发动机气门生产中虚拟技术的应用与研究
|
摘要
面对发动机气门生产流程日益复杂化、用户需求多样化,市场竞争不断加剧,传统的设计已经很难适应这些变化,尤其体现在生产线可视化交互和实时监控的先进性和创造性需求方面,这也是用户在方案设计阶段最为关注的。采用虚拟制造技术可以解决这些问题,并为制造系统规划设计提供了新的思路和手段。它是多个学科领域知识的综合集成与应用,计算机仿真、建模和优化技术是虚拟制造的核心关键技术。对设计、制造等生产过程进行统一建模,在产品设计阶段或产品制造之前,就能真实地模拟出产品的未来制造全过程及其对产品设计的影响,预测产品的性能、成本及可制造性,及早地发现和解决潜在问题,从而更有效、更经济、更灵活地组织生产,达到缩短产品开发周期、降低成本、提高生产效率的目的。
本文主要研究虚拟制造技术在发动机气门生产线中的实现。首先,分析了虚拟制造技术的关键技术和研究现状;接着,分析发动机气门成形加工的状况及关键流程,并指出设计中存在的不足,提出了虚拟生产线的设计框架;再接着,在设计框架的指导下,在Multigen Creator中建立生产设备的3D模型外观,并应用面向对象技术,通过对虚拟设备行为抽象,分析归纳各类生产设备的共同和独特的属性与行为,建立了相应的设备模型库,为制造单元的设备布局设计以及快速重组设计提供了有效的建模和分析工具。然后,在研究Vega相关的虚拟现实技术的基础上,利用设备模型库和Visual C++的MFC类库开发虚拟工厂系统,实现了快速布局和生产流程仿真功能。最后,论文设计了简单的调度对象和基本的调度方案,让系统能进行简单的生产仿真。
本论文首次在发动机气门加工中实现了虚拟生产线的新思路,为以后建立与工厂的日常生产全面结合的接口,进行可视化的监控和管理提供了一种新的平台。本文成功地实现了虚拟制造技术的应用,实时模拟出产品的未来制造过程,为对气门加工工艺流程的改进和新质量检测技术的进一步研究奠定了基础。
Facing the increasingly complication of the engine valve production procedure, diversification of user demands and sharpening market competition, it is very difficult for the tradition technique of design to adapt these changes, especially in the demand of advancement and creativity in visual interaction of production line and real-time monitoring. They are what the customers pay the most attention to in scheme design stage. The can not satisfy these requirements, not to mention the real-time interaction in design process. The adoption of virtual manufacturing can solve these problems. It provides new ideas and methods for manufacture system layout. It is the meta-synthesis and appliance of multidisciplinary. Its crucial technologies include computer simulation, modeling and optimization technique. It can model uniformly in design and manufacture. The whole manufacture process and the affects are simulated in advance to forecast the performance, cost and manufacturability of the product to find and resolve the latent problem as early as possible, so that the production can be organized more effectively, economically and flexibly. It can shorten the development cycle, reduce the cost and lower the decision risk.
This application of virtual manufacturing in engine valve production is mainly studied in this paper. First, key technologies and research status of virtual manufacture are analyzed. Then, the situation of valve forming and key processes are analyzed. The the existing flaws are pointed out, and the design frame of virtual production line is put forward. And then, 3D models are built in Multigen Creator. Using object-oriented method, behavior of the virtual equipments is abstracted. Properties and behavior in common and unique are analyzed. Corresponding model library is built. It provides an effective tool for modeling and analysis of the facility layout and reconfiguration rapidly of manufacturing cell. Then, based on VR technology of Vega, model library and MFC of Visual C++ are used to develop the virtual factory. Quick layout and production process simulation is realized. Finally, simple scheduling objects and plan are designed to simulate the production.
The new way of virtual production line using in production and processing of engine valve is implemented for the first time. It offers a new platform for the interface to the routine production, and for the visual monitoring and management in future. Application of virtual manufacturing is realized successfully in the thesis. The whole process of product's manufacture in the future is simulated in real time. This will lay the foundation for modification of treatment process and research on quality detection in future.
