机电设备在役再制造工程理论研究及应用
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摘要
机电设备运行可靠是设计制造的目的,也是其发挥功效、创造价值的阶段。针对国内机电设备运行可靠性差、运行效率低、与生产过程不匹配且自适应调控差等现状,提出机电设备在役再制造工程概念,构建了包含适用对象、工程目标、设计基础、生命周期、工程价值五个方面内容的在役再制造理论框架。在役再制造性评价是机电设备在役再制造的前提,基于监测数据、可靠性数据、维修数据、分析化验数据,开展机电设备健康度评价、可靠性评价和能效水平评价,数据驱动决策开展在役再制造个性化再设计,构建在役再制造性评价指标体系和评价模型,量化在役再制造性评价指标。以某催化裂化装置主风机静叶可调执行机构阀位锁位或跑位故障率高、运行可靠性差为例,针对常规电液控制系统进行在役再制造,结果表明,在役再制造工程具有巨大的经济效益和社会效益。
Electromechanical equipment operation reliability is the purpose of design and manufacture, as well as the stage of creating value and playing function efficiency. Aiming at the poor operation reliability, low running efficiency, poor matching with process production and poor self-adaptive control of domestic electromechanical equipment, the concept of remanufacturing engineering in service is proposed, and the remanufacturing in service theoretical framework, which comprise applicable object, project objectives, design basis, life cycle and engineering value, is constructed. Remanufacturability in Service assessment is the precondition of remanufacturing for electromechanical equipment. Health level assessment, reliability evaluation and efficiency level evaluation are carried out based on the condition monitoring data, reliability data, maintainability data and analysis data. The personalized redesign is executed based on data-driven decision-making, and then the Remanufacturability in Service evaluation index system and evaluation model are constructed to quantify Remanufacturability in Service. The static blade adjustable actuator for axial-blower with high failure rate, poor operational reliability are often suffered valve position locking or running out of control in the fluid catalytic cracking unit (FCCU), the traditional electro-hydraulic control system is remanufactured in service. Application case proves that Remanufacturing Engineering in Service can create huge economic and social benefits.
Electromechanical equipment operation reliability is the purpose of design and manufacture, as well as the stage of creating value and playing function efficiency. Aiming at the poor operation reliability, low running efficiency, poor matching with process production and poor self-adaptive control of domestic electromechanical equipment, the concept of remanufacturing engineering in service is proposed, and the remanufacturing in service theoretical framework, which comprise applicable object, project objectives, design basis, life cycle and engineering value, is constructed. Remanufacturability in Service assessment is the precondition of remanufacturing for electromechanical equipment. Health level assessment, reliability evaluation and efficiency level evaluation are carried out based on the condition monitoring data, reliability data, maintainability data and analysis data. The personalized redesign is executed based on data-driven decision-making, and then the Remanufacturability in Service evaluation index system and evaluation model are constructed to quantify Remanufacturability in Service. The static blade adjustable actuator for axial-blower with high failure rate, poor operational reliability are often suffered valve position locking or running out of control in the fluid catalytic cracking unit (FCCU), the traditional electro-hydraulic control system is remanufactured in service. Application case proves that Remanufacturing Engineering in Service can create huge economic and social benefits.
引文
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[14]王维民,高金吉,李燕,等.离心压缩机轴位移故障自愈调控系统试验研究[J].机械工程学报,2010,46(5):49-54.WANG Weimin,GAO Jinji,LI yan,et al.Experiment study about centrifugal compressor axial displacement fault self-recovering system[J].Journal of Mechanical Engineering,2010,46(5):49-54.
[15]王庆锋,高金吉,袁庆斌,等.主风机静叶可调执行机构自愈化智能电液控制系统研究与应用[J].机械工程学报,2016,52(20):185-192.WANG Qingfeng,GAO Jinji,YUAN Qinbin,et al.Research and application of self-recovery smart electro-hydraulic control system on axial-blower static blade adjustable actuator[J].Journal of Mechanical Engineering,2016,52(20):185-192.
[16]徐滨士.新时代中国特色再制造的创新发展[J].中国表面工程,2018(1):1-6.XU Binshi.Innovation and development of remanufacturing with Chinese characteristics for a new era[J].China Surface Engineering,2018(1):106.
[17]吕运容,陈学东,高金吉,等.我国大型工艺压缩机故障情况调研及失效预防对策[J].流体机械,2013,41(1):14-20LüYurong,CHEN Xuedong,GAO Jinji,et al.Survey of failure of large process compressor in Chinese and failure prevention countermeasure[J].Fluid Machinery,2013,41(1):14-20.
[18]高金吉,杨国安.流程工业设备绿色化、智能化与在役再制造[J].中国工程科学,2015,17(7):54-62.GAO Jinji,YANG Guoan.Greenization,intelligentization and remanufacture in service of equipment in process industry[J].Engineering Science,2015,17(7):54-62.
[19]赵地.无级气量调节系统在加氢装置往复压缩机的应用[J].通用机械,2014(4):49-51.ZHAO Di.Application of stepless gas volume control system in reciprocating compressor of hydrogenation unit[J].General Machinery,2014(4):49-51.
[2]徐滨士.绿色再制造工程设计基础及其关键技术[J].中国表面工程,2001(2):12-15.XU Binshi.Green remanufacture engineering design basis and its key technology[J].China Surface Engineering,2001(2):12-15.
