可重构机床设计理论与方法研究
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摘要
可重构制造系统的独特性在于其系统、机床和控制结构都能快速、经济地转换,以响应市场/客户需求的变化。可重构机床及其系统的设计方法学是构建可重构制造系统的基石。可重构机床设计不仅是对特定任务配置现有机床模块,而是设计一种能阐释可重构科学理念的新型机床。本文结合浙江省自然科学基金资助项目——“可重构制造设备和单元的基础和技术研究”(编号:598042),对可重构机床的设计理论与方法进行了系统的研究,为可重构机床理论体系的建立、实际应用和发展创造条件,为制造企业成功实施可重构制造系统提供坚实的理论和方法上的指导。
在分析传统机床的需求发展、设计演变和存在问题的基础上,结合制造业的未来发展趋势,阐述了可重构机床设计面临的挑战和需求。结合国内外有关可重构机床设计研究的现状和不足,提出了本文研究的出发点、目标和意义,并给出了本文的主要研究内容。
针对建立系统的可重构机床理论体系,阐述了可重构机床概念的定义和内涵,从可重构角度出发,建立了机床成本模型并揭示了可重构机床的本质特性。分析结果表明:可重构机床不是传统机床的替代品,而是在新的环境下对传统机床的一种有效的补充。从实现机床的可重构和定制化角度出发,阐释了可重构机床的基本原理和特性,提出了一种基于工艺规划和配置生成并行的可重构机床设计方法学,深入地分析了设计方法学的体系结构和实现过程步骤,为本文的后继研究奠定了科学基础。
面向工序族设计是可重构机床设计的本质特征,为此研究了对整个零件族的工序需求划分和识别同一可重构机床需完成的工序族的问题。给出了基于位置公差、并行加工的单一零件工序的组合原则和条件,并着重对基于并行加工的工序组合中相似空间模式工序组合的识别问题进行了探讨,给山了该模式识别问题的数学模型、分类和算法。提出了单一零件工序组合之间的相似性判定准则,和利用改进的k-平均(k-模式)算法解决整个零件族的多零件工序组合问题的方法。提出了基于模糊聚类分析的工序组合(包括单一零件和多零件)的合并方法,以确定同一可重构机床需完成的一系列加工工序——工序族(由于这一系列加工工序来自于零件族的不同零件,故称为工序族),并采用基于规则的方法对工序族的所有工序进行了排序,以保证所设计的可重构机床可行。
针对实现可重构机床的定制化柔性,提出了一种基丁旋量和图的可重构机床机械系统的模块化设计方法。在该方法中,利用旋量方法建立了可重构机床基本功能和机床模块的运动学模型,通过比较二者的运动旋量并利用机床模块库,将可重构机床所需的每个功能(运动和结构)映射为模块库中的一系列机床模块或模块的组合(也称构件块);利用图论设计了可重构机床的功能结构和定义了机床模块的可连结性,并给出了生成满足工序需求变化的可重构机床配置及重构配置(图)的方法。为了实现可重构机床的在线重构和最大化地利用机床资源,给出了一种利用旋量方法来建立机床的重构需求模型,进而设计可重
The uniqueness of the Reconfigurable Manufacturing System (RMS) is that the structure of the system as well as its machines and controls can be rapidly and cost-effectively converted in response to the demand changes of market/custom. Reconfigurable Machine Tool (RMT) and its systemic design methodology are the cornerstones of RMS. The design of RMT is not just configuring the existing modules for a specific task, but rather a design of a new type of machine, which can illustrate the ideas of reconfiguration science. With financially supported by the Provincial Natural Science Foundation of Zhejiang province (NO: 598042), the theory and method for RMT design are systematically studied in this dissertation. The thesis aims to create the conditions for building the systematic theory of RMT, implementing and developing, as well as provide theoretical and methodological guidance for implementing RMS successfully. Based on the analysis of the requirement developments, design evolvements, and existent questions of the conventional machines, the challenges and requirements of RMT design are discussed. The research status and lacks of RMT design are analyzed in the detail. Based on it, the origin, objective and significance of the research in this dissertation are presented, as well as the main research contents. In allusion to establish the systematic architecture of RMT theory, the definition and intension of the RMT concept are expounded. In the view of the reconfiguration, the cost model of machine is established, and the essence of RMT is revealed. In the view of realizing the reconfiguration and customized flexibility & control of RMT, the basic principles and characteristics of RMT are discussed, and a RMT design methodology based concurrency of process planning and machine configuration building is proposed, as well as the architecture and steps of the design methodology. All of above established the scientific base for the subsequent research of this dissertation. As designing for an operation family is the essence of RMT design, so the method for identifying the operation family from the operation demands of part family is proposed, and the operation family must be machined on the same RMT. The tolerance-based and concurrency-based clustering principles and conditions for single part are given, and the pattern recognition issue for the similar special operation clustering in the concurrency-based clustering is discussed, and the mathematic model, category, and algorithm of the pattern recognition are proposed. The similarity measure between the single part operation clustering is presented, and the problem of multi-part operation clustering using modified k-means (k-modes) algorithm is studied. A method for grouping
