基于eM-Engineer的车身焊装车间人机工程仿真研究
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摘要
人机工程学把人—机—环境系统作为一个统一的整体来研究,以创造适合于人操作的机械设备和作业环境,使人—机—环境系统相协调,从而保证人安全、健康、高效、舒适的工作状态。随着社会的发展、科学技术的进步,人们对工作和生活质量的要求越来越高,人机工程学的应用也越来越快捷、准确。本文应用人机工程学仿真技术以及人机工程学的理论与方法,评估了某汽车企业车身焊装生产车间的人机工程现状,对典型人机工程问题进行分析,并提出了可行的改善方案,实践证明改善效果明显。
本文首先通过计算机辅助人机工程学、人机工程原理与分析方法和焊装工位建模仿真技术的总结,引入了eM-Engineer仿真软件。接着在eM-Engineer软件中构建了焊装工位的三维虚拟模型并仿真工人操作的全过程,还原生产现场真实场景。
本文通过计算机仿真,并结合人机工程理论,分析并改善了焊装车间内人机状况较差的工位上的具体问题:(1)设计了一种具有宜人结构的车门外板物料架,使工人取外板的动作更舒适,减轻了工人的劳动强度,整个操作的动作数和时间也减少了一半;(2)引入了机械吊具解决车门的双人手工搬运问题,减轻了工人负荷;(3)设计了一种无遮挡、梯形结构的物料箱,将物料在箱内按层排列,工人能轻松的抓起物料,不需寻找、弯腰;(4)在工位上增加锤的喇叭型套筒支架和砂轮的支架,改善了工人在取放工具时必须寻找、弯腰的问题;(5)在工位上增加工业吹风机,由工人手持将散落在外板上的焊渣吹落,避免了非常困难的手举外板抖落焊渣的动作;(6)更换了一种滑动式的焊枪悬挂锁链,简化了工人旋转焊枪的多余动作,缩短了作业时间。
最后,本文借助eM-Engineer软件的人机工程分析工具,讨论了影响劳动负荷的因素;引入了模糊层次分析法,对不同工种的工人在正常工作时所承受的劳动负荷进行评价,得到了满意的评价结果;然后,根据评价的结果及经验,提出了保持工人最佳劳动负荷的方法。
Operators-machines-condition system is considered as a unified whole in ergonomics, so that the equipment and condition that adapt for human are created and the operators-machines-condition system is corresponded, so as to ensure a safe, healthy, high-effective, and comfortable working status. With the development of society and science, more and more people begin to realize the importance of work safety and life quality, and application of ergonomics has also become increasingly convenient and accurate. This paper applies the simulation technology and theory in ergonomics. The situation of car body welding workshops in a motor company is evaluated. Typical ergonomics problems in the situation are analyzed and improvements for these problems are carried out. Through the contrast and analysis between old and new project, the improvement effect is obvious.
First and foremost, this paper analyzes and summarizes the computer-aided ergonomics (CAE), ergonomics and welding workstation modeling and simulation technology. The eM-Engineer software is introduced to build a 3D virtual model for welding workstation and simulate the operations of workers.
Second, the following ergonomics problems are analyzed and improved one by one based on computer simulation and theory in ergonomics. (1) A car door plate shelf whose structure is improved is designed. It makes the operations of getting plates comfortable and reduces workers' labor intensity. The number of actions and the time are reduced by half, too. (2) A hanger is introduced to solve the problem of manual material handling and reduce workers' workload. (3) A ladder structure material box without walls is designed. The materials are arranged by layers in this box. So the workers can easily get the materials without searching and bending. (4) A horn-type sleeve for hammer and a bracket for grinding wheel are added in the workstations so that the worker gets the tools without searching and bending. (5) An industrial blower is added in the workstation so that the worker can hold it and clear the welding slag scattered on the door plate. Thus, the actions of shaking off slag by hands can be avoided. (6) A sliding-type hanging chain for welding gun is introduced to simplify the redundant motions of rotating gun and shorten the operating time.
Finally, with the help of ergonomics analysis tool of eM-Engineer software, this paper discusses the factors that affect the workload. A method for evaluating workloads of workers in different types of work is introduced by applying the fuzzy analytic hierarchy process (FAHP). The evaluation results are approving widely. Then, a method to maintain the optimal workload is introduced based on the evaluation results and experience.
