考虑质量、成本与资源利用率的再制造机床优化选配方法
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摘要
针对再制造机床装配过程中存在的装配精度低,再制造资源利用率低以及生产成本高等问题,提出一种新的再制造机床综合优化选配方法,综合考虑装配精度、再制造资源利用率与成本,采用田口质量损失函数与剩余件成本函数,以封闭环尺寸链为约束条件,在保证装配精度及最小成本的目标下,建立综合选配模型,并给出基于粒子群遗传算法的模型求解过程,求解出再制造装配过程的最优选配方案,减少了再制造装配过程中的不确定因素,降低因选配方案不合理而带来的资源浪费,保证了装配产品的质量。最后,以废旧CAK6150机床主轴箱为例,对其主轴装配过程进行优化选配,最终验证了该方法不仅解决了再制造零件选配过程中精度低的问题,而且大大提高了选配过程的再制造资源利用率,降低企业成本。
Aiming to poor assembly accuracy,low utilization of remanufacturing resource and low assembly efficiency in the process of remanufacturing assembly,a new selective assembly method optimization for remanufactured machinery is proposed.Considering assembly accuracy,utilization of remanufactured parts and assembly efficiency,Taguchi quality loss function(QLF)and cost function of remaining parts are both employed.Ensuring assembly accuracy and minimum cost,a comprehensive matching model is established with closed loop dimension chain as the constraint condition,and the solution procedure of PSO-GA model is given to obtain the optimal matching scheme.Uncertainties and resource wastes causing by unreasonable matching schemes are both reduced to ensure the quality of remanufactured machine.Finally,the spindle box of a wasted CAK6163 is selected to implement optimization and matching to the reassembly procedure,and the results show the proposed method can not only eliminate the problem of low success rate in remanufactured parts matching process,but also greatly improve the utilization of remanufacturing resource and reduce the cost.
Aiming to poor assembly accuracy,low utilization of remanufacturing resource and low assembly efficiency in the process of remanufacturing assembly,a new selective assembly method optimization for remanufactured machinery is proposed.Considering assembly accuracy,utilization of remanufactured parts and assembly efficiency,Taguchi quality loss function(QLF)and cost function of remaining parts are both employed.Ensuring assembly accuracy and minimum cost,a comprehensive matching model is established with closed loop dimension chain as the constraint condition,and the solution procedure of PSO-GA model is given to obtain the optimal matching scheme.Uncertainties and resource wastes causing by unreasonable matching schemes are both reduced to ensure the quality of remanufactured machine.Finally,the spindle box of a wasted CAK6163 is selected to implement optimization and matching to the reassembly procedure,and the results show the proposed method can not only eliminate the problem of low success rate in remanufactured parts matching process,but also greatly improve the utilization of remanufacturing resource and reduce the cost.
引文
[1]张根保,赵洪乐,李冬英.多装配特征影响下的装配质量特性预测方法[J].计算机应用研究,2015,32(3):709-712.ZHANG Genbao,ZHAO Hongle,LI Dongying.Prediction method of assembly quality characteristics under the influence of multiple assembly features[J].Journal of Computer Applications,2015,32(3):709-712.
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[16]潘勇,郭晓冬.一种基于遗传算法改进的粒子群优化算法[J].计算机应用与软件,2011,28(9):222-224.PAN Yong,GUO Xiaodong.A particle swarm optimization algorithm based on improved genetic algorithm[J].Journal of Computer Applications and Software,2011,28(9):222-224.
[17]KENNEDY J,EBERHART R.Particle swarm optimization[C]//Neural Networks,1995.Proceedings.,IEEE International Conference on.IEEE,1995:1942-1948.
[18]刘逸,慕彩红,刘敬.结合邻域信息粒子群聚类用于SAR图像变化检测[J].西安电子科技大学学报,2015,42(1):187-193.LIU Yi,MU Caihong,LIU Jing.Combining neighborhood information particle swarm clustering for SAR image change detection[J].Journal of Xidian University,2015,42(1):187-193.
[19]FERGUSON M,GUIDC VD,KOCA E,et al.The value of quality gradingin remanufacturing[J].Production and Operations Management Society,2009,18(3):300-314.
[2]朱胜,姚巨坤.再制造技术与工艺[M].北京:机械工业出版社,2010.ZHU Sheng,YAO Jukun.Remanufacturing technique and technology[M].Beijing:China Machine Press,2010.
[3]PRABHAHARAN G,ASOKAN P,RAJENDRAN S.Sensitivity-based conceptual design and tolerance allocation using the continuous ants colony algorithm(CACO)[J].The International Journal of Advanced Manufacturing Technology,2005,25(5-6):516-526.
