Fiber optic sensor array fork-lug flexible monitoring of large components.

To realize the flexible monitoring and online pose correction of the complex assembly of large components, an optical fiber sensor array-based tooling condition monitoring network was built. First, an ANSYS simulation analysis was conducted to obtain the strain sensitive position of the tooling, and the maximum deformation was 0.0368 mm; then, the combination relationship between the monitoring position of the fiber grating sensor and the test data was determined. Next, a flexible sensor packaging structure was designed to achieve optimal strain sensitivity for ensuring flexible assembly. Finally, a three-dimensional reconstruction calculation model of stress field distribution and assembly pose adjustment was developed. The changes in the stress field distribution caused by different assembly problems were analyzed, and the corresponding pose correction parameters were solved. The results show that the inversion accuracy of the position deformation of the optical fiber sensor was better than 0.0058 mm, and the minimum correction accuracy of the position was 0.17 mm. The optical fiber flexible detection system works with the assembly structure to realize the intelligent assembly of large components and addresses the limitations of existing three-dimensional digital measurement processes due to environmental vibration, test openness, and other factors.