Variation analysis driven by small-sample data for compliant aero-structure assembly

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PurposeAssembly variation analysis generally demands probability distributions of variation sources. However, due to small production volume in aircraft manufacturing, especially prototype manufacturing, the probability distributions are hard to obtain, and only the small-sample data of variation sources can be consulted. Thus, this paper aims to propose a variation analysis method driven by small-sample data for compliant aero-structure assembly.Design/methodology/approachFirst, a hybrid assembly variation model, integrating rigid effects with flexibility, is constructed based on the homogeneous transformation and elasticity mechanics. Then, the bootstrap approach is introduced to estimate a variation source based on small-sample data. The influences of bootstrap parameters on the estimation accuracy are analyzed to select suitable parameters for acceptable estimation performance. Finally, the process of assembly variation analysis driven by small-sample data is demonstrated.FindingsA variation analysis method driven by small-sample data, considering both rigid effects and flexibility, is proposed for aero-structure assembly. The method provides a good complement to traditional variation analysis methods based on probability distributions of variation sources.Practical implicationsWith the proposed method, even if probability distribution information of variation sources cannot be obtained, accurate estimation of the assembly variation could be achieved. The method is well suited for aircraft assembly, especially in the stage of prototype manufacturing.Originality/valueA variation analysis method driven by small-sample data is proposed for aero-structure assembly, which can be extended to deal with other similar applications.