基于新一代GPS框架的公差设计理论与方法研究
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摘要
新一代GPS是面向数字化设计、制造与检验的标准与计量信息体系，基于新一代GPS框架进行公差设计理论与方法的研究是该体系建立亟待解决的重要技术问题。本文在全面总结国内外公差设计最新研究成果的基础上，系统研究了新一代GPS框架下公差设计的若干理论和关键技术，主要研究内容和创新点如下：
建立了面向新一代GPS标准体系的公差数学表示模型。根据新一代GPS体系最新的几何要素分类和要素获取的操作方法，借助小位移旋量(Small displacement torsor，SDT)对几何要素的形状、位置、方向和尺寸偏差进行定量的描述，研究了基于SDT的公差数学模型，为进一步探讨一维到三维的公差设计技术奠定了理论基础。
提出了面向三维尺寸公差和几何公差的综合设计方法。探讨了各种公差区域和各种连接的SDT的描述方法；基于新一代GPS表面模型的概念，提出用表面模型来实现对装配体的描述，并且借助于小位移旋量确定装配体任意表面之间的相对位置；为了计算任意两表面间的旋量，定义了两种操作规则：顺序运算和并行运算；基于各个功能要素对于整个装配功能要求的影响，创建三维公差设计尺寸链，实现三维尺寸公差和几何公差的综合设计；给出三维公差设计实例对所提出的方法加以验证。
研究了基于矢量环模型的包括几何特征变动在内的三维公差分析技术。鉴于新一代GPS体系与CAD／CAPP／CAM／CAQ技术集成的需要，建立了基于矢量环的公差分析模型；研究了零件尺寸特征变动、几何特征变动和装配运动学调整对于整个装配公差累积的影响，并把这些影响集成于公差分析模型以实现包括几何特征变动在内的三维公差分析；分别给出了二维和三维装配工程实例验证所提出公差分析模型的有效性。
基于新一代GPS并行设计的思想，提出了面向多重相关特征产品的并行公差设计方法。在对零件的加工工序规划进行深入分析的基础上，重点推导了多重相关特征产品的质量损失与有关零件工序公差的函数关系；建立了基于制造成本-质量损失的设计公差和工序公差的并行优化设计模型，实现基于提高产品质量和降低成本的并行优化公差设计；圆锥齿轮装配的并行公差设计实例验证了所提出的设计方法。
提出了新一代GPS面向产品全生命周期的公差优化设计模型。考虑产品质量特征随着时间退化的影响，用多变量质量损失函数在连续复利条件下把产品特征的退化作为一个连续的现金流量函数进行建模，从而建立了相关特征产品的期望质量损失现值与其公差的函数关系；在此基础上把质量损失的现值和产品随时间退化的影响集成到总成本模型中，提出了新的相关特征产品公差优化设计模型；一个板簧公差设计的实例验证了推荐模型的有效性。
开发了新一代GPS框架下公差设计原型系统。该系统是以AutoCAD2007为开发平台，采用开发工具是ObjectARX、Visual C++等，并用工程实例验证了该系统的有效性。
New generation GPS standards system is an information system of standard & metrology oriented the digitizing design, manufacturing and verification. The study on theory and methodology of tolernace design within the framework of the new generation GPS system has become the very important technology issue, which is in urgent need to settle during the course of establishing the system. On the basis of summarizing the latest research results in tolerancing both of at home and abroad, this dissertation aims to solve the key theories and technique problems on tolerance design currently unsolved in the GPS system. The main researches and creative points are as follows:
A mathematical representation model of tolerance has been established oriented the new generation GPS system. According to the geometrical feature types and the operation methods extracting features newly defined in the GPS system, the SDT-based mathematical model of tolerance is studied by using the small displacement torsors (SDT) to characterize the deviations of shape, position, orientation and size of geometrical featrues. It also establishes theoretical basis for tolerance design from 1-D to 3-D assemblies, which is further studied in the following chapters.
A comprehensive method of tolerance design for 3-D dimensional tolerances and geometrical tolerances is proposed. The description methods of various tolerance zones and kinematic links based on SDT are studied. Based on the surface model concept newly presented in new generation GPS system, we apply surface models to describe an assembly, and use the SDT to express the relative position between any two surfaces of an assembly. In order to determine the torsor between any two surfaces, two governing rules are defined: the union and the intersection. Based on the effect of each functional element on the whole functional requirements of products, the 3-D dimension-chain is created, and 3-D dimensional and geometrical tolerance design is realized. The engineering examples involving 3-D tolerance design are given to test the proposed method.
