面向关键质量特性的大型注塑装备保质设计技术及其应用研究
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摘要
针对大型注塑装备全寿命周期各阶段关键质量特性具有多层次性、多尺度性、多耦合性、多不确定性的特点,本文提出了面向关键质量特性的大型注塑装备保质设计方法,将关键质量特性保证措施与产品设计过程有机地结合,综合考虑产品全寿命周期的关键质量特性,对面向概念方案的大型注塑装备设计意图驱动质量特性偏好决策方法、面向动态分配的大型注塑装备多部件寿命均衡规划方法、面向多元波动的大型注塑装备关键质量特性稳健设计方法、面向使用维护的大型注塑装备混合策略维修方案设计规划方法和面向报废回收的大型注塑装备绿色指数多准则优化方法进行了深入研究,依托国家自然科学基金资助项目,结合实施企业的具体工程应用将上述方法应用于产品设计开发中,取得了良好的工程应用效果。
论文的主要工作如下：
第一章综述了大型注塑装备的结构和设计发展趋势,阐述了关键质量特性的内涵和保质设计研究现状,分析了现有大型注塑装备的保质设计方法不足,给出了面向关键质量特性的大型注塑装备保质设计的主要思想和研究背景。
第二章分析了产品概念方案中产品设计意图的表达,引入物元理论对设计意图进行形式化描述,为机械产品的设计意图表达提供了统一的形式化描述方式。提出了一种基于二元语义的设计意图驱动的产品关键质量特性偏好决策方法,为设计意图驱动的产品关键质量特性优化提供可靠的分析依据。
第三章面向动态分配提出了以有效工作寿命度量多种预防性维护措施下机械产品关键零部件工作寿命的寿命均衡规划方法。针对产品关键零部件的失效率不一致,导致关键零部件的工作寿命不均衡的问题,构建了机械产品多部件寿命均衡数学模型,通过有限时间区间的机械产品预防性维护优化方案,在机械产品关键零部件发生故障之前实施预防性维护措施减少或消除关键零部件故障的发生,使得机械产品各关键部件的工作寿命趋于均衡,同时满足机械产品可靠性指标与机械产品维护费用指标。
第四章面向多元波动提出了基于最小灵敏域估计的产品关键质量特性稳健设计方法。针对产品设计参数发生变差,导致产品关键质量特性的最优化解变为违反约束条件的问题,定义了产品关键质量特性灵敏域,对产品关键质量特性的稳健性进行度量,建立了基于最小灵敏域估计的产品关键质量特性稳健优化数学模型,提出了多目标产品关键质量特性稳健优化设计流程。在满足产品关键质量特性设计要求的前提下,优化产品关键质量特性同时提高产品关键质量特性对设计参数变差的稳健性。
第五章面向使用维护提出了基于维修效率策略和维修成本策略的混合策略大型注塑装备维修方案设计方法。针对机械产品使用维护阶段关键零部件尤其易损件的维修关键质量特性,构建了基于维修效率策略和维修成本策略的混合策略复杂机械产品维修性能优化数学模型,以维修效率和维修成本度量机械产品的维修性能。采用基于改进的强度Pareto进化算法的复杂机械产品的维修性能设计流程,根据维修性能优化数学模型,求得了多目标维修性能优化问题的Pareto最优解集,并优选出最优解,在优化产品维修效率的同时优化产品维修成本。
第六章面向报废回收提出了报废回收阶段的产品绿色质量指数多准则优化分析方法。从零部件的拆解、零部件的重用加工污染、零部件的回收处理环境影响等多个方面多角度综合考虑对产品设计方案的影响,建立了基于改进产品拆解约束图的机械产品多元拆解模型表达方法,提出了面向报废回收的产品绿色质量指数多准则优化分析方法,构建了基于产品回收拆解效率因子、产品回收拆解作业收益因子和产品回收拆解作业环境影响因子的综合绿色质量指数的复杂机械产品设计方案绿色质量指数多准则优化模型。
第七章结合企业工程项目需求和本文研究成果,开发了面向关键质量特性的HT-SIP大型注塑机保质设计系统,以工程实践验证了所提理论和方法的正确性和可行性。
第八章总结了本文的主要研究内容和成果,并展望了今后的研究工作。
To deal with multi-scale, collaboration, coupling, uncertainty et.al problems in the quality control process of large scale injection moulding equipment, a new technology of design for quality of large scale injection moulding equipment oriented to key quality characteristics is proposed in this dissertation. The assurance measures of key quality characteristics and product design process are integrated of the new technology, which is mainly consisted of an extraction method of quality characteristics for large scale injection molding equipment based on design intention, multi-components life balanced planning approach for large scale injection molding equipment, the robust programming of large scale injection molding equipment, repairable design for large scale injection molding equipment based on mixed strategy and the green multi-criteria optimization for product design of large scale injection molding equipment at the end of life. Furthermore, the effective applications on practical projects proved advancement and validity as well.
