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大型空分设备关键部机质量的多尺度智能化协同化控制理论及其应用
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摘要
为解决空分设备中关键部机质量控制过程中所面临的多尺度问题、协同化问题、耦合性问题、不确定因素影响问题等,本文提出了多尺度协同化、智能化的空分设备关键部机质量控制方法,对空分设备客户需求的处理、需求与质量特性映射模型的构建、质量特性实现水平的确定、供应链的构建、模块的划分与粒度的确定、各尺度的质量控制和质量控制方案的评价与选择进行了深入研究,依托国家重点资助项目并结合企业的具体应用将上述方法应用于深冷式空分设备关键部机的质量控制中,取得了良好的效果。
     论文的主要内容如下:
     第一章综述了一般产品质量控制方法的内涵和发展历程,回顾了当前国内外产品质量控制方法的研究现状。描述了空分设备的产品结构和质量控制特点,阐述了空分设备质量控制的内涵和所面临的挑战。在分析了现有产品质量控制方法不足的基础之上,介绍了本课题的主要思想和研究背景,同时给出了面向空分设备关键部机质量控制的多尺度协同化智能化控制理论。
     第二章分析了空分设备整机客户需求与质量特性映射过程中所具有的多重耦合性问题,提出了客户需求的模糊DEMATEL处理方法,提出了基于Shafer模糊效用推理理论的质量特性映射模型,给出了质量特性实现水平的多目标模糊表达式,进而利用非支配排序进化算法进行求解并获得多个可行的参考解。利用模糊信息熵优选原理对这些参考接进行评价来获得综合最优的质量特性实现水平从而为后续质量控制提供基础。以空分设备的客户需求处理、质量特性映射、质量特性实现水平的确定为实例,验证了方法的实用性。
     第三章提出了空气压缩机零部件尺度的质量、成本、交货期控制以及供应链构建的二阶段优化方法。建立了空分设备零部件质量、成本、交货期的多目标优化模型,利用Epsilon策略来改进强度帕累托进化算法,将改进后的算法用于模型求解并得到了良好的供应备选方案。将伯努利预测模型和傅里叶修正技术了融入到多属性决策机制中,采用这一机制对供应商进行评价得出最佳的供应商和对应的高质量、低成本、交货周期短的零部件,从而实现了构建了空气压缩机零部件优化设计。上述方法在空气压缩机的具体成功应用,表明了方法的有效性。
     第四章提出了基于质量准则的空气压缩机模块构建与粒度确定方法。研究以模块尺度上的质量损失最小、质量独立性最大、质量稳定性最大为模块划分的目标准则,并由此给出质量需求与空气压缩机模块的耦合变动度计算模型。利用新的模糊C均值算法对空气压缩机的模块化体系结构进行构建,利用混合青蛙跳跃算法进行求解,得到不同粒度层次下的模块化结构方案。给出了衡量客户满意度、装配复杂度以及变型设计复杂度等量化指标来对各粒度层次下的模块方案进行数学评价进而确定最优的方案和合理的粒度。最后详细分析了空气压缩机模块划分与粒度确定的实际应用案例。
     第五章提出了透平膨胀机整机尺度上的质量、成本控制方法。针对透平膨胀机在配置、组装过程中需要受到很多不确定因素影响这一问题,提出了基于集对分析理论的质量、成本综合控制联系度模型。通过设计相应的编码规则和约束处理机制来改进演化细胞学自动机算法,并将改进后的算法用于求解上述模型并得到相对确定条件下的质量、成本控制方案的优劣排序关系-基序。考虑不确定因素的影响,采用随机模拟的方式对不确定环境进行模拟,通过模糊集值统计方法确定差异度进而得到透平膨胀机质量、成本控制方案的最终优劣排序-扩展序。以透平膨胀机质量、成本控制过程的数值仿真作为演示案例,证明所提方法可以为企业产品研发提供一种有效的参考。
     第六章提出了基于模糊Choquet积分与证据理论的透平膨胀机质量控制方案的评价与选择方法。首先考虑透平膨胀机质量控制方案的评价信息具有模糊性、不完备性等问题,利用α-截集的模糊评价法对各质量准则进行评价;其次,考虑到透平膨胀机质量控制方案的各个质量准则具有耦合性和关联性,采用模糊Choquet积分对方案评价模型进行建模。最后,针对各个评价专家之间的意见具有冲突性,采用证据理论对各专家意见进行融合以达到协同决策的目的。以三个专家对四种透平膨胀机质量控制方案的评价和选择为例,说明上述决策模型的有效性。
     第七章依托国家科研项目,结合企业的实际工程需求和本文的研究成果,开发了空分设备质量、成本控制的数字化信息系统(HY-ASEQCS)。以图文并茂的形式演示了HY-ASEQCS的应用过程和操作方法,通过具体的项目实施验证了本文所提出的理论和方法的有效性和可行性。
     第八章总结了全文的主要研究内容、意义、成果以及创新点,并展望了未来的研究工作。
To deal with multi-scale, collaboration, coupling, uncertainty et.al problems in the quality control process of air separation equipment, a new multi-scale collaborative intelligent technology consisting of customer requirements, mappings between customer requirements and quality characteristics, quality characteristics fulfillments level, suppliers chain construction, module division and granule decision, quality control for each scale, quality control scheme evaluation and selection, is proposed in this dissertation. Relying on important projects supported by national basic foundation, referring to realistic application of corporation, the effeteness and validity is proved.
