复杂机械产品性能驱动设计方法及其典型应用研究
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摘要
随着以大型装备为代表的现代机械产品的复杂性日益增加,其设计开发过程向着智能化、快速化和集成化等方向发展,对产品设计理论与方法提出了新的期望与要求,因此设计领域需要有更先进的现代设计理论与方法体系来统帅产品的整个设计过程,并在全局上指导设计高质高效地进行。为此,本文在对相关领域的国内外学术研究现状及软件企业产品进行全面综述的基础上,开展了以性能驱动为特征的复杂机械产品现代设计理论的研究与探索,主要包括以下几个方面:
1.提出了性能驱动设计方法的总体架构,分析了复杂机械产品的功能、性能和质量等设计三要素,论述了性能在现代产品设计流程中的核心地位,并分别从需求、特征和参数三个层面开展了多角度研究,阐述了性能指标体系架构及其对应的性能模型等概念及其基本组成,从而完善了性能驱动设计方法的基础理论体系研究。
2.结合QFD和数字样机等理论方法,提出了以功能需求引导的、功构映射为主体的横向设计过程与以性能需求驱动的、性能仿真为核心的纵向分析过程相结合的性能驱动设计方法的基本流程,细化了性能驱动设计方法的总体架构。
3.定义了性能驱动设计流程的基本元素——性能分析构件,系统分析了相关的基本流程和模块。结合QFD技术,提出了性能质量屋的组成和基本流程,及其在计算过程中存在的问题;深入研究了性能分析模块中的性能模型的建立、性能分析的实施以及设计方案的决策等基本环节,并构建了性能分析矩阵和方案选择矩阵等关键决策工具,以辅助参数级和方案级的设计权衡与决策,从而完善了性能驱动设计方法的框架和流程。
4.针对性能驱动设计流程中信息的不确定性、耦合性及其在转换过程中的特点,研究了性能驱动设计过程的关键使能技术,主要包括:基于QFD、粗糙集和灰关联分析技术的性能指标重要度的确定方法,以充分考虑客户的主观感受和专家的经验;MDO算法中多子系统二级协调策略、数字实验和敏感性分析等技术相结合的备选设计方案定义方法,以实现产品整体性能最优;粗糙集与灰关联分析技术相结合的最终设计方案决策方法,用来同时考虑定量和定性指标的影响;基于特征映射机理的“性能特征—结构特征—工艺特征”顺序映射机制,从而提高加工的效率和精度。
在上述研究的基础上,本文以水电机组为典型的复杂机械产品,对其整机性能进行了分析定义,构建了机组关键部件——推力轴承的性能驱动设计基本流程,实现了性能驱动设计方法在水电机组及其关键部件产品设计中的应用,从而验证性能驱动设计流程及其使能技术的可行性和实用性。同时,结合齿轮倒角加工性能计算分析问题,从性能特征映射的角度进一步验证了性能驱动设计方法的技术可行性。
With the increase in complexity of modern mechanical product as represented by large-scale equipment, the design and development process is developing to intelligentized, high-efficiency and integrated, which put forward the new requirement and hopeness to the theory and method of product design. Therefore, more advanced modern design theory and method will be required to drive the wholl design process, and guide high-quality and high-efficiency design process as a whole. The research status at home and abroad and the product of software company has comprehensive reviewed for the correlative domains with this research, and carry out the research and exploration on the method of performance driving design for complex mechanical product. The key research contents were determined as follows through the present problems and future development trends.
1. The general architecture of performance driving design method was put forward, and design elements, such as function, performance and quality, of complex mechanical product was analyzed respectively. And then, the core position of performance in the modern product design flow was discussed, and the definition of performance was studied from three aspects, such as requirement, feature and parameter. Finally, the index system and performance model was expounded in detail.
2. Based on the technology of QFD and digital prototyping, the basic flow of performance driving design method was proposed. It is composed with the transverse design process which is driven by function requirement and focuses on function structural mapping, and the longitudinal analysis process which is driven by performance requirement makes performance simulation as the core. This flow describes the general architecture of performance driving design method in detail.
3. The performance analysis component is used as the basic element of the performance driving design method flow was defined. The related basic flow and module was analysis systematically, and the elementary steps were studied intensively, such as establishment of the performance model, construction of analysis matrix, scheme determination, and so on. The key decision-making aided tools were proposed, such as performance analysis matrix and scheme selection matrix, which perfect the frame and flow of performance driving design method.
4. According to the uncertainty, coupling and the transforming characteristics of performance driving design process, a series of key enabling technology was studied deeply. Firstly, the method of performance index weight determination based on the technology of QFD, rough set, and gray relation analysis, in order to pay attention to the subjective feeling of customs and the experience of experts. Secondly, the method of design alternatives definition combined with two coordinated strategies of multiple subsystems in MDO, digital experiment and sensitivity analysis technology so as to achieve the whole optimization of product performance was set up. Thirdly, final design scheme method composed of rough set and gray relation analysis was found, in order to consider quantitative index and qualitative index simultaneously. Finally, a feature mapping mechanism from performance feature, structural feature to process feature based on feature mapping theory was carried out to improve machining efficiency and accuracy.