本文首先通过计算机辅助人机工程学、人机工程原理与分析方法和焊装工位建模仿真技术的总结,引入了eM-Engineer仿真软件。接着在eM-Engineer软件中构建了焊装工位的三维虚拟模型并仿真工人操作的全过程,还原生产现场真实场景。
本文通过计算机仿真,并结合人机工程理论,分析并改善了焊装车间内人机状况较差的工位上的具体问题:(1)设计了一种具有宜人结构的车门外板物料架,使工人取外板的动作更舒适,减轻了工人的劳动强度,整个操作的动作数和时间也减少了一半;(2)引入了机械吊具解决车门的双人手工搬运问题,减轻了工人负荷;(3)设计了一种无遮挡、梯形结构的物料箱,将物料在箱内按层排列,工人能轻松的抓起物料,不需寻找、弯腰;(4)在工位上增加锤的喇叭型套筒支架和砂轮的支架,改善了工人在取放工具时必须寻找、弯腰的问题;(5)在工位上增加工业吹风机,由工人手持将散落在外板上的焊渣吹落,避免了非常困难的手举外板抖落焊渣的动作;(6)更换了一种滑动式的焊枪悬挂锁链,简化了工人旋转焊枪的多余动作,缩短了作业时间。
最后,本文借助eM-Engineer软件的人机工程分析工具,讨论了影响劳动负荷的因素;引入了模糊层次分析法,对不同工种的工人在正常工作时所承受的劳动负荷进行评价,得到了满意的评价结果;然后,根据评价的结果及经验,提出了保持工人最佳劳动负荷的方法。
Operators-machines-condition system is considered as a unified whole in ergonomics, so that the equipment and condition that adapt for human are created and the operators-machines-condition system is corresponded, so as to ensure a safe, healthy, high-effective, and comfortable working status. With the development of society and science, more and more people begin to realize the importance of work safety and life quality, and application of ergonomics has also become increasingly convenient and accurate. This paper applies the simulation technology and theory in ergonomics. The situation of car body welding workshops in a motor company is evaluated. Typical ergonomics problems in the situation are analyzed and improvements for these problems are carried out. Through the contrast and analysis between old and new project, the improvement effect is obvious.
First and foremost, this paper analyzes and summarizes the computer-aided ergonomics (CAE), ergonomics and welding workstation modeling and simulation technology. The eM-Engineer software is introduced to build a 3D virtual model for welding workstation and simulate the operations of workers.
Second, the following ergonomics problems are analyzed and improved one by one based on computer simulation and theory in ergonomics. (1) A car door plate shelf whose structure is improved is designed. It makes the operations of getting plates comfortable and reduces workers' labor intensity. The number of actions and the time are reduced by half, too. (2) A hanger is introduced to solve the problem of manual material handling and reduce workers' workload. (3) A ladder structure material box without walls is designed. The materials are arranged by layers in this box. So the workers can easily get the materials without searching and bending. (4) A horn-type sleeve for hammer and a bracket for grinding wheel are added in the workstations so that the worker gets the tools without searching and bending. (5) An industrial blower is added in the workstation so that the worker can hold it and clear the welding slag scattered on the door plate. Thus, the actions of shaking off slag by hands can be avoided. (6) A sliding-type hanging chain for welding gun is introduced to simplify the redundant motions of rotating gun and shorten the operating time.
Finally, with the help of ergonomics analysis tool of eM-Engineer software, this paper discusses the factors that affect the workload. A method for evaluating workloads of workers in different types of work is introduced by applying the fuzzy analytic hierarchy process (FAHP). The evaluation results are approving widely. Then, a method to maintain the optimal workload is introduced based on the evaluation results and experience.
引文
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[31]Karhu O,Kansi P,Kuorinka I.Correcting working postures in industry:a practical method for analysis[J].Applied Ergonomics.1977,8(4):199-201.
[32]Sporrong H,Sandsj(o|¨) L,Kadefors R,et al.Assessment of workload and arm position during different work sequences:a study with portable devices on construction workers[J].Applied Ergonomics.1999,(30):495-503.
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[34]Chung M K,Kee D.Evaluation of lifting tasks frequently performed during fire brick manufacturing processes using NIOSH lifting equations[J].International Journal of Industrial Ergonomics.2000,25:423-433.
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[38]彭晓武.VDT作业脑力劳动负荷评价的实验研究[D].华中科技大学博士学位论文.2006:12-13.
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[2]Robin H,Jonathan D,Nick W,et al.Impact of a joint labormanagement ergonomics program on upper extremity musculoskeletal symptoms among garment workers[J].Applied Ergonomics.2001,32(5):453-460.
[3]朱序璋.人机工程学[M].西安:西安电子科技大学出版社,1999:1-2.
[4]王秀玲.人机工程学的应用与发展[J].机械设计与制造.2007,1(1):151-152.
[5]俞碧华.人机工程学在SGM汽车工程项目中的设计与实践应用[D].上海交通大学硕士学位论文.2001:2.
[6]罗仕鉴,孙守迁,唐明晰,等.计算机辅助人机工程设计研究[J].浙江大学学报(工学版).2005,39(6):806-809.
[7]徐孟,孙守迁.计算机辅助人机工程研究进展[J].计算机辅助设计与图形学学报.2004,16(11):1469-1474.
