基于多故障模式的复杂机械设备预防性维修决策
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摘要
目前,复杂设备的维修维护往往是基于多部件的,然而单个部件往往具有多故障模式,且故障之间具有复杂的关联关系,导致基于多部件的维修决策方案并不一定合理。针对这一难题,提出一种复杂机械装备预防性维修决策方法,与传统的基于多部件的预防性维修决策不同,从故障模式的角度切入分析。根据系统结构和功能特征进行关键故障模式辨识,并将其分为突发类和退化类两类。讨论了复杂机械设备故障模式之间的依赖性、维修级别和维修效果等,进一步利用故障时间分布即寿命分布构建预防性维修决策的目标成本函数,并通过遗传算法实现含整型约束的非线性优化问题求解。所提出的方法在某镗床滑枕进给传统子系统中得到验证,并表现出良好性能。
Based on the analysis of multiple failure modes,a Preventive Maintenance(PM)scheduling for complex mechanical device was proposed.According to system structure and function features,the key failure modes were identified.The dependences between failure modes,the maintenance level and the maintenance effects of complex mechanical device were discussed.The objective cost function of PM was constructed further by using failure time distribution,and the integer-constrained nonlinear optimization problem achieved by genetic algorithm was adopted to solve this function.The proposed approach was illustrated in a ram feed subsystem of a boring machine,and theeffectiveness was proved.
Based on the analysis of multiple failure modes,a Preventive Maintenance(PM)scheduling for complex mechanical device was proposed.According to system structure and function features,the key failure modes were identified.The dependences between failure modes,the maintenance level and the maintenance effects of complex mechanical device were discussed.The objective cost function of PM was constructed further by using failure time distribution,and the integer-constrained nonlinear optimization problem achieved by genetic algorithm was adopted to solve this function.The proposed approach was illustrated in a ram feed subsystem of a boring machine,and theeffectiveness was proved.
引文
[1]ZHOU Xiaojun,LU Zhiqiang,XI Lifeng.Preventive maintenance optimization for a multi-component system under changing job shop schedule[J].Reliability Engineering&System Safety,2012,101(5):14-20.
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[3]BADA F G,BERRADE M,CAMPOS A.Optimal inspection and preventive maintenance of units with revealed and unrevealed failures[J].Reliability Engineering&System Safety,2002,78(2):157-163.
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[6]DING Fangfang,TIAN Zhigang.Opportunistic maintenance optimization for wind turbine systems considering imperfect maintenance actions[J].International Journal of Reliability,Quality and Safety Engineering,2011,18(5):463-481.
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[12]SHAHANAGHI K,BABAEJ H,ARASH B,et al.A new condition based maintenance model with random improvements on the system after maintenance actions:optimizing by Monte Carlo simulation[J].World Journal of Modelling and Simulation,2008,4(3):230-236.
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[14]CHENG J L.Condition based maintenance optimization for multi-component systems using proportional hazards model.Reliability Engineering&System Safety,2011,96(5):581-589.
[15]HONG H P,ZHOU W,ZHANG S,et al.Optimal condition-based maintenance decisions for systems with dependent stochastic degradation of components[J].Reliability Engineering&System Safety,2014,121:276-288.
[16]TIAN Z G,JIN T D,WU B R,et al.Condition based maintenance optimization for wind power generation systems under continuous monitoring[J].Renewable Energy,2011,36(5):1502-1509.
[17]FUJIYAMA K,NAGAI S,AKIKUVI Y,et al.Risk-based inspection and maintenance systems for steam turbines[J].International Journal of Pressure Vessels and Piping.2004,81(10):825-835.
[18]HU Jinqiu,ZHANG Laibin.Risk based opportunistic maintenance model for complex mechanical systems[J].Expert Systems with Applications,2014,41(6):3105-3115.
[19]ZHOU Xiaojun,XI Lifeng,LEE J.Opportunistic preventive maintenance scheduling for a multi-unit series system based on dynamic programming[J].International Journal of Production Economics,2009,118(2):361-366.
[20]ZHU Qiushi,PENG Hao,HOUTUM G J V.A conditionbased maintenance policy for multi-component systems with a high maintenance setup cost[J].OR Spectrum,2015,37(4):1007-1035.
