformationanddatashareamongdifferentdesignandanalysissteps,andsotheconcurrentsimulationanddesignoptimizationarecarriedout.Asanexampleofapplication,theintegrateddesignforalarge-scaleopto-mechanicalstructureisintroduced,includingopticaldesign,structuredesignandanalysis,whichfurthervalidatestheadvantagesofthemethod.DuetocomprehensiveconsiderationofthedesignandanalysisprocessbyCADandCAEbasedonPDM,theintegrateddesignwellattainsthestructureoptimizationwithhighefficiency.
Keywords:
integrateddesign,CAD/CAE,large-scalestructure,opticalinstrument.
1.Introduction
Large-scaleopticalinstruments,suchaslargetelescopesandlasercommunicationterminals,belongtotheoptical-mechanical-electricintegratedsystems,whicharecharacterizedbyalarge-scaleclearapertureandhighprecision[1,2].Developmentofsuchinstrumentsinvolvesmanykeytechniques,forinstance,largemirrormountingdesign,high-accuracyspecialbaseframe,largeprecisionshafting,high-accuracydrivingtechnique,ultrathinopticalcomponentsupport,activecontrolforthinmirrorsurfacedeformation,newmaterialandmachinetechnique,andsoon.
Intheearlydesignoflarge-scaleopticalinstruments,duetothelackofdesignexperience,sufficienttolerancesareusuallyscheduledforinitialdesignparameters.Aftertheengineeringprototypeiscompleted,itsactualtestresultsarecontrastedtothedesignindexestoevaluatethedesignquality,andsomestructuresandparametersmayinturnbemodifiedtilltheinstrumentdesignisinagreementwiththedesignrequirements.Atpresent,thismethodisnotencouragedforheavytask,highexpense,longcycle,andespeciallyunattainable
optimizationofthedesignresults.
Withthewideapplicationofcomputertechniquesinvariousengineeringfields,thetechniquesofCADandCAEhaverapidlydevelopedandledtotheinnovationindesignmethodsofmodernopticalinstrumentstructure.In1980,JacobM.Miller,AmericanresearcheratHoneywellElectro-OpticalSystemsCenter,firstlyproposedtheconceptsandstepsofoptical-mechanical-electricintegrateddesignmethod,andenumeratedthesoftwareused.Meanwhilehesuccessfullyanalyzedtheoptical--electricsensorbyusingthemethod.BasedonCAD/CAEtechniques,theoptical--mechanical-electricintegratedmethodisusedtoanalyzeandsimulatethegeometrymodelandfiniteelementmodelcorrespondingtothevirtualprototypeoftheinstrument,andoverall,considersmutualactionsandconstraintsofvarioussubsystemssothatthestructureparametersaresystemically,consistentlyanddynamicallybalancedtofinallyoptimizethewholesystemparameters.
Inthepaper,wefurtherdiscussanintegrateddesignmethod,whichfullyconsidersthemodeltransformationandoptimizationoftheparametersduringtheentiredesignprocess,mainlyincludingopto-mechanicalstructuredesignandanalysisbyCAD,CAEandespeciallytheintegratedinformationsharethroughproductdatamanagement(PDM).Asanexample,alarge-scaleopticalinstrumentstructureisdevelopedbythismethod.Theintegrateddesignandsimulationarecarriedoutfortheoverallsystem.
2.Opto-mechanicalstructureCADmodel
Themechanicalstructureasthemountingsupportstheopticssystemandensurestheopticsperformanceandthesystemreliability.Theconstraintsofmechanicalstructurearegenerallydividedintotwotypesaccordingtotheireffectivenessinopticssystemandapplicationenvironment,theauxiliarypartsofopticssystemandthemountingmechanismsofopticscomponents.Theopto-mechanicalstructuresincludetwoaspectsofstaticstructureanddynamicalone,andbothofthemcollaborativelyrealizetheopticsperformanceunderthedifferentapplicationconditions.Therefore,thestructuredesignneedstocorrespondinglyconsiderstaticstiffnessandmotionreliability.Asregardsalargemechanicalstructure,especiallyusedinspecialenvironmentsuchasspaceconditions,theweight,volumeandpowerconsumptionbecomethemainfactorstobeconsidered,andsomespecialstructure,materialandtechnologyaretobeadoptedtooptimizethesystemdesign.
Figure1showstheopto-mechanicalstructureACDflow.Firstly,accordingtotheopticssystemrequirements,aconceptofstructuredesignisputforwardandpreliminarycalculationiscarriedout.Then,avirtualprototypeofthewholestructureisbuilt,includingallparts,allcomponentsandoverallassembly.Finally,afterthegeometrydimensionsandmaterialsareset,thecharacterparametersandstructurerationalitycanbetestedandmodifiedinturn.Togetherwiththedynamicalperformancesimulationbasedonvirtualmotionmodel,wecanfullycheckthefeasibilityofthedesignprojectanddecidewhetherornottochangethedesigndetailsoreventheproject.Moreover,wecaneitherimporttheCADmodelintoFEAsoftwarebyformattransformationsuchasIGES,STEP,DFX,etc.,ortransfertheCADmodeltoFEAsoftwarethroughtheinterfaceprocessingprogramprocessor.