The main contents of this dissertation are as follows:
Chapter 1 gives the reviews of design for quality and large scale injection molding equipment design. The connotation and current research of design for quality are discussed as well. Based on the analyzing the deficiencies in existing method of design for quality of large scale injection molding equipment, the main ideas and research background of design for quality of large scale injection molding equipment oriented to key quality characteristics are given.
Chapter 2 analyzes the research of design intetion about product, discusses the characteristics of quality conception for complex mechanical products, proposes the concept of design intetion matter-element for complex mechanical products, gives the expression method of design intetion matter-element, and constructs the multidimensional design intetion matter-element model by translated into equivalent 2-tuple type. And then extension evaluating method of multidimensional design intetion matter-element for complex mechanical products is put forward. The instance of model construction and quality evaluating for large scale injection molding equipment is given to illustrate the feasibility of the methods.
Chapter 3 proposes a components life equilibrium planning optimization method based on the analysis and measurement of dynamic effective working-age of component. Based on the mathematical model of product quality characteristics robust optimization design the Pareto set for the multi-objective optimization problem is obtained. The optimal preventive maintenance schedules optimize the life of components to be the same as the design required by replacing or maintaining the components before it failed. It minimizes the total cost of preventive maintenance schedule and the system failure rates of the mechanical product. The efficiency and effectiveness of the proposed method are illustrated by components life equilibrium planning of molded part of large scale injection molding equipment.
Chapter 4 proposes the mathematical model of product quality characteristics robust optimization design based on minimum sensitivity region estimation. A multi-objective optimization approach using generalized differential evolution algorithm is put forward on the foundation of the analysis and measuring of product quality characteristics sensitivity region. The approach obtained the multi-objective robust Pareto optimum solutions which are satisfied with the design requirements and insensitive to parameter variations. The efficiency and effectiveness of the proposed method is illustrated by the product quality characteristics robust optimization design of large scale injection molding equipment.
Chapter 5 proposes the mathematical model is established based on mixed strategy which consisted of maintenance strategy of minimum idle rate and minimum costs of service operations. An optimization process using strength Pareto evolutionary algorithm 2+(SPEA2+) is put forward on the foundation of the analysis and measuring of the characteristics of maintenance and repairs. Based on the mathematical model of product optimization design for maintenance and repairs, the Pareto set for the multi-objective optimization problem is obtained. The multi-objective Pareto-optimal solutions are facilitating service operations. The efficiency and effectiveness of the proposed method is illustrated by the product optimization design for maintenance and repairs of large scale injection molding equipment.
Chapter 6 proposes a mathematical model is established based on synthesis key-green-quality index which is composed of the operation efficiency, the economic costs and the environmental impact by the measurement and analysis of EOL processing. An optimization process is put forward on the foundation of the analysis and measuring of the characteristics of EOL processing. Based on the mathematical model of product optimization design for EOL processing, the Pareto set for the multi-objective optimization problem is obtained using the multi-objective optimization algorithm. The multi-objective Pareto-optimal solutions are facilitating operations of the EOL phase. The efficiency and effectiveness of the proposed method is illustrated by the green multi-criteria optimization for product design project of large scale injection molding equipment.