[22]DOOSTPARAST M,KOLAHAN F,DOOSTPARAST M.A reliability-based approach to optimize preventive maintenance scheduling for coherent systems[J].Reliability Engineering&System Safety,2014,126:98-106.DOI:10.101b/j.ress.2014.01.010.
[23]TSAI Y T,WANG K S,TSAI L C.A study of availabilitycentered preventive maintenance for multi-component systems[J].Reliability Engineering&System Safety,2004,84(3):261-270.
[24]XU Houbao,HU Weiwei.Modelling and analysis of repairable systems with preventive maintenance[J].Applied Mathematics and Computation,2013,224:46-53.DOI:10.101b/j.amc.2013.08.051.
[25]XIA T,XI L,ZHOU X,DU S.Modeling and optimizing maintenance schedule for energy systems subject to degradation[J].Computers&Industrial Engineering,2012,63(3):607-614.
[26]XIA Tangbin,XI Lifeng,ZHOU Xiaojun,et al.Dynamic maintenance decision-making for series-parallel manufacturing system based on MAM-MTW methodology[J].European Journal of Operational Research,2012,221(1):231-240.
[27]TIAN Zhigang,LIN Daming,WU Bairong.Condition based maintenance optimization considering multiple objectives[J].Journal of Intelligent Manufacturing,2012,23(2):333-340.
[28]DEKKER R,PLASMEIJER R P,SWART J H.Evaluation of a new maintenance concept for the preservation of highways[J].IMA Journal of Management Mathematics,1998,9(2):109-156.
[29]SATOW T,OSAKI S.Optimal replacement policies for a two-unit system with shock damage interaction[J].Computers and Mathematics with Applications,2003,46(7):1129-1138.
[30]LAI M,CHEN Y.Optimal periodic replacement policy for a two-unit system with failure rate interaction[J].The International Journal of Advanced Manufacturing and Technology,2006,29(3/4):367-371.
[31]DEEP K,SINGH K P,KANSAL M L,et al.A real coded genetic algorithm for solving integer and mixed integer optimization problems[J].Applied Mathematics and Computation,2009,212(2):505-518.
[32]WANG Yuanhang,DENG Chao,WU Jun,et al.A corrective maintenance scheme for engineering equipment[J].Engineering Failure Analysis,2014,36:269-283.
[2]KALLEN M J,VAN NOORTWIJK J M.Optimal maintenance decisions under imperfect inspection[J].Reliability Engineering and System Safety,2005,90(2/3):177-85.
[3]BADA F G,BERRADE M,CAMPOS A.Optimal inspection and preventive maintenance of units with revealed and unrevealed failures[J].Reliability Engineering&System Safety,2002,78(2):157-163.
[4]CHANG C C.Optimum preventive maintenance policies for systems subject to random working times,replacement,and minimal repair[J].Computers&Industrial Engineering,2014,67(1):185-194.
[5]PHAM H,WANG H.Imperfect maintenance[J].European Journal of Operational Research,1996;94(3):425-438.
[6]DING Fangfang,TIAN Zhigang.Opportunistic maintenance optimization for wind turbine systems considering imperfect maintenance actions[J].International Journal of Reliability,Quality and Safety Engineering,2011,18(5):463-481.
[7]GUO Chiming,WANG Wenbin,GUO Bo,et al.A maintenance optimization model for mission-oriented systems based on Wiener degradation[J].Reliability Engineering&System Safety,2013,111:183-194.
[8]FAN Hongdong,HU Changhua,CHEN Maoyin,et al.Cooperative predictive maintenance of repairable systems with dependent failure modes and resource constraint[J].IEEE Transactions on Reliability,2011,60(1):144-157.
[9]SAMROUT M,CHATELET E,KOUTA R.Optimization of maintenance policy using the proportional hazard model[J].Reliability Engineering&System Safety,2009,94(1):44-52.
[10]YOU Mingyi,LI Hongguang,MENG Guang.Control-limit preventive maintenance policies for components subject to imperfect preventive maintenance and variable operational conditions[J].Reliability Engineering&System Safety,2011,96(5):590-598.
[11]ZHOU Xiaojun,XI Lifeng,LEE Jay.Reliability-centered predictive maintenance scheduling for a continuously monitored system subject to degradation[J].Reliability Engineering&System Safety,2007,92(4):530-534.
