面向复杂机电产品的模块化产品平台设计方法学研究
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摘要
随着经济全球化以及产品多样化的发展,先进的设计制造模式、现代管理方法以及高级信息技术的应用成为制造企业改革的必然趋势。大批量定制是当今制造企业广泛推崇的生产模式,模块化产品平台能够对其提供良好的支持。但模块化产品平台作为一种先进而系统的设计管理方式,需要建立在系统论及先进设计方法学的基础上。本文以复杂机电产品为对象,在深入分析模块化理论与设计方法学研究现状后,提出了构建模块化产品平台的多层次方法学体系及实施过程模型。对不同模块化层次中的关键问题进行了深入研究,并结合实际项目对已有产品模块化进行了方法学的验证和应用实施。
第一章结合哲学思想对方法学的产生、发展和成果进行了论述,探讨了设计方法学的相关概念和定义,对设计方法学研究现状进行了评述,并对系统化设计、公理设计以及TRIZ理论等主流的设计理论进行了比较分析。在此基础上,对模块化设计的相关定义与概念进行了明确,结合模块化以及设计方法学方面的研究成果提出了模块化设计的方法学策略。最后,总结了模块化设计方法学研究的必要性和创新性,给出了论文的主要内容和组织架构。
第二章首先从模块化理论、系统设计方法以及PDM发展三方面对模块化设计方法的需求进行了分析。对本文涉及的已有产品、新产品、产品平台、产品族、模块类型以及模块化产品平台等概念进行了定义,并提出了以已有产品为对象的模块化产品平台建模体系。围绕该体系,在深入分析模块化产品平台特点的基础上,从方法层、技术层以及数据层对模块化设计方法中的关键技术进行了明确。将技术体系与模块化产品平台模型相结合,提出了基于模块化主结构提取过程的已有产品多层次设计过程模型。
第三章对已有产品的产品层模块化设计过程进行了建模,并对新产品的产品层模块化进行了比较研究。分阶段地分析了产品层模块化的特点、各阶段的目标以及目标实现的具体方法。针对过程中的产品平台划分评价的问题,本文通过计算产品族复杂网络的节点总介数与平均介数确定节点在网络中和产品实例中的重要性,同时结合产品功能分析的结果提炼出平台关键节点。通过计算关联度,确定平台内的其它节点,并采用信息公理评价备选平台的性能,实现循环的设计过程。本章最后从产品层面对已有产品和新产品模块化产品主结构的生成、演变过程进行了对比。
第四章对已有产品的部件层／零件层模块化设计过程进行了建模,并对新产品进行了比较研究,讨论了产品层、部件层、零件层模块化的关系。分阶段地阐述了部件层／零件层模块化的特点、各阶段的目标以及目标实现的具体方法。对ATO、MTO和ETO模块进行了定义,深入分析了已有产品中ATO和MTO模块在设计过程中特点和设计方法差异。针对模块划分后的评价问题,提出了基于全生命周期的产品模块模糊评价方法。首先对生命周期评价要素进行建模,提出了模块评价的生命周期七要素,然后采用三角模糊数进行模块的综合评价。
第五章针对新产品模块化概念设计过程中的原理解、变型解及其组合方法进行了深入研究,基于发明问题解决原理(TRIZ)和形态学方法在产品设计原理求解中具有的时序相关性与功能互补性,提出了集成形态学矩阵和TRIZ原理的设计过程模型。将形态学分析的适用范围拓展到概念层,展开原理解的组合性分析；将冲突解决原理在原理解的产生与设计解耦两方面进行综合应用。并以手持电钻和手动剃须刀的创新研发过程为例,验证了面向新设计的双矩阵应用过程以及面向变型设计的嵌套子循环实现过程,证明了该模型及方法在针对不同设计问题时的灵活性与可操作性。
第六章将本文的模块化产品平台设计过程模型以及相应的关键技术、方法在某工程机械企业进行了验证和实施。从产品层、部件层、零件层提取了5吨轮式装载机的产品模块化主结构,进而形成相应的模块化产品平台。并对其中的产品平台划分、模块模糊评价等关键阶段进行了轮式装载机实践。在此基础上构建了模块化方案支持系统,从数据模型、文档模型及过程模型三方面实现对本文理论推广和实施的支持。
第七章对全文工作进行了总结,并对后续研究工作进行了展望。
With the developing of economic globalization and product diversification, the application of advanced design and manufacturing model, modern management methods and advanced information technology is becoming the inevitable trend of manufacturing enterprise reform. Mass customization is widely respected in today's manufacturing production, and modular product platform can provide it well. However, as an advanced and systematic design management method, modular product platform needs to be based on advanced design methodology and system theory. In this paper, taking the complex mechanical and electrical products as object, on the thorough analysis of the research status of modular theory and design methodology, it puts forward the multi-level methodology system and implement process model for modular product platform (facing existing product and new product) construction. And it researchs on the key problems in different modular levels, then does the validation of the modular methodology and application of the product modularization with an actual project for existing products.