Chapter 7 develops the large scale injection moulding equipment design system (TH-SIP) oriented quality characteristics with the project requirement and research results, which shows the validity and feasibility of the new theory and method proposed in the dissertation.
Chapter 8 summarizes the key research contents and achievements, and givens conclusions along with recommendations for future research.
论文的主要工作如下：
第一章综述了大型注塑装备的结构和设计发展趋势,阐述了关键质量特性的内涵和保质设计研究现状,分析了现有大型注塑装备的保质设计方法不足,给出了面向关键质量特性的大型注塑装备保质设计的主要思想和研究背景。
第二章分析了产品概念方案中产品设计意图的表达,引入物元理论对设计意图进行形式化描述,为机械产品的设计意图表达提供了统一的形式化描述方式。提出了一种基于二元语义的设计意图驱动的产品关键质量特性偏好决策方法,为设计意图驱动的产品关键质量特性优化提供可靠的分析依据。
第三章面向动态分配提出了以有效工作寿命度量多种预防性维护措施下机械产品关键零部件工作寿命的寿命均衡规划方法。针对产品关键零部件的失效率不一致,导致关键零部件的工作寿命不均衡的问题,构建了机械产品多部件寿命均衡数学模型,通过有限时间区间的机械产品预防性维护优化方案,在机械产品关键零部件发生故障之前实施预防性维护措施减少或消除关键零部件故障的发生,使得机械产品各关键部件的工作寿命趋于均衡,同时满足机械产品可靠性指标与机械产品维护费用指标。
第四章面向多元波动提出了基于最小灵敏域估计的产品关键质量特性稳健设计方法。针对产品设计参数发生变差,导致产品关键质量特性的最优化解变为违反约束条件的问题,定义了产品关键质量特性灵敏域,对产品关键质量特性的稳健性进行度量,建立了基于最小灵敏域估计的产品关键质量特性稳健优化数学模型,提出了多目标产品关键质量特性稳健优化设计流程。在满足产品关键质量特性设计要求的前提下,优化产品关键质量特性同时提高产品关键质量特性对设计参数变差的稳健性。
第五章面向使用维护提出了基于维修效率策略和维修成本策略的混合策略大型注塑装备维修方案设计方法。针对机械产品使用维护阶段关键零部件尤其易损件的维修关键质量特性,构建了基于维修效率策略和维修成本策略的混合策略复杂机械产品维修性能优化数学模型,以维修效率和维修成本度量机械产品的维修性能。采用基于改进的强度Pareto进化算法的复杂机械产品的维修性能设计流程,根据维修性能优化数学模型,求得了多目标维修性能优化问题的Pareto最优解集,并优选出最优解,在优化产品维修效率的同时优化产品维修成本。
第六章面向报废回收提出了报废回收阶段的产品绿色质量指数多准则优化分析方法。从零部件的拆解、零部件的重用加工污染、零部件的回收处理环境影响等多个方面多角度综合考虑对产品设计方案的影响,建立了基于改进产品拆解约束图的机械产品多元拆解模型表达方法,提出了面向报废回收的产品绿色质量指数多准则优化分析方法,构建了基于产品回收拆解效率因子、产品回收拆解作业收益因子和产品回收拆解作业环境影响因子的综合绿色质量指数的复杂机械产品设计方案绿色质量指数多准则优化模型。
第七章结合企业工程项目需求和本文研究成果,开发了面向关键质量特性的HT-SIP大型注塑机保质设计系统,以工程实践验证了所提理论和方法的正确性和可行性。
第八章总结了本文的主要研究内容和成果,并展望了今后的研究工作。
To deal with multi-scale, collaboration, coupling, uncertainty et.al problems in the quality control process of large scale injection moulding equipment, a new technology of design for quality of large scale injection moulding equipment oriented to key quality characteristics is proposed in this dissertation. The assurance measures of key quality characteristics and product design process are integrated of the new technology, which is mainly consisted of an extraction method of quality characteristics for large scale injection molding equipment based on design intention, multi-components life balanced planning approach for large scale injection molding equipment, the robust programming of large scale injection molding equipment, repairable design for large scale injection molding equipment based on mixed strategy and the green multi-criteria optimization for product design of large scale injection molding equipment at the end of life. Furthermore, the effective applications on practical projects proved advancement and validity as well.