the operation clustering (include single part and multi-parts) based on the fuzzy clustering analysis is given, so the set of operations required on the same RMT is decided, that is called operation family (because the set of operations are grouped from different parts in a part family). Using the rule-based method, the sequence of the operation clustering and the operation sequence in each operation clustering are obtained, thereby the feasibility of RMT designed is ensured.Aim at to realize the customized flexibility of RMT, a modular design method for mechanical system of RMT which based on the screw and graph is presented. Within this method, the kinematics modeling of RMT basic functions and machine tool modules are established using screw method. By comparing the twist between them, each function (kinetic and structure) is then mapped to a feasible set of modules (or named building block) in the module library. Using the graph theory, a set of feasible structural configurations of the RMT is designed, as well as the connectivity of each machine module is defined. A method for generating a series alternative RMT configuration and reconfiguration (graph) met the operation requirements is given. In order to realize the reconfiguration online of RMT and maximumly use the machine resources, a design method for reconfigurable machine module is developed using screw method. Employing such machine module, the functionality of an RMT can be changed without replacing modules.In order to realize the objective that synchronously reconfigure the control and machine of RMT, a modular design method for RMT controller is proposed. Within this method, both the entire controller and its individual control module are acted as a set consisting of a Finite State Machine (FSM) and input & output event set pairs, and each pair of input & output event set was defined as a port of the control module, and the input event set on a given port formed the port acceptable Language. Thus, when the mechanical modules are assembled, the control modules will be connected using port Language, and the entire controller is created or reconfigured. The definitions of control module with FSM and module combination are given. A design and construction principles of modular controller are proposed, and the principles correctness are proved. Once the control modules are properly designed and connected, the resulting controller is guaranteed to be controllable. When the demand is changed, the control module can be reused by redefining the port language without change the controllability.In order to minimize the redundancy capacity and functionality of machine, a configuration design method for configuration path of RMT in the early stage of configuration design is proposed, which is designed for changing requires scenario. By evaluating the configuration economics and reconfigurability over the lifetime of RMT, the method
在分析传统机床的需求发展、设计演变和存在问题的基础上,结合制造业的未来发展趋势,阐述了可重构机床设计面临的挑战和需求。结合国内外有关可重构机床设计研究的现状和不足,提出了本文研究的出发点、目标和意义,并给出了本文的主要研究内容。
针对建立系统的可重构机床理论体系,阐述了可重构机床概念的定义和内涵,从可重构角度出发,建立了机床成本模型并揭示了可重构机床的本质特性。分析结果表明:可重构机床不是传统机床的替代品,而是在新的环境下对传统机床的一种有效的补充。从实现机床的可重构和定制化角度出发,阐释了可重构机床的基本原理和特性,提出了一种基于工艺规划和配置生成并行的可重构机床设计方法学,深入地分析了设计方法学的体系结构和实现过程步骤,为本文的后继研究奠定了科学基础。
面向工序族设计是可重构机床设计的本质特征,为此研究了对整个零件族的工序需求划分和识别同一可重构机床需完成的工序族的问题。给出了基于位置公差、并行加工的单一零件工序的组合原则和条件,并着重对基于并行加工的工序组合中相似空间模式工序组合的识别问题进行了探讨,给山了该模式识别问题的数学模型、分类和算法。提出了单一零件工序组合之间的相似性判定准则,和利用改进的k-平均(k-模式)算法解决整个零件族的多零件工序组合问题的方法。提出了基于模糊聚类分析的工序组合(包括单一零件和多零件)的合并方法,以确定同一可重构机床需完成的一系列加工工序——工序族(由于这一系列加工工序来自于零件族的不同零件,故称为工序族),并采用基于规则的方法对工序族的所有工序进行了排序,以保证所设计的可重构机床可行。
针对实现可重构机床的定制化柔性,提出了一种基丁旋量和图的可重构机床机械系统的模块化设计方法。在该方法中,利用旋量方法建立了可重构机床基本功能和机床模块的运动学模型,通过比较二者的运动旋量并利用机床模块库,将可重构机床所需的每个功能(运动和结构)映射为模块库中的一系列机床模块或模块的组合(也称构件块);利用图论设计了可重构机床的功能结构和定义了机床模块的可连结性,并给出了生成满足工序需求变化的可重构机床配置及重构配置(图)的方法。为了实现可重构机床的在线重构和最大化地利用机床资源,给出了一种利用旋量方法来建立机床的重构需求模型,进而设计可重
The uniqueness of the Reconfigurable Manufacturing System (RMS) is that the structure of the system as well as its machines and controls can be rapidly and cost-effectively converted in response to the demand changes of market/custom. Reconfigurable Machine Tool (RMT) and its systemic design methodology are the cornerstones of RMS. The design of RMT is not just configuring the existing modules for a specific task, but rather a design of a new type of machine, which can illustrate the ideas of reconfiguration science. With financially supported by the Provincial Natural Science Foundation of Zhejiang province (NO: 598042), the theory and method for RMT design are systematically studied in this dissertation. The thesis aims to create the conditions for building the systematic theory of RMT, implementing and developing, as well as provide theoretical and methodological guidance for implementing RMS successfully. Based on the analysis of the requirement developments, design evolvements, and existent questions of the conventional machines, the challenges and requirements of RMT design are discussed. The research status and lacks of RMT design are analyzed in the detail. Based on it, the