[12]SHAHANAGHI K,BABAEJ H,ARASH B,et al.A new condition based maintenance model with random improvements on the system after maintenance actions:optimizing by Monte Carlo simulation[J].World Journal of Modelling and Simulation,2008,4(3):230-236.
[13]HORENBEEK V A,PINTELON L.A dynamic predictive maintenance policy for complex multi-component systems[J].Reliability Engineering&System Safety,2013,120:39-50.DOI:10.101b/j.ress.2013.02.029.
[14]CHENG J L.Condition based maintenance optimization for multi-component systems using proportional hazards model.Reliability Engineering&System Safety,2011,96(5):581-589.
[15]HONG H P,ZHOU W,ZHANG S,et al.Optimal condition-based maintenance decisions for systems with dependent stochastic degradation of components[J].Reliability Engineering&System Safety,2014,121:276-288.
[16]TIAN Z G,JIN T D,WU B R,et al.Condition based maintenance optimization for wind power generation systems under continuous monitoring[J].Renewable Energy,2011,36(5):1502-1509.
[17]FUJIYAMA K,NAGAI S,AKIKUVI Y,et al.Risk-based inspection and maintenance systems for steam turbines[J].International Journal of Pressure Vessels and Piping.2004,81(10):825-835.
[18]HU Jinqiu,ZHANG Laibin.Risk based opportunistic maintenance model for complex mechanical systems[J].Expert Systems with Applications,2014,41(6):3105-3115.
[19]ZHOU Xiaojun,XI Lifeng,LEE J.Opportunistic preventive maintenance scheduling for a multi-unit series system based on dynamic programming[J].International Journal of Production Economics,2009,118(2):361-366.
[20]ZHU Qiushi,PENG Hao,HOUTUM G J V.A conditionbased maintenance policy for multi-component systems with a high maintenance setup cost[J].OR Spectrum,2015,37(4):1007-1035.
[22]DOOSTPARAST M,KOLAHAN F,DOOSTPARAST M.A reliability-based approach to optimize preventive maintenance scheduling for coherent systems[J].Reliability Engineering&System Safety,2014,126:98-106.DOI:10.101b/j.ress.2014.01.010.
[23]TSAI Y T,WANG K S,TSAI L C.A study of availabilitycentered preventive maintenance for multi-component systems[J].Reliability Engineering&System Safety,2004,84(3):261-270.
[24]XU Houbao,HU Weiwei.Modelling and analysis of repairable systems with preventive maintenance[J].Applied Mathematics and Computation,2013,224:46-53.DOI:10.101b/j.amc.2013.08.051.
[25]XIA T,XI L,ZHOU X,DU S.Modeling and optimizing maintenance schedule for energy systems subject to degradation[J].Computers&Industrial Engineering,2012,63(3):607-614.
[26]XIA Tangbin,XI Lifeng,ZHOU Xiaojun,et al.Dynamic maintenance decision-making for series-parallel manufacturing system based on MAM-MTW methodology[J].European Journal of Operational Research,2012,221(1):231-240.
[27]TIAN Zhigang,LIN Daming,WU Bairong.Condition based maintenance optimization considering multiple objectives[J].Journal of Intelligent Manufacturing,2012,23(2):333-340.
[28]DEKKER R,PLASMEIJER R P,SWART J H.Evaluation of a new maintenance concept for the preservation of highways[J].IMA Journal of Management Mathematics,1998,9(2):109-156.
[29]SATOW T,OSAKI S.Optimal replacement policies for a two-unit system with shock damage interaction[J].Computers and Mathematics with Applications,2003,46(7):1129-1138.
[30]LAI M,CHEN Y.Optimal periodic replacement policy for a two-unit system with failure rate interaction[J].The International Journal of Advanced Manufacturing and Technology,2006,29(3/4):367-371.
[31]DEEP K,SINGH K P,KANSAL M L,et al.A real coded genetic algorithm for solving integer and mixed integer optimization problems[J].Applied Mathematics and Computation,2009,212(2):505-518.
[32]WANG Yuanhang,DENG Chao,WU Jun,et al.A corrective maintenance scheme for engineering equipment[J].Engineering Failure Analysis,2014,36:269-283.