[4]SIVA K M,KANNAN S M,JAYABALAN V.A new algorithm for optimum tolerance allocation of complex assemblies with alternative processes selection[J].International Journal of Advanced Manufacturing Technology,2009,40(7-8):819-836.
[5]FEI J F,LU C,WANG S L.Minimizing surplus parts in selective assembly using GA[J].Applied Mechanics&Materials,2012,215(8):175-181.
[6]RAJ M V,SANKAR S S,PONNAMBALAM S G.Ant colony optimization to improve precision of complex assembly[J].Communications in Computer and Information Science,2011,152(12):86-93.
[7]朱胜,姚巨坤.再制造设计理论及应用[M].北京:机械工业出版社,2009.ZHU Sheng,YAO Jukun.Remanufacturing design theory and application[M].Beijing:China Mechine Press,2009.
[8]张根保,赵洪乐,李冬英.多装配特征影响下的装配质量特性预测方法[J].计算机应用研究,2015,32(3):709-712.ZHANG Genbao,ZHAO Hongle,LI Dongying.Prediction method of assembly quality characteristics under the influence of multi-assembly features[J].Journal of Computer Applications,2015,32(3):709-712.
[9]张根保,王立平.国产数控机床可靠性技术综述[J].航空制造技术,2013(5):26-31.ZHANG Genbao,WANG Liping.Overview of reliability technology of domestic CNC machine tools[J].Aviation Manufacturing Technology,2013(5):26-31.
[10]刘明周,王强,赵志彪,等.机械机械产品再制造装配过程动态工序质量控制系统[J].计算机集成制造系统,2014,20(4):817-824.LIU Mingzhou,WANG Qiang,ZHAO Zhibiao,et al.Dynamic process quality control system for mechanical and mechanical product remanufacturing and assembly process[J].Computer Integrated Manufacturing Systems,2014,20(4):817-824.
[11]刘明周,刘从虎,邢玲玲,等.面向质量目标的再制造复杂机械产品装配分组优化配置方法[J].机械工程学报,2014,50(8):150-155.LIU Mingzhou,LIU Conghu,XING Lingling,et al.Assembly grouping optimization method for remanufacturing complex mechanical products oriented to quality objectives[J].Journal of Mechanical Engineering,2014,50(8):150-155.
[12]刘明周,邢玲玲,刘从虎,等.面向再制造复杂机械产品装配过程的质量控制点公差带在线优化方法[J].中国机械工程,2015,26(1):55-62.LIU Mingzhou,XING Lingling,LIU Conghu,et al.On-line optimization method for quality control point tolerance zone for remanufacturing complex mechanical product assembly process[J].China Mechanical Engineering,2015,26(1):55-62.
[13]宿彪,黄向明,任莹晖,等.基于蚁群算法的工程机械再制造优化选配方法研究[J].机械工程学报,2017,53(5):60-68.SU Biao,HUANG Xiangming,REN Yinghui,et al.Research on optimization method of engineering machinery remanufacturing based on ant colony algorithm[J].Journal of Mechanical Engineering,2017,53(5):60-68.
[14]王俊伟,汪定伟.粒子群算法中惯性权重的实验与分析[J].系统工程学报,2005(2):194-198.WANG Junwei,WANG Dingwei.Experiment and analysis of inertia weight in particle swarm optimization algorithm[J].Journal of Systems Engineering,2005(2):194-198.
[15]黄辉先,陈资滨.一种改进的粒子群优化算法[J].系统仿真学报,2007,19(21):4922-4925.HUANG Huixian,CHEN Zibin.An improved particle swarm optimization algorithm[J].Journal of System Simulation,2007,19(21):4922-4925.
[16]潘勇,郭晓冬.一种基于遗传算法改进的粒子群优化算法[J].计算机应用与软件,2011,28(9):222-224.PAN Yong,GUO Xiaodong.A particle swarm optimization algorithm based on improved genetic algorithm[J].Journal of Computer Applications and Software,2011,28(9):222-224.
[17]KENNEDY J,EBERHART R.Particle swarm optimization[C]//Neural Networks,1995.Proceedings.,IEEE International Conference on.IEEE,1995:1942-1948.
[18]刘逸,慕彩红,刘敬.结合邻域信息粒子群聚类用于SAR图像变化检测[J].西安电子科技大学学报,2015,42(1):187-193.LIU Yi,MU Caihong,LIU Jing.Combining neighborhood information particle swarm clustering for SAR image change detection[J].Journal of Xidian University,2015,42(1):187-193.
[19]FERGUSON M,GUIDC VD,KOCA E,et al.The value of quality gradingin remanufacturing[J].Production and Operations Management Society,2009,18(3):300-314.