     The main contents of this dissertation are as follows:
     Chapter1gives the reviews of quality control methods for common product, which consists of development process and current research trend. The physical structure and quality control characteristics of air separation equipment are discussed, as well. Based on the deficiencies analyzed in existing method of quality control, the main ideas and research background of quality control for air separation equipment products are given. At last, a new multi-scale collaborative intelligent technology of quality control is given.
     Chapter2analyzes issues existing in most traditional methods for mapping from customer requirements to quality characteristics, a novel method using a combination of multi-criteria decision models and multi-objective optimization algorithm is put forward. With the focus on influences among customer requirements, fuzzy DEMATEL method is used for determining importance ratings of customer requirements. Shafer integral is applied to aggregate relationships between requirements and quality characteristics, so importance ratings of quality characteristics will be determined. Considering other factors conditioning quality characteristics implement, the multiple objective optimization models for quality characteristics fulfillment levels is constructed. The improved strength pareto evolutionary algorithm(NSGA-Ⅱ) was employed to acquire the Pareto solutions set. Finally, entropy optimal selection technique was adopted to choose the best solution from the Pareto solutions set. Finally, the feasibility and validity of the proposed method was illustrated.
     Chapter3aims at two-dimensional limitations about components optimization and suppliers evaluation existing in the traditional optimization design methods where suppliers were involved with, a novel two-stage method consisting of multi-objective optimization and dynamic multi-attribute decision was proposed. In the first stage, multi-objective optimization model for quality, cost and delivery time was built, and Epsilon-strength Pareto evolutionary algorithm was employed to solve abovementioned model and to get finite Pareto solutions. In the second stage, Bernoulli forecasting-based fuzzy dynamic multi-attribute decision was applied to evaluate suppliers pertaining to Pareto solutions, and then the optimal supplier for each component was selected and the best product planning scheme was acquired. A case study of product development of large scale deep cooling air-separating equipment was provided to illustrate the application and validation of the proposed method through simulation and computation.
     Chapter4analyzes some prevalent limitations of current product module partition, along with the features of product configuration, Fuzzy C Means, which is criticized because of clustering objective function invalidity and climb-hill method for searching solutions, is improved to plan product modular architecture. The improved Fuzzy C Means Cluster is joined with a novel algorithm, named Shuffled Frog-Leaping Algorithm, so the intelligent cluster algorithm is a combination of those two and used for product granularity division. On the base of analysis for main factors affecting configuration design, three quantified indices, namely, satisfaction degree, assembly complexity and variant design complexity, are proposed to evaluate validity for granularity division results and to decide optimal module components. Finally, a practical case is studied, so feasibility and validity can be proven.
     Chapter5analyzes quality and cost control process for air separation equipment, which were affected by lots of uncertain factors hard to model precisely. To that end, set pair analysis(SPA) was adopted to build the multi-objective relative degree of nearness optimization model for quality and cost control. Evolutionary cellular learning automata algorithm was adaptively improved to solve that optimization model, and then quality and cost control alternatives set's priority ordering, basic ordering, was acquired under the relative certain condition. Considering uncertain influences, fuzzy set-valued statistics was utilized to obtain discrepancy degree coefficient Δ. So that the basic ordering was reordered in the light of relation coefficient, and the optimal product quality and cost control concept alternative was selected. At the end of this paper, large scale deep cooling air-separating equipment's quality and cost control process as a practical case was provided to illustrate the application and validation of the proposed method through simulation and computation.
     Chapter6points out that air separation equipment concept evaluation is a classic multiple criteria group collaborative decision-making process with lots of uncertain factors involved. For one thing, a-cut fuzzy evaluation method was applied to evaluate each criterion of product design concept. Taking interrelations and non-linear combination between those evaluation criteria into account, a criteria aggregation model based on Choquet integral was introduced for product design concept holistic evaluation. And then, preference comparison matrices were constructed and algorithm for priority of fuzzy complementary judgment matrix was adopted, so that priority ordering for was acquired. On the other hand, aiming at cross-function experts' evaluation opinions with discrepancy, the improved evidence theory was utilized to synthesize each expert decision result of product design concepts preference sorting, and the relatively stable and harmonious decision-making result for product design concept evaluation was reached. At the end, a practical case was provided to illustrate the application and validation of the proposed method through simulation and computation.
     Chapter7relies national research projects and develops the air separation equipment quality control digital information system (HY-ASEQCS). Through vivid demonstration of utilization with the graph and scripts, the validity and feasibility of the new technology and method proposed in this paper is shown.
     Chapter8summarizes the key research contents, novelties, and achievements, and givens conclusions along with recommendations for future research.
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