[8]Chung M K,Lee I,Kee D,et al.A Postural Workload Evaluation System Based on a Macro-postural Classification[J].Human Factors and Ergonomics in Manufacturing.2002,12(3):267-277.
[9]Messing K,Kilbom(?).Standing and very slow walking:foot pain-pressure threshold,subjective pain experience and work activity[J].Applied Ergonomics.2001,32(1):81-90.
[10]Sue A F,William S M,Burr D.Workplace design guidelines for asymptomatic vs.low-back-injured workers[J].Applied Ergonomics.2005,36(1):85-95.
[11]Cote H J,Coury G.Time trends in ergonomic intervention research for improved musculoskeletal health and comfort in Latin America[J].Applied Ergonomics.2005,36(2):249-252.
[12]St-Vincent M,Denis D,Imbeau D,et al.Work factors affecting manual materials handling in a warehouse superstore[J].International Journal of Industrial Ergonomics.2005,35(1):33-46.
[13]庞新福,杜茂华.基于工业工程中模特法的动作研究[J].机电产品开发与创新.2007,20(3):28-30.
[14]Santos J,Sarriegi J M,Serrano N,et al.Using ergonomic software in non-repetitive manufacturing processes:A case study[J].International Journal of Industrial Ergonomics.2007,37(3):267-275.
[15]L(a|¨)mkull D,Hanson L,(O|¨)rtengren R.A comparative study of digital human modeling simulation results and their outcomes in reality:A case study within manual assembly of automobiles[J].International Journal of Industrial Ergonomics.2008,39:428-441.
[16]朱传敏,袁双喜.基于eM-Human的人机工程仿真与分析的实现[J].现代制造工程.2007,(8):57-60.
[17]徐明芳,蒋祖华,胥志峰.轿车前纵梁总成工序的人机工程研究[J].人类工效学.2006,12(4):21-23.
[18]姜海涛,邓友银.虚拟装配环境的构建与应用[J].先进制造与管理.2007,26(4):24-25.
[19]胥志峰,蒋祖华,韦进.汽车装配生产线手工搬运作业的工效学分析[J].人类工效学.2006,12(4):4-7.
[20]易树平,郭伏.基础工业工程[M].北京:机械工业出版社,2005:245.
[21]周密.IE方法实战精解[M].广州:广东经济出版社,2003:47.
[22]刘胜军.精益生产现代IE[M].深圳:海天出版社,2003:50-51.
[23]李永锋,许映秋.计算机辅助人机工程在人性化工厂设计中的应用[J].机械制造与自动化.2007,36(2):17-20.
[24]Tecnomatix.eM-Engineer 7.6 Reference Manual.
[25]沙尔文迪.工业工程手册(第1分册)[M].郑力,李从东.第三版.北京:清华大学出版社,2005:319.
[26]Kazuaki I,Masahiko O,Koji T,et al.Virtual manufacturing systems as advanced information infrastructure for integrating manufacturing resources and activities[J].CIRP Annals.1997,46(1):335-338.
[27]Kimura F.Product and Process Modeling as a Kernel for Virtual Manufacturing Environment[J].Annals of the CIRP.1993,42(1):147-150.
[28]Weyrich M,Drews P.An Interactive environment for virtual manufacturing:the virtual workbench[J].Computer in Industry.1999,38(1):5-15.
[29]严隽琪,范秀敏,马登哲.虚拟制造的理论、技术基础与实践[M].上海:上海交通大学出版社,2003:98-99.
[30]邵立,钟廷修,严隽琪,等.虚拟制造环境与仿真[J].中国机械工程.2000,11(8):919-922.
[31]Karhu O,Kansi P,Kuorinka I.Correcting working postures in industry:a practical method for analysis[J].Applied Ergonomics.1977,8(4):199-201.
[32]Sporrong H,Sandsj(o|¨) L,Kadefors R,et al.Assessment of workload and arm position during different work sequences:a study with portable devices on construction workers[J].Applied Ergonomics.1999,(30):495-503.
[33]张献宝.人机工程设计的虚拟现实人开发与应用研究[D].西北工业大学硕士学位论文.1999:53-55.
[34]Chung M K,Kee D.Evaluation of lifting tasks frequently performed during fire brick manufacturing processes using NIOSH lifting equations[J].International Journal of Industrial Ergonomics.2000,25:423-433.
[35]程灏.工业工程导论[M].北京:化学工业出版社,2004:84.
[36]丁玉兰.人因工程学[M].上海:上海交通大学出版社,2004:35-36.
[37]周美玉.工业设计应用人类工程学[M].北京:中国轻工业出版社,2001:50.
[38]彭晓武.VDT作业脑力劳动负荷评价的实验研究[D].华中科技大学博士学位论文.2006:12-13.
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