Figure1.ThedesignprocessofopticalstructureofACD.
3.Opto-mechanicalstructureCAEanalysis
Duetothelargestructureandhighprecisioninalarge-scaleopticalinstrument,itisnecessarytoevaluatethedesignbyfiniteelementanalysismethod,includingstructureanalysis,thermalanalysisandopticalanalysis.Inordertorealizetheintegrateddesignandsystemoptimization,collaborativesimulationandanalysismustcoverthewholeprocessincludingprojectselection,structuredesign,motionsimulation,thermaldesign,assemblyanalysisandmachiningprocess.Generally,thestepsofFEAmethodconsistofsolidmodeling,generatingmeshes,settingconditions,solvingandpost-processing.Thestructurestaticsanalysisisintendedforresearchintothestructureresponseshownbystrainandstress.Foralarge-scalestructure,thegravityeffectmustbeconsidered,whichusuallyinducestheelasticdeformation,especiallyseriousinspaceenvironment.Thedynamicsanalysismainlyresolvesthevibrationmodeandgainsthedynamicrigidity.Inotherwords,thestructureweaknessaswellastheresistingfracturecapabilitycanbefoundthroughthevibrationmodeanalysis.Conduction,convectionandradiationasthreeheattransfermodeswidelyexistinlarge-scaleinstruments,includingsteadyandtransienttemperaturefield.Throughthethermalanalysistogetthermalperformance,thethermalcontrolprojectofopticalinstrumentcanbeimplemented,whichwillguidethestructuredesigntomeettherequirementsofopticsperformance.
However,nomaterwhichprojectofthemechanicalstructureisused,itmustcentertheopticssystem,andthefinalanalysisistoimprovetheopticalperformance.Figure2givesrelationsofthevariousanalysisprocesses,whichcanberealizedbythedatainterchangeandintegrationamongdifferentsoftware.TheZernikefittingmethodisusuallyemployedtoevaluatetheopticsperformancesuchaswavefrontanalysis,transformationfunction,andsoon.InFigure3,anexampleofourpriorFEAonalarge-scaleopto-mechanicalstructureisshown.
Figure.2.RelationsamongdifferentFEAprocesses.
4.PDMinformationintegration
PDMastheintegratedplatformbridgesthedesignandanalysisprocess,andsharesdatabasedonthevirtualmainmodel,whichapproachestheparameterdriveandrealtimemodificationduringthewholedesign.
PDMgenerallyincludesCADmodeldata,technologyandfiledata,FEAanalysisandsimulationdata,etc.DifferentCADandCAEsubsystemsallcansharedatainformationbyPDM.Forinstance,inCIMS(computerintegratedmanufacturingsystem)basedonconcurrentengineering,PDMplaysakeyrolefordifferentsubsystemswithhighefficiency.Moreover,withthedevelopmentofnetworktechnology,PDMreliesontheCAN(controllerareanetwork)andclient-serversystemstructurewillefficientlybuildthecollaborativeandintegratedworkenvironment,includingprojectdesign,systemsimulationandanalysis,productmanagementoverthewholelifecycle,andevenalltheproductionandserviceprocessinthemarket.Figure4showsPDMapplicationinopticalinstrumentdesignandanalysis.
Fig.3.FEAprocessofaprismassembly.
Fig.4.DesignandsimulationbasedonPDMsystem.
5.Adesignexampleofalarge-scaleopticalstructure
WedevelopaFizeauinterferometerwitha360mmclearaperturebytheintegrateddesignmethod.Figure5showsthedesignandoptimizationflowofthereferencemirrorandmountingstructureintheinterferometer.WeuseWindchillPDMLinktosolvethedistributedproductdatamanagementproblem,includingfilemanagement,modeldatamanagement,informationsavingandopening.CADandCAEsoftwareincludeopticsdesignsoftwareofCODEV,2Dand3DdesignsoftwareofAutoCADandPro/Engineer,FEAsoftwareofAnsys,calculationsoftwareofMatlab,etc.
Fig.5.Anexampleofdesignprocess:
integrateddesignofreferencemirrorstructureoftheFizeau.
InFigure5thearrowsshowthedataflowbetweendifferentdesignmodules.Firstly,thevirtualmodeloftheopticalinstrumentisconceptuallydesignedbyPro/EngineeringandCODEV.Thenthefiniteelementmethodistakenforthestaticanddynamicalanalys