Assembly tooling is essential equipment in aircraft production. Reconfigurable tooling can adapt to multiple aircraft products by reorganizing modular components. Its service state directly determines the final quality, production cycle, and economic cost of the aircraft assembly. This research developed a reusable Digital Twin (DT) system for reconfigurable tooling to monitor and evaluate its service state. A virtual entity of the DT system is established, containing geometric, physical, behavioral, and rule models. Particularly, both geometric-material similarity and individuality of tooling modules are considered, and calibration parameters are introduced into the behavioral model to ensure the consistency between the virtual and the physical entities. Rules governing positioning deviation identification, assembly sequence, and bolt tightening angle are also included in the rule model, so that the indicative processing data is supplied to evaluate the service state of the tooling and guide the assembly process. The high accuracy and generalizability of the developed DT system for monitoring and evaluating the service state of the tooling are verified by assembly experiments.

装配工装是飞机生产中必不可少的设备。可重构工具可以通过重组模块化组件来适应多种飞机产品。其服役状态直接决定飞机总装的最终质量、生产周期和经济成本。本研究为可重构工具开发了可重复使用的数字孪生 (DT) 系统，以监控和评估其服务状态。建立了DT系统的虚拟实体，包含几何模型、物理模型、行为模型和规则模型。特别地，同时考虑了几何材料相似性和工具模块的个性，并将校准参数引入行为模型以确保虚拟和物理实体之间的一致性。管理定位偏差识别、装配顺序的规则，和螺栓拧紧角度也包含在规则模型中，以便提供指示性加工数据以评估工装的使用状态并指导装配过程。通过装配实验验证了所开发的工装服役状态监测与评估DT系统的高精度和通用性。