基于DAP分析的船舶分段制造流程优化
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摘要
分段建造是整个船舶建造过程的重要组成部分。随着船舶工业的迅猛发展,造船企业年吨位产量的不断提高,企业对自身分段制作能力也有了全新的要求。
在分段制造水平方面,国内造船企业与国外相比尚有一定差距。日、韩大型船厂制造一个分段平均周期约为7～10天,而我国同样吨位则需要25～35天。因此,研究分段制作流程,提高分段制造场地利用率显得尤为迫切与需要。
分段详细组立流程(DETAIL ASSEMBLY PROCEDURE)设计是以分段划分为基础,建立分段从小组立、中组立、大组立三个阶段所有零件、部件、组件的装配关系和先后顺序。
本文首先阐述了课题的研究背景、目的和意义,后基于DAP分析来研究船舶分段制作流程,主要内容有:
1、基于中间产品原理对组立件进行分析,研究了中小组立特性,形成中间产品族;随后对零部件的托盘管理及零部件流向进行了形式化表达,在此基础上实现零部件的专业化生产和分段组立工作量的前移,从而改善了分段施工条件,即高空作业平地做,封闭舱室敞开做;减少大组的装焊工作量及焊接变形,有利于精度控制。
2、选取一分段为模型,以装配工作量、装配条件、焊接总长度、开敞焊接工作量等为指标,利用模糊综合评判法,对分段建造流程的评判各参数进行量化分析,从四种常用分段建造流程中优选出一最佳建造流程。
3、对各类结构化舾装件特性及其分类进行分析,特别对作业类舾装件进行了重点研究;并对结构化舾装件与DAP的联系进行了分析举例,通过安装阶段前移实现结构化舾装件的托盘优化,缩短分段建造周期。
4、在前文分析的基础上,研究各类典型分段的制作流程,形成典型分段之DAP,逐步推广到全船、全企业分段,提高单位场地分段周转率。
Hull block assembly is a very important stage of shipbuilding. Shipyard now has a high requirement on block assembly ability with the development of shipbuilding industry and improvement of large tonnage vessels built. Shipyard in china still has a big difference on hull block assembly efficiency compared with foreign advanced yard. The period of one block building in Japan and South Korea in about 7 to 10 days, but Chinese average time is about 25 to 35 days. So it is very important to analyze the block building sequence.
The design of DAP also consists of structure outfitting pars. The outfitting parts have less relation with system can be fitted during hull sub assembly and unit assembly.
The main contents of this paper as follows after described the background, aim and meaning of the project:
1. Study the character of unit assembly based on mid-product theory. Describe the piece management and movement. On this base shipyard can product with high efficiency and improve working condition: High stage working changed to plat areas; closed working changed to open areas; Reducing welding work at grand assembly stage and deformation at the same time.
2. Take use of fuzzy comprehensive assessment based on one block model, with the parameters of fabrication work, fabrication condition, length of welding etc., analyze these parameters, choose one best building procedure from four basic procedure.
3. Analyze the character and types of structure outfitting; analyze the relation between hull structure and structure outfitting parts with examples. Shipyard can get the result of shorting building time with structure outfitting to be fitted at forehead stages.
4. The practice of DAP. Study different types of blocks based on DAP, put the analyze method into use to all types of blocks of all vessels building at shipyard.
在分段制造水平方面,国内造船企业与国外相比尚有一定差距。日、韩大型船厂制造一个分段平均周期约为7～10天,而我国同样吨位则需要25～35天。因此,研究分段制作流程,提高分段制造场地利用率显得尤为迫切与需要。
分段详细组立流程(DETAIL ASSEMBLY PROCEDURE)设计是以分段划分为基础,建立分段从小组立、中组立、大组立三个阶段所有零件、部件、组件的装配关系和先后顺序。
本文首先阐述了课题的研究背景、目的和意义,后基于DAP分析来研究船舶分段制作流程,主要内容有:
1、基于中间产品原理对组立件进行分析,研究了中小组立特性,形成中间产品族;随后对零部件的托盘管理及零部件流向进行了形式化表达,在此基础上实现零部件的专业化生产和分段组立工作量的前移,从而改善了分段施工条件,即高空作业平地做,封闭舱室敞开做;减少大组的装焊工作量及焊接变形,有利于精度控制。
2、选取一分段为模型,以装配工作量、装配条件、焊接总长度、开敞焊接工作量等为指标,利用模糊综合评判法,对分段建造流程的评判各参数进行量化分析,从四种常用分段建造流程中优选出一最佳建造流程。
3、对各类结构化舾装件特性及其分类进行分析,特别对作业类舾装件进行了重点研究;并对结构化舾装件与DAP的联系进行了分析举例,通过安装阶段前移实现结构化舾装件的托盘优化,缩短分段建造周期。
4、在前文分析的基础上,研究各类典型分段的制作流程,形成典型分段之DAP,逐步推广到全船、全企业分段,提高单位场地分段周转率。
Hull block assembly is a very important stage of shipbuilding. Shipyard now has a high requirement on block assembly ability with the development of shipbuilding industry and improvement of large tonnage vessels built. Shipyard in china still has a big difference on hull block assembly efficiency compared with foreign advanced yard. The period of one block building in Japan and South Korea in about 7 to 10 days, but Chinese average time is about 25 to 35 days. So it is very important to analyze the block building sequence.
