针对传统直接和间接变形监测方法难以满足结构高精度实时变形监测的问题,提出一种数字孪生驱动的结构全场变形高精度反演方法。首先,通过融合仿真和实测应变数据,构建了结构多方向数字孪生应变场,降低载荷偏差等因素对仿真可靠性影响,保证变形反演的应变精度要求;其次,提出了一种基于多目标优化的模态坐标求解和变形反演方法,使用结构多方向应变参与模态坐标求解,解决使用单方向应变时反演结果稳定性不足问题,提升结构全场变形反演的鲁棒性;最后,基于所提出方法,以机翼结构为对象开展试验验证,与仿真及传统模态法的变形反演结果进行对比,结果表明,所提出方法在变形较大处反演精度具有更高优势。在变形较大位置,所提出方法反演结果与试验测量变形相对误差小于0.5%,绝对误差小于0.06 mm,相比传统模态法和仿真分析方法变形反演误差分别降低8%和13%。同时,所提出方法对多个测点位置变形反演平均相对误差为0.8%,相比传统模态法和仿真分析方法变形反演误差分别降低6.1%和9.6%,表明所提出方法具有较高的变形反演精度。
Aiming at the traditional direct and indirect deformation monitoring methods that are difficult to meet the problem of high-precision real-time deformation monitoring of structures, a digital twin-driven method for high-precision reconstruction method of full-field deformation of structures is proposed. Firstly, a multi-directional digital twin strain field is constructed by integrating the simulation and measured strain data, which reduces the impact of load deviation and other factors on the reliability of simulation and ensures the strain accuracy of deformation reconstruction; secondly, a multi-objective optimization-based modal coordinate solving and deformation reconstruction method is proposed, which uses the multi-directional strains of the structure to participate in modal coordinate solving, and solves the problem of insufficient stability of the deformation reconstruction results when single-directional strains are used, and improves the robustness of the full-field deformation reconstruction of the structure. Finally, based on the proposed method, the experimental validation is carried out using the wing structure as an object, and the results are compared with the simulation and the deformation reconstruction results of the traditional modal method, and the results show that the proposed method has a higher advantage of deformation reconstruction accuracy in the place of large deformation. The relative error between the reconstruction results of the proposed method and the measured deformation is less than 0.5%, and the absolute error is less than 0.06 mm, which is 8% and 13% lower than that of the traditional modal method and the simulation method, respectively. Meanwhile, the average relative error of deformation reconstruction of the proposed method for multiple measurement points is 0.8%, which is 6.1% and 9.6% lower than that of the traditional modal method and the simulation analysis method, respectively, indicating that the proposed method has a high accuracy of deformation reconstruction.