origin, objective and significance of the research in this dissertation are presented, as well as the main research contents. In allusion to establish the systematic architecture of RMT theory, the definition and intension of the RMT concept are expounded. In the view of the reconfiguration, the cost model of machine is established, and the essence of RMT is revealed. In the view of realizing the reconfiguration and customized flexibility & control of RMT, the basic principles and characteristics of RMT are discussed, and a RMT design methodology based concurrency of process planning and machine configuration building is proposed, as well as the architecture and steps of the design methodology. All of above established the scientific base for the subsequent research of this dissertation. As designing for an operation family is the essence of RMT design, so the method for identifying the operation family from the operation demands of part family is proposed, and the operation family must be machined on the same RMT. The tolerance-based and concurrency-based clustering principles and conditions for single part are given, and the pattern recognition issue for the similar special operation clustering in the concurrency-based clustering is discussed, and the mathematic model, category, and algorithm of the pattern recognition are proposed. The similarity measure between the single part operation clustering is presented, and the problem of multi-part operation clustering using modified k-means (k-modes) algorithm is studied. A method for grouping
the operation clustering (include single part and multi-parts) based on the fuzzy clustering analysis is given, so the set of operations required on the same RMT is decided, that is called operation family (because the set of operations are grouped from different parts in a part family). Using the rule-based method, the sequence of the operation clustering and the operation sequence in each operation clustering are obtained, thereby the feasibility of RMT designed is ensured.Aim at to realize the customized flexibility of RMT, a modular design method for mechanical system of RMT which based on the screw and graph is presented. Within this method, the kinematics modeling of RMT basic functions and machine tool modules are established using screw method. By comparing the twist between them, each function (kinetic and structure) is then mapped to a feasible set of modules (or named building block) in the module library. Using the graph theory, a set of feasible structural configurations of the RMT is designed, as well as the connectivity of each machine module is defined. A method for generating a series alternative RMT configuration and reconfiguration (graph) met the operation requirements is given. In order to realize the reconfiguration online of RMT and maximumly use the machine resources, a design method for reconfigurable machine module is developed using screw method. Employing such machine module, the functionality of an RMT can be changed without replacing modules.In order to realize the objective that synchronously reconfigure the control and machine of RMT, a modular design method for RMT controller is proposed. Within this method, both the entire controller and its individual control module are acted as a set consisting of a Finite State Machine (FSM) and input & output event set pairs, and each pair of input & output event set was defined as a port of the control module, and the input event set on a given port formed the port acceptable Language. Thus, when the mechanical modules are assembled, the control modules will be connected using port Language, and the entire controller is created or reconfigured. The definitions of control module with FSM and module combination are given. A design and construction principles of modular controller are proposed, and the principles correctness are proved. Once the control modules are properly designed and connected, the resulting controller is guaranteed to be controllable. When the demand is changed, the control module can be reused by redefining the port language without change the controllability.In order to minimize the redundancy capacity and functionality of machine, a configuration design method for configuration path of RMT in the early stage of configuration design is proposed, which is designed for changing requires scenario. By evaluating the configuration economics and reconfigurability over the lifetime of RMT, the method
引文
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