In chapterⅠ, it discusses the production, the development and the achievement of methodology from the philosophical level, and the related concepts and definition of design methodology are extended. Then it evaluates the research status of methodology in different country from time and space, and does comparative analysis between mainstream design theory including systematic design, axiomatic design and TRIZ theory. On this basis, it makes the definition and the related concepts of modular design clear, and combined the modular with the study of design methodology, so that the methodology strategy for modular design is proposed. Finally, summarizes the necessity and innovation of research on modular design methodology, and gives the main content and structure of this paper.
In chapterⅡ, it firstly analyses the demands of the modular design method based on modularization theory, system design method and PDM development. Then defines the concept of existing products, new products, product platform, product family, module type and modular product platform etc., which are involved in this paper, and puts forward modular product platform modeling system oriented to existing products. Around the system, based on the thorough analysis of modular products platform characteristics, it makes the key technologies clear from method layer, technical layer and data layer. After the combination of technology system and modular product platform model, it proposes the existing products'multi-level design process model which based on the extraction process of the modular main structure.
In chapterⅢ, it builds a model of existing products'modular design process in product level, and does comparative study to the new products. It analyses the characteristics of modularization in product level, the goal of each stage and methods to achieve the goals stage by stage. For the problem of product platform division and evaluation, it determines the importance of each node by using the total and average betweennesses of nodes in structure net of product family, and gets the key platform nodes with results of function analysis. Then it gets other important nodes by calculating the correlative coefficient between them and key nodes. Using the information axiom evaluates the alternative platforms at last, and realizes the design loop. At the end of this chapter, compares existing products with new products in the formation and evolution process of modular product main structure on product level.
In ChapterⅣ, it does modeling for modularization design process on components level and parts level for existing products. Then it deals with a comparative study between existing products and new products, and discusses the relationship of modularization among products level, components level and parts level. The characteristics of components level modularization and parts level modularization, the goal of each stage and specific methods to achieve the goal are elaborated by stages as well. This chapter defines ATO module, MTO module and ETO module, and analyzes deeply differences between characteristics and design methods in design process of ATO module and MTO module. For evaluation problem after module division, product module fuzzy evaluation method based on the product life cycle is proposed. First of all, it does modeling for life cycle assessment elements and puts forward seven elements of life cycle for module evaluation, then evaluate comprehensively modules by means of triangular fuzzy numbers.
In ChapterⅤ, Based on the temporal correlation and function complement between morphological methods and theory of inventive problem solving (TRIZ) on generating and analyzing the principle solutions in product design process, a double-matrix integrated model which combines morphological matrix and contradiction matrix is proposed,. The model consists of concept model, process model and related model, and follows a top-down spiral design approach. The applicable scope of morphological analysis is extended to concept level by the model, so that the combination capability of principle solutions can be analyzed; the contradiction resolving principles is used on generating solutions and solving design decoupling. Taking the research on the innovative development process of a hand driller and manual razer as examples, it validates the application process of double-matrix on new product design and the implementation of the nested sub-cycle on variant design, and proves the flexibility and operability of the model when facing deferent designing problems.