[3]张伟,徐滨士,张纾,等.再制造研究应用现状及发展策略[J].装甲兵工程学院学报,2009,23(5):1-5.ZHANG Wei,XU Binshi,ZHANG Shu,et al.Status and development of remanufacturing research and application[J].Journal of Academy of Armored Force Engineering,2013,23(5):1-5.
[4]刘纯,曹华军,刘飞,等.机电设备绿色再制造综合评价模型及其应用[J].现代制造工程,2003,41(6):163-167.LIU Chun,CAO Huajun,LIU Fei,et al.Comprehensive assessment model and its application of waste electro mechanical products green remanufacturing[J].Modern Manufacturing Engineering,2003,41(6):163-167.
[5]杜彦斌,李聪波.机械设备再制造可靠性研究现状及展望[J].计算机集成制造系统,2014,20(11):2643-2650.DU Yanbin,LI Congbo.Overview and perspective on reliability of machinery equipment remanufacturing[J].Computer Integrated Manufacturing Systems,2014,20(2):2643-2651.
[6]杜彦斌,廖兰.基于失效特征的机械零部件可再制造度评价方法[J].计算机集成制造系统,2015,21(1):135-142.DU Yanbin,LIAO Lan.Remanufacturability evaluation method for mechanical parts based on failure features[J].Computer Integrated Manufacturing Systems,2015,21(1):135-142.
[7]刘渤海,徐滨士,史佩京.再制造综合评价指标体系的设计研究[J].检验检疫学刊,2010,20(2):53-56.LIU Bohai,XU Binshi,SHI Peijing.Design for integrated assessment indexing system of remanufacturing[J].Journal of Inspection and Quarantine,2010,20(2):53-56.
[8]宋守许,刘明,刘光复,等.现代产品主动再制造理论与设计方法[J].机械工程学报,2016,52(7):132-141.SONG Shouxu,LIU Ming,LIU Guangfu,et al.Theories and design methods for proactive remanufacturing of modern products[J].Journal of Mechanical Engineering,2016,52(7):132-141.
[9]宋守许,刘明,柯庆镝,等.基于强度冗余的零部件再制造优化设计方法[J].机械工程学报,2013,49(9):121-127.SONG Shouxu,LIU Ming,KE Qingdi,et al.Components optimization design for remanufacturing based on residual strength[J].Journal of Mechanical Engineering,2013,49(9):121-127.
[10]李晗,萧德云.基于数据驱动的故障诊断方法综述[J].控制与决策,2011,26(1):1-16.LI Han,XIAO Deyun.Survey on data driven fault diagnosis methods[J].Control and Deisgn,2011,26(1):1-16.
[11]刘博元,王焕钢,范文慧,等.基于大数据的复杂生产系统健康度实时评估方法[J].清华大学学报,2014,54(10):1377-1383.LIU Boyuan,WANG Huangang,FAN Wenhui,et al.Real-time health level assessment for complex production line system based on big data[J].Journal of Tsinghua University,2014,54(10):1377-1383.
[12]周黔,吴铁军.一种动态数据流的实时趋势分析算法[J].控制与决策,2008,23(10):1182-1185.ZHOU Qian,WU Tiejun.A real time algorithm for trend analysis of dynamic data streams[J].Control and Deisgn,2008,23(10):1182-1185.
[13]潘鑫,吴海琦,高金吉.旋转机械气压液体式不平衡振动故障靶向自愈调控系统[J].机械工程学报,2015,51(1):146-152.PAN Xin,WU Haiqi,GAO Jinji.Rotating machinery targeting self-recovery regulation system for imbalance vibration fault with liquid-transfer active balancing device[J].Journal of Mechanical Engineering,2015,51(1):146-152.
[14]王维民,高金吉,李燕,等.离心压缩机轴位移故障自愈调控系统试验研究[J].机械工程学报,2010,46(5):49-54.WANG Weimin,GAO Jinji,LI yan,et al.Experiment study about centrifugal compressor axial displacement fault self-recovering system[J].Journal of Mechanical Engineering,2010,46(5):49-54.
[15]王庆锋,高金吉,袁庆斌,等.主风机静叶可调执行机构自愈化智能电液控制系统研究与应用[J].机械工程学报,2016,52(20):185-192.WANG Qingfeng,GAO Jinji,YUAN Qinbin,et al.Research and application of self-recovery smart electro-hydraulic control system on axial-blower static blade adjustable actuator[J].Journal of Mechanical Engineering,2016,52(20):185-192.
[16]徐滨士.新时代中国特色再制造的创新发展[J].中国表面工程,2018(1):1-6.XU Binshi.Innovation and development of remanufacturing with Chinese characteristics for a new era[J].China Surface Engineering,2018(1):106.
[17]吕运容,陈学东,高金吉,等.我国大型工艺压缩机故障情况调研及失效预防对策[J].流体机械,2013,41(1):14-20LüYurong,CHEN Xuedong,GAO Jinji,et al.Survey of failure of large process compressor in Chinese and failure prevention countermeasure[J].Fluid Machinery,2013,41(1):14-20.
[18]高金吉,杨国安.流程工业设备绿色化、智能化与在役再制造[J].中国工程科学,2015,17(7):54-62.GAO Jinji,YANG Guoan.Greenization,intelligentization and remanufacture in service of equipment in process industry[J].Engineering Science,2015,17(7):54-62.
[19]赵地.无级气量调节系统在加氢装置往复压缩机的应用[J].通用机械,2014(4):49-51.ZHAO Di.Application of stepless gas volume control system in reciprocating compressor of hydrogenation unit[J].General Machinery,2014(4):49-51.