Three-dimensional tolerance analysis technique based on the vector-loop tolerance model including the geometric feature variations is studied. In view of the needs for the new generation GPS system to integrate with CAD/CAPP/CAM/CAQ techniques, the tolerance analysis model based on the vector-loop is established at first. The discussions focus on the effects of dimensional variations and geometric feature variations of each individual component in the assembly, and variations due to small kinematic adjustments among components which occur at assembly time. And the effects of all variations are integrated in the tolerance analysis model so as to realize 3-D tolerance analysis including all geometric feature variations. The tolerance analysis examples of 2-D and 3-D assemblies are given to demonstrate the effectiveness of the proposed model, respectively.
A concurrent tolerance design method for the products with correlated characteristics is presented based on the concept of concurrent engineering in the new generation GPS. On the basis of analyzing in detail manufacturing process plans of parts, the functional relationship between quality loss of products with correlated characteristics and process tolerances of correlated parts is derived. And a comprehensive model to concurrently allocate optimal design and process tolerances based on minimizing the combination of quality loss and manufacturing cost is established so that the concurrent tolerance design is realized, and product quality improvement and cost reduction are achieved. An example of the bevel gear assembly involving concurrent tolerance design is given to verify the presented method.
An optimal tolerance design model for product life cycle is proposed within the frame of the new generation GPS system. Considering product degradation on quality characteristics over time, the multivariate quality loss function is used to model quality loss due to product degradation as a continuous cash flow function under continuous compounding. As a result, the functional relationship between the present worth of expected loss of product with correlated characteristics and its related tolerances is derived. The present worth of quality loss and product degradation over time is integrated into the total cost model, and a new optimization model for the tolerance design of products with correlated characteristics is presented. An example of the leaf spring involving optimal tolerance design is given to demonstrate the effectiveness of the proposed model.
A prototype system for tolerance design within the framework of the new generation GPS system is developed. The software platform of the system is based on AutoCAD2007, development tools adopted involve ObjectARX, Visual C++ etc. The engineering examples are studied to demonstrate the effectiveness of this system.
建立了面向新一代GPS标准体系的公差数学表示模型。根据新一代GPS体系最新的几何要素分类和要素获取的操作方法，借助小位移旋量(Small displacement torsor，SDT)对几何要素的形状、位置、方向和尺寸偏差进行定量的描述，研究了基于SDT的公差数学模型，为进一步探讨一维到三维的公差设计技术奠定了理论基础。
提出了面向三维尺寸公差和几何公差的综合设计方法。探讨了各种公差区域和各种连接的SDT的描述方法；基于新一代GPS表面模型的概念，提出用表面模型来实现对装配体的描述，并且借助于小位移旋量确定装配体任意表面之间的相对位置；为了计算任意两表面间的旋量，定义了两种操作规则：顺序运算和并行运算；基于各个功能要素对于整个装配功能要求的影响，创建三维公差设计尺寸链，实现三维尺寸公差和几何公差的综合设计；给出三维公差设计实例对所提出的方法加以验证。
研究了基于矢量环模型的包括几何特征变动在内的三维公差分析技术。鉴于新一代GPS体系与CAD／CAPP／CAM／CAQ技术集成的需要，建立了基于矢量环的公差分析模型；研究了零件尺寸特征变动、几何特征变动和装配运动学调整对于整个装配公差累积的影响，并把这些影响集成于公差分析模型以实现包括几何特征变动在内的三维公差分析；分别给出了二维和三维装配工程实例验证所提出公差分析模型的有效性。
基于新一代GPS并行设计的思想，提出了面向多重相关特征产品的并行公差设计方法。在对零件的加工工序规划进行深入分析的基础上，重点推导了多重相关特征产品的质量损失与有关零件工序公差的函数关系；建立了基于制造成本-质量损失的设计公差和工序公差的并行优化设计模型，实现基于提高产品质量和降低成本的并行优化公差设计；圆锥齿轮装配的并行公差设计实例验证了所提出的设计方法。
提出了新一代GPS面向产品全生命周期的公差优化设计模型。考虑产品质量特征随着时间退化的影响，用多变量质量损失函数在连续复利条件下把产品特征的退化作为一个连续的现金流量函数进行建模，从而建立了相关特征产品的期望质量损失现值与其公差的函数关系；在此基础上把质量损失的现值和产品随时间退化的影响集成到总成本模型中，提出了新的相关特征产品公差优化设计模型；一个板簧公差设计的实例验证了推荐模型的有效性。
开发了新一代GPS框架下公差设计原型系统。该系统是以AutoCAD2007为开发平台，采用开发工具是ObjectARX、Visual C++等，并用工程实例验证了该系统的有效性。
New generation GPS standards system is an information system of standard & metrology oriented the digitizing design, manufacturing and verification. The study on theory and methodology of tolernace design within the framework of the new generation GPS system has become the very important technology issue, which is in urgent need to settle during the course of establishing the system. On the basis of summarizing the latest research results in tolerancing both of at home and abroad, this dissertation aims to solve the key theories and technique problems on tolerance design currently unsolved in the GPS system. The main researches and creative points are as follows:
A mathematical representation model of tolerance has been established oriented the new generation GPS system. According to the geometrical feature types and the operation methods extracting features newly defined in the GPS system, the SDT-based mathematical model of tolerance is studied by using the small displacement torsors (SDT) to characterize the deviations of shape, position, orientation and size of geometrical featrues. It also establishes theoretical basis for tolerance design from 1-D to 3-D assemblies, which is further studied in the following chapters.
A comprehensive method of tolerance design for 3-D dimensional tolerances and geometrical tolerances is proposed. The description methods of various tolerance zones and kinematic links based on SDT are studied. Based on the surface model concept newly presented in new generation GPS system, we apply surface models to describe an assembly, and use the SDT to express the relative position between any two surfaces of an assembly. In order to determine the torsor between any two surfaces, two governing rules are defined: the union and the intersection. Based on the effect of each functional element on the whole functional requirements of products, the 3-D dimension-chain is created, and 3-D dimensional and geometrical tolerance design is realized. The engineering examples involving 3-D tolerance design are given to test the proposed method.
Three-dimensional tolerance analysis technique based on the vector-loop tolerance model including the geometric feature variations is studied. In view of the needs for the new generation GPS system to integrate with CAD/CAPP/CAM/CAQ techniques, the tolerance analysis model based on the vector-loop is established at first. The discussions focus on the effects of dimensional variations and geometric feature variations of each individual component in the assembly, and variations due to small kinematic adjustments among components which occur at assembly time. And the effects of all variations are integrated in the tolerance analysis model so as to realize 3-D tolerance analysis including all geometric feature variations. The tolerance analysis examples of 2-D and 3-D assemblies are given to demonstrate the effectiveness of the proposed model, respectively.
A concurrent tolerance design method for the products with correlated characteristics is presented based on the concept of concurrent engineering in the new generation GPS. On the basis of analyzing in detail manufacturing process plans of parts, the functional relationship between quality loss of products with correlated characteristics and process tolerances of correlated parts is derived. And a comprehensive model to concurrently allocate optimal design and process tolerances based on minimizing the combination of quality loss and manufacturing cost is established so that the concurrent tolerance design is realized, and product quality improvement and cost reduction are achieved. An example of the bevel gear assembly involving concurrent tolerance design is given to verify the presented method.
An optimal tolerance design model for product life cycle is proposed within the frame of the new generation GPS system. Considering product degradation on quality characteristics over time, the multivariate quality loss function is used to model quality loss due to product degradation as a continuous cash flow function under continuous compounding. As a result, the functional relationship between the present worth of expected loss of product with correlated characteristics and its related tolerances is derived. The present worth of quality loss and product degradation over time is integrated into the total cost model, and a new optimization model for the tolerance design of products with correlated characteristics is presented. An example of the leaf spring involving optimal tolerance design is given to demonstrate the effectiveness of the proposed model.
A prototype system for tolerance design within the framework of the new generation GPS system is developed. The software platform of the system is based on AutoCAD2007, development tools adopted involve ObjectARX, Visual C++ etc. The engineering examples are studied to demonstrate the effectiveness of this system.
引文
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