In ChapterⅥ, it validates and implements this modular product platform design process model and corresponding key technologies, methods in a state-owned construction machinery enterprise. From the products level, components level and parts level, it extracted the main product modular structure of the five-ton wheel loaders, and then formed the corresponding modular product platform. And it practises the product platform division phase and fuzzy evaluation method for modules on wheel loader. On this basis, the modularization planning system is built. It supports the promotion and implementation of theory in this paper by the data model, document model and process model.
The last chapter is conculsion and outlook. The achievements of the dissertation were summarized, and the innovations were pointed. The future research works were put forward to outlook.
第一章结合哲学思想对方法学的产生、发展和成果进行了论述,探讨了设计方法学的相关概念和定义,对设计方法学研究现状进行了评述,并对系统化设计、公理设计以及TRIZ理论等主流的设计理论进行了比较分析。在此基础上,对模块化设计的相关定义与概念进行了明确,结合模块化以及设计方法学方面的研究成果提出了模块化设计的方法学策略。最后,总结了模块化设计方法学研究的必要性和创新性,给出了论文的主要内容和组织架构。
第二章首先从模块化理论、系统设计方法以及PDM发展三方面对模块化设计方法的需求进行了分析。对本文涉及的已有产品、新产品、产品平台、产品族、模块类型以及模块化产品平台等概念进行了定义,并提出了以已有产品为对象的模块化产品平台建模体系。围绕该体系,在深入分析模块化产品平台特点的基础上,从方法层、技术层以及数据层对模块化设计方法中的关键技术进行了明确。将技术体系与模块化产品平台模型相结合,提出了基于模块化主结构提取过程的已有产品多层次设计过程模型。
第三章对已有产品的产品层模块化设计过程进行了建模,并对新产品的产品层模块化进行了比较研究。分阶段地分析了产品层模块化的特点、各阶段的目标以及目标实现的具体方法。针对过程中的产品平台划分评价的问题,本文通过计算产品族复杂网络的节点总介数与平均介数确定节点在网络中和产品实例中的重要性,同时结合产品功能分析的结果提炼出平台关键节点。通过计算关联度,确定平台内的其它节点,并采用信息公理评价备选平台的性能,实现循环的设计过程。本章最后从产品层面对已有产品和新产品模块化产品主结构的生成、演变过程进行了对比。
第四章对已有产品的部件层／零件层模块化设计过程进行了建模,并对新产品进行了比较研究,讨论了产品层、部件层、零件层模块化的关系。分阶段地阐述了部件层／零件层模块化的特点、各阶段的目标以及目标实现的具体方法。对ATO、MTO和ETO模块进行了定义,深入分析了已有产品中ATO和MTO模块在设计过程中特点和设计方法差异。针对模块划分后的评价问题,提出了基于全生命周期的产品模块模糊评价方法。首先对生命周期评价要素进行建模,提出了模块评价的生命周期七要素,然后采用三角模糊数进行模块的综合评价。
第五章针对新产品模块化概念设计过程中的原理解、变型解及其组合方法进行了深入研究,基于发明问题解决原理(TRIZ)和形态学方法在产品设计原理求解中具有的时序相关性与功能互补性,提出了集成形态学矩阵和TRIZ原理的设计过程模型。将形态学分析的适用范围拓展到概念层,展开原理解的组合性分析；将冲突解决原理在原理解的产生与设计解耦两方面进行综合应用。并以手持电钻和手动剃须刀的创新研发过程为例,验证了面向新设计的双矩阵应用过程以及面向变型设计的嵌套子循环实现过程,证明了该模型及方法在针对不同设计问题时的灵活性与可操作性。
第六章将本文的模块化产品平台设计过程模型以及相应的关键技术、方法在某工程机械企业进行了验证和实施。从产品层、部件层、零件层提取了5吨轮式装载机的产品模块化主结构,进而形成相应的模块化产品平台。并对其中的产品平台划分、模块模糊评价等关键阶段进行了轮式装载机实践。在此基础上构建了模块化方案支持系统,从数据模型、文档模型及过程模型三方面实现对本文理论推广和实施的支持。
第七章对全文工作进行了总结,并对后续研究工作进行了展望。
With the developing of economic globalization and product diversification, the application of advanced design and manufacturing model, modern management methods and advanced information technology is becoming the inevitable trend of manufacturing enterprise reform. Mass customization is widely respected in today's manufacturing production, and modular product platform can provide it well. However, as an advanced and systematic design management method, modular product platform needs to be based on advanced design methodology and system theory. In this paper, taking the complex mechanical and electrical products as object, on the thorough analysis of the research status of modular theory and design methodology, it puts forward the multi-level methodology system and implement process model for modular product platform (facing existing product and new product) construction. And it researchs on the key problems in different modular levels, then does the validation of the modular methodology and application of the product modularization with an actual project for existing products.