As a typical application example, the overall performance of bulb-tubular hydraulic generator which typically represents complex mechanical product has been conceptually proposed after analyzing its basic structural characteristics. The basic performance driving design flow of thrust bearing which is the key part in the hydraulic generator was firstly constructed, in order to realize the practical application of the method in hydraulic generator and its key parts design. It is successfully verification that the method of performance driving design in complex mechanical product development own practicability and technical feasibility. Furthermore, according to the problem of gear chamfering manufacturing performance calculation and analysis, the technical feasibility of this method was further verified from performance feature mapping.
1.提出了性能驱动设计方法的总体架构,分析了复杂机械产品的功能、性能和质量等设计三要素,论述了性能在现代产品设计流程中的核心地位,并分别从需求、特征和参数三个层面开展了多角度研究,阐述了性能指标体系架构及其对应的性能模型等概念及其基本组成,从而完善了性能驱动设计方法的基础理论体系研究。
2.结合QFD和数字样机等理论方法,提出了以功能需求引导的、功构映射为主体的横向设计过程与以性能需求驱动的、性能仿真为核心的纵向分析过程相结合的性能驱动设计方法的基本流程,细化了性能驱动设计方法的总体架构。
3.定义了性能驱动设计流程的基本元素——性能分析构件,系统分析了相关的基本流程和模块。结合QFD技术,提出了性能质量屋的组成和基本流程,及其在计算过程中存在的问题;深入研究了性能分析模块中的性能模型的建立、性能分析的实施以及设计方案的决策等基本环节,并构建了性能分析矩阵和方案选择矩阵等关键决策工具,以辅助参数级和方案级的设计权衡与决策,从而完善了性能驱动设计方法的框架和流程。
4.针对性能驱动设计流程中信息的不确定性、耦合性及其在转换过程中的特点,研究了性能驱动设计过程的关键使能技术,主要包括:基于QFD、粗糙集和灰关联分析技术的性能指标重要度的确定方法,以充分考虑客户的主观感受和专家的经验;MDO算法中多子系统二级协调策略、数字实验和敏感性分析等技术相结合的备选设计方案定义方法,以实现产品整体性能最优;粗糙集与灰关联分析技术相结合的最终设计方案决策方法,用来同时考虑定量和定性指标的影响;基于特征映射机理的“性能特征—结构特征—工艺特征”顺序映射机制,从而提高加工的效率和精度。
在上述研究的基础上,本文以水电机组为典型的复杂机械产品,对其整机性能进行了分析定义,构建了机组关键部件——推力轴承的性能驱动设计基本流程,实现了性能驱动设计方法在水电机组及其关键部件产品设计中的应用,从而验证性能驱动设计流程及其使能技术的可行性和实用性。同时,结合齿轮倒角加工性能计算分析问题,从性能特征映射的角度进一步验证了性能驱动设计方法的技术可行性。
With the increase in complexity of modern mechanical product as represented by large-scale equipment, the design and development process is developing to intelligentized, high-efficiency and integrated, which put forward the new requirement and hopeness to the theory and method of product design. Therefore, more advanced modern design theory and method will be required to drive the wholl design process, and guide high-quality and high-efficiency design process as a whole. The research status at home and abroad and the product of software company has comprehensive reviewed for the correlative domains with this research, and carry out the research and exploration on the method of performance driving design for complex mechanical product. The key research contents were determined as follows through the present problems and future development trends.
1. The general architecture of performance driving design method was put forward, and design elements, such as function, performance and quality, of complex mechanical product was analyzed respectively. And then, the core position of performance in the modern product design flow was discussed, and the definition of performance was studied from three aspects, such as requirement, feature and parameter. Finally, the index system and performance model was expounded in detail.
2. Based on the technology of QFD and digital prototyping, the basic flow of performance driving design method was proposed. It is composed with the transverse design process which is driven by function requirement and focuses on function structural mapping, and the longitudinal analysis process which is driven by performance requirement makes performance simulation as the core. This flow describes the general architecture of performance driving design method in detail.
3. The performance analysis component is used as the basic element of the performance driving design method flow was defined. The related basic flow and module was analysis systematically, and the elementary steps were studied intensively, such as establishment of the performance model, construction of analysis matrix, scheme determination, and so on. The key decision-making aided tools were proposed, such as performance analysis matrix and scheme selection matrix, which perfect the frame and flow of performance driving design method.
4. According to the uncertainty, coupling and the transforming characteristics of performance driving design process, a series of key enabling technology was studied deeply. Firstly, the method of performance index weight determination based on the technology of QFD, rough set, and gray relation analysis, in order to pay attention to the subjective feeling of customs and the experience of experts. Secondly, the method of design alternatives definition combined with two coordinated strategies of multiple subsystems in MDO, digital experiment and sensitivity analysis technology so as to achieve the whole optimization of product performance was set up. Thirdly, final design scheme method composed of rough set and gray relation analysis was found, in order to consider quantitative index and qualitative index simultaneously. Finally, a feature mapping mechanism from performance feature, structural feature to process feature based on feature mapping theory was carried out to improve machining efficiency and accuracy.
As a typical application example, the overall performance of bulb-tubular hydraulic generator which typically represents complex mechanical product has been conceptually proposed after analyzing its basic structural characteristics. The basic performance driving design flow of thrust bearing which is the key part in the hydraulic generator was firstly constructed, in order to realize the practical application of the method in hydraulic generator and its key parts design. It is successfully verification that the method of performance driving design in complex mechanical product development own practicability and technical feasibility. Furthermore, according to the problem of gear chamfering manufacturing performance calculation and analysis, the technical feasibility of this method was further verified from performance feature mapping.
引文
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