Digital twin-driven design and application paradigm for assembly accuracy performance prototype

This paper proposes a Digital Twin-driven Assembly Accuracy Performance Prototype Design and Application Paradigm (DT-DAP-AAPP). It aims to address the challenges of assembly accuracy control in complex product assembly processes. By incorporating digital twin technology, a reference model for assembly accuracy performance prototypes is constructed. This model is centred around perception, analysis, decision, control and execution. It includes four levels: the physical entity, the virtual entity, twin data, and service. The paradigm achieves deep integration of assembly process design and execution through a dual closed-loop optimisation mechanism. It significantly enhances assembly accuracy, efficiency, and intelligence. The core components of the paradigm include an assembly accuracy prediction module, a tolerance adjustment scheme recommendation module, and a visualisation assembly guidance module. These components dynamically analyse the laws of assembly error propagation, generate optimal tolerance adjustment strategies, and optimise assembly paths and process flows in real time. Experiments with a scaled test piece of a satellite structure, as well as a real-world case study, validate the effectiveness and practical value of this paradigm. The results show significant improvements in the first-pass assembly success rate and assembly efficiency compared to traditional assembly modes.