The main contents of this dissertation are as follows:
Chapter 1 gives the reviews of design for quality and large scale injection molding equipment design. The connotation and current research of design for quality are discussed as well. Based on the analyzing the deficiencies in existing method of design for quality of large scale injection molding equipment, the main ideas and research background of design for quality of large scale injection molding equipment oriented to key quality characteristics are given.
Chapter 2 analyzes the research of design intetion about product, discusses the characteristics of quality conception for complex mechanical products, proposes the concept of design intetion matter-element for complex mechanical products, gives the expression method of design intetion matter-element, and constructs the multidimensional design intetion matter-element model by translated into equivalent 2-tuple type. And then extension evaluating method of multidimensional design intetion matter-element for complex mechanical products is put forward. The instance of model construction and quality evaluating for large scale injection molding equipment is given to illustrate the feasibility of the methods.
Chapter 3 proposes a components life equilibrium planning optimization method based on the analysis and measurement of dynamic effective working-age of component. Based on the mathematical model of product quality characteristics robust optimization design the Pareto set for the multi-objective optimization problem is obtained. The optimal preventive maintenance schedules optimize the life of components to be the same as the design required by replacing or maintaining the components before it failed. It minimizes the total cost of preventive maintenance schedule and the system failure rates of the mechanical product. The efficiency and effectiveness of the proposed method are illustrated by components life equilibrium planning of molded part of large scale injection molding equipment.
Chapter 4 proposes the mathematical model of product quality characteristics robust optimization design based on minimum sensitivity region estimation. A multi-objective optimization approach using generalized differential evolution algorithm is put forward on the foundation of the analysis and measuring of product quality characteristics sensitivity region. The approach obtained the multi-objective robust Pareto optimum solutions which are satisfied with the design requirements and insensitive to parameter variations. The efficiency and effectiveness of the proposed method is illustrated by the product quality characteristics robust optimization design of large scale injection molding equipment.
Chapter 5 proposes the mathematical model is established based on mixed strategy which consisted of maintenance strategy of minimum idle rate and minimum costs of service operations. An optimization process using strength Pareto evolutionary algorithm 2+(SPEA2+) is put forward on the foundation of the analysis and measuring of the characteristics of maintenance and repairs. Based on the mathematical model of product optimization design for maintenance and repairs, the Pareto set for the multi-objective optimization problem is obtained. The multi-objective Pareto-optimal solutions are facilitating service operations. The efficiency and effectiveness of the proposed method is illustrated by the product optimization design for maintenance and repairs of large scale injection molding equipment.
Chapter 6 proposes a mathematical model is established based on synthesis key-green-quality index which is composed of the operation efficiency, the economic costs and the environmental impact by the measurement and analysis of EOL processing. An optimization process is put forward on the foundation of the analysis and measuring of the characteristics of EOL processing. Based on the mathematical model of product optimization design for EOL processing, the Pareto set for the multi-objective optimization problem is obtained using the multi-objective optimization algorithm. The multi-objective Pareto-optimal solutions are facilitating operations of the EOL phase. The efficiency and effectiveness of the proposed method is illustrated by the green multi-criteria optimization for product design project of large scale injection molding equipment.
Chapter 7 develops the large scale injection moulding equipment design system (TH-SIP) oriented quality characteristics with the project requirement and research results, which shows the validity and feasibility of the new theory and method proposed in the dissertation.
Chapter 8 summarizes the key research contents and achievements, and givens conclusions along with recommendations for future research.
引文
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