In chapterⅠ, it discusses the production, the development and the achievement of methodology from the philosophical level, and the related concepts and definition of design methodology are extended. Then it evaluates the research status of methodology in different country from time and space, and does comparative analysis between mainstream design theory including systematic design, axiomatic design and TRIZ theory. On this basis, it makes the definition and the related concepts of modular design clear, and combined the modular with the study of design methodology, so that the methodology strategy for modular design is proposed. Finally, summarizes the necessity and innovation of research on modular design methodology, and gives the main content and structure of this paper.
In chapterⅡ, it firstly analyses the demands of the modular design method based on modularization theory, system design method and PDM development. Then defines the concept of existing products, new products, product platform, product family, module type and modular product platform etc., which are involved in this paper, and puts forward modular product platform modeling system oriented to existing products. Around the system, based on the thorough analysis of modular products platform characteristics, it makes the key technologies clear from method layer, technical layer and data layer. After the combination of technology system and modular product platform model, it proposes the existing products'multi-level design process model which based on the extraction process of the modular main structure.
In chapterⅢ, it builds a model of existing products'modular design process in product level, and does comparative study to the new products. It analyses the characteristics of modularization in product level, the goal of each stage and methods to achieve the goals stage by stage. For the problem of product platform division and evaluation, it determines the importance of each node by using the total and average betweennesses of nodes in structure net of product family, and gets the key platform nodes with results of function analysis. Then it gets other important nodes by calculating the correlative coefficient between them and key nodes. Using the information axiom evaluates the alternative platforms at last, and realizes the design loop. At the end of this chapter, compares existing products with new products in the formation and evolution process of modular product main structure on product level.
In ChapterⅣ, it does modeling for modularization design process on components level and parts level for existing products. Then it deals with a comparative study between existing products and new products, and discusses the relationship of modularization among products level, components level and parts level. The characteristics of components level modularization and parts level modularization, the goal of each stage and specific methods to achieve the goal are elaborated by stages as well. This chapter defines ATO module, MTO module and ETO module, and analyzes deeply differences between characteristics and design methods in design process of ATO module and MTO module. For evaluation problem after module division, product module fuzzy evaluation method based on the product life cycle is proposed. First of all, it does modeling for life cycle assessment elements and puts forward seven elements of life cycle for module evaluation, then evaluate comprehensively modules by means of triangular fuzzy numbers.
In ChapterⅤ, Based on the temporal correlation and function complement between morphological methods and theory of inventive problem solving (TRIZ) on generating and analyzing the principle solutions in product design process, a double-matrix integrated model which combines morphological matrix and contradiction matrix is proposed,. The model consists of concept model, process model and related model, and follows a top-down spiral design approach. The applicable scope of morphological analysis is extended to concept level by the model, so that the combination capability of principle solutions can be analyzed; the contradiction resolving principles is used on generating solutions and solving design decoupling. Taking the research on the innovative development process of a hand driller and manual razer as examples, it validates the application process of double-matrix on new product design and the implementation of the nested sub-cycle on variant design, and proves the flexibility and operability of the model when facing deferent designing problems.
In ChapterⅥ, it validates and implements this modular product platform design process model and corresponding key technologies, methods in a state-owned construction machinery enterprise. From the products level, components level and parts level, it extracted the main product modular structure of the five-ton wheel loaders, and then formed the corresponding modular product platform. And it practises the product platform division phase and fuzzy evaluation method for modules on wheel loader. On this basis, the modularization planning system is built. It supports the promotion and implementation of theory in this paper by the data model, document model and process model.
The last chapter is conculsion and outlook. The achievements of the dissertation were summarized, and the innovations were pointed. The future research works were put forward to outlook.
引文
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