The design of DAP also consists of structure outfitting pars. The outfitting parts have less relation with system can be fitted during hull sub assembly and unit assembly.
The main contents of this paper as follows after described the background, aim and meaning of the project:
1. Study the character of unit assembly based on mid-product theory. Describe the piece management and movement. On this base shipyard can product with high efficiency and improve working condition: High stage working changed to plat areas; closed working changed to open areas; Reducing welding work at grand assembly stage and deformation at the same time.
2. Take use of fuzzy comprehensive assessment based on one block model, with the parameters of fabrication work, fabrication condition, length of welding etc., analyze these parameters, choose one best building procedure from four basic procedure.
3. Analyze the character and types of structure outfitting; analyze the relation between hull structure and structure outfitting parts with examples. Shipyard can get the result of shorting building time with structure outfitting to be fitted at forehead stages.
4. The practice of DAP. Study different types of blocks based on DAP, put the analyze method into use to all types of blocks of all vessels building at shipyard.
引文
[1] 雷伟诚. 浅析中国造船现状及发展趋势,船舶设计通讯,上海船舶研究设计所 2006.1
[2] 周光霁,应长春.现代造船模式研究报告 中国船舶工业总公司第十一研究所 1999
[3] 王世利. 基于现代造船模式船体编码研究与应用,工程硕士论文,上海交通大学 2006
[4] 刘建峰.基于 PWBS 船体建造运作策略研究,博士学位论文,上海交通大学 2000
[5] 郭庆祝,苏德利. 影响中国造船模式转变的关键因素及解决方案,中外船舶科技,江苏 科技大学 2006.4
[6] 翁德伟.造船成组技术 上海交通大学出版社 1990
[7] 徐学光.采用“成组-相似工程”技术创建我国现代造船模式 船舶工程 1997(4)
[8] 钟宏才,谭家华,陈强.造船中间产品专业化生产运作体系及关键技术研究 上海交通大学 2003
[9] 饶辉章,周琦. 实托盘配送在 SWS 的应用研究,第五届发展论坛论文集,上海外高桥造 船有限公司 2005 (12)
[10] 徐昌文.模糊数学在船舶工程中的应用 国防工业出版社 1992
[11] 王光远.论综合评判几种数学模型的实质及其应用 模糊数学 1984(4)
[12] 王勇毅. 船舶建造工艺学 民交通出版社 1988
[13] 纪卓尚. 船舶制造工艺力学 国防工业出版社 2005
[14] 伊群,谢诈水.船舶相贯结构切口形式的力学分析 华东船舶工业学院 1996
[15] 黄浩.船体工艺手册 国防工业出版社 1989
[16] 顾新涛,刘建峰,马登哲. 基于模糊综合评判法的平直分段建造流程优选的方法研究,外 高桥造船技术 2006.2
[17] 郭荣奎. SWS 采用肋板拉入法工艺研究,外高桥造船技术 2005.2
[18] 章祖岐. 现代造船的基本理论及其应用,外高桥造船技术 2005.1
[19] 张明华.精益造船模式研究 中国经济出版社 2005
[20] 高介祜,郁照荣.现代造船模式及其形成 造船技术 1997(3)
[21] 刘建峰,高爱华.以工法为先导实现一体化设计的 WSD 研究,上海造船工程协会学术论文选 2005(3)
[2] 周光霁,应长春.现代造船模式研究报告 中国船舶工业总公司第十一研究所 1999
[3] 王世利. 基于现代造船模式船体编码研究与应用,工程硕士论文,上海交通大学 2006
[4] 刘建峰.基于 PWBS 船体建造运作策略研究,博士学位论文,上海交通大学 2000
[5] 郭庆祝,苏德利. 影响中国造船模式转变的关键因素及解决方案,中外船舶科技,江苏 科技大学 2006.4
[6] 翁德伟.造船成组技术 上海交通大学出版社 1990
[7] 徐学光.采用“成组-相似工程”技术创建我国现代造船模式 船舶工程 1997(4)
[8] 钟宏才,谭家华,陈强.造船中间产品专业化生产运作体系及关键技术研究 上海交通大学 2003
[9] 饶辉章,周琦. 实托盘配送在 SWS 的应用研究,第五届发展论坛论文集,上海外高桥造 船有限公司 2005 (12)
[10] 徐昌文.模糊数学在船舶工程中的应用 国防工业出版社 1992
[11] 王光远.论综合评判几种数学模型的实质及其应用 模糊数学 1984(4)
[12] 王勇毅. 船舶建造工艺学 民交通出版社 1988
[13] 纪卓尚. 船舶制造工艺力学 国防工业出版社 2005
[14] 伊群,谢诈水.船舶相贯结构切口形式的力学分析 华东船舶工业学院 1996
[15] 黄浩.船体工艺手册 国防工业出版社 1989
[16] 顾新涛,刘建峰,马登哲. 基于模糊综合评判法的平直分段建造流程优选的方法研究,外 高桥造船技术 2006.2
[17] 郭荣奎. SWS 采用肋板拉入法工艺研究,外高桥造船技术 2005.2
[18] 章祖岐. 现代造船的基本理论及其应用,外高桥造船技术 2005.1
[19] 张明华.精益造船模式研究 中国经济出版社 2005
[20] 高介祜,郁照荣.现代造船模式及其形成 造船技术 1997(3)
[21] 刘建峰,高爱华.以工法为先导实现一体化设计的 WSD 研究,上海造船工程协会学术论文选 2005(3)