本文主要研究虚拟制造技术在发动机气门生产线中的实现。首先,分析了虚拟制造技术的关键技术和研究现状;接着,分析发动机气门成形加工的状况及关键流程,并指出设计中存在的不足,提出了虚拟生产线的设计框架;再接着,在设计框架的指导下,在Multigen Creator中建立生产设备的3D模型外观,并应用面向对象技术,通过对虚拟设备行为抽象,分析归纳各类生产设备的共同和独特的属性与行为,建立了相应的设备模型库,为制造单元的设备布局设计以及快速重组设计提供了有效的建模和分析工具。然后,在研究Vega相关的虚拟现实技术的基础上,利用设备模型库和Visual C++的MFC类库开发虚拟工厂系统,实现了快速布局和生产流程仿真功能。最后,论文设计了简单的调度对象和基本的调度方案,让系统能进行简单的生产仿真。
本论文首次在发动机气门加工中实现了虚拟生产线的新思路,为以后建立与工厂的日常生产全面结合的接口,进行可视化的监控和管理提供了一种新的平台。本文成功地实现了虚拟制造技术的应用,实时模拟出产品的未来制造过程,为对气门加工工艺流程的改进和新质量检测技术的进一步研究奠定了基础。
Facing the increasingly complication of the engine valve production procedure, diversification of user demands and sharpening market competition, it is very difficult for the tradition technique of design to adapt these changes, especially in the demand of advancement and creativity in visual interaction of production line and real-time monitoring. They are what the customers pay the most attention to in scheme design stage. The can not satisfy these requirements, not to mention the real-time interaction in design process. The adoption of virtual manufacturing can solve these problems. It provides new ideas and methods for manufacture system layout. It is the meta-synthesis and appliance of multidisciplinary. Its crucial technologies include computer simulation, modeling and optimization technique. It can model uniformly in design and manufacture. The whole manufacture process and the affects are simulated in advance to forecast the performance, cost and manufacturability of the product to find and resolve the latent problem as early as possible, so that the production can be organized more effectively, economically and flexibly. It can shorten the development cycle, reduce the cost and lower the decision risk.
This application of virtual manufacturing in engine valve production is mainly studied in this paper. First, key technologies and research status of virtual manufacture are analyzed. Then, the situation of valve forming and key processes are analyzed. The the existing flaws are pointed out, and the design frame of virtual production line is put forward. And then, 3D models are built in Multigen Creator. Using object-oriented method, behavior of the virtual equipments is abstracted. Properties and behavior in common and unique are analyzed. Corresponding model library is built. It provides an effective tool for modeling and analysis of the facility layout and reconfiguration rapidly of manufacturing cell. Then, based on VR technology of Vega, model library and MFC of Visual C++ are used to develop the virtual factory. Quick layout and production process simulation is realized. Finally, simple scheduling objects and plan are designed to simulate the production.
The new way of virtual production line using in production and processing of engine valve is implemented for the first time. It offers a new platform for the interface to the routine production, and for the visual monitoring and management in future. Application of virtual manufacturing is realized successfully in the thesis. The whole process of product's manufacture in the future is simulated in real time. This will lay the foundation for modification of treatment process and research on quality detection in future.
引文
[1]万苏文.面向21世纪的虚拟制造技术[J].机电一体化,2004,(02):11-14.
[2]刘凯,曾忠.虚拟制造技术研究及其发展[J].机械工程师,2007,(09):100-102.
[3]魏安顺,周印,谢叻.虚拟现实技术及其在制造业的应用[J].模具技术,2004,(05):54-58.
[4]邵立.基于虚拟制造技术的自动线设计研究[D].上海交通大学博士学位论文,2000.2:5-16.
[5]Kimura F.Product and Process Modeling as a Kemal for Virtual Manufacturing Environment[J].Annals of the CIRP,1993,42(1):147-154.
[6]Masahiko Onosato,Kazuaki Iwata et.al.,Development of VM System by Integrating Product Models and Factory Models[J].Annals of the CIRP,1993Vol.42(1)
[7]Kazuaki Iwata et.al.,Virtual Manufacturing Systems as Advanced Information Infrastructure for Integrating Resource and Activities[J].Annals of the CIRP,1997Vol.46(1):335-338.
[8]肖田元,郑会永,王新龙,韩向利.虚拟制造体系结构研究[J].计算机集成制造系统-CIMS,1999,(01):33-38
[9]S.Nahavandi.A virtual manufacturing environment with an element of reality.Factory 2000-Advanced Factory Automation,1994 October.
[10]Lin E.,Minis I.Nau D S,et.al.Contribution to Virtual Manufacturing Background Research.Technical report.The University of Maryland,1997.
[11]Gloria J.Wiens.An overview of virtual manufacturing[M].Virtual manufacturing-proceeding of 2nd agile manufacturing conference(AMC'95)
[12]肖田元,韩向利,张林煊.虚拟制造内涵及其应用研究[J].系统仿真学报,2001.1,13(1):118-123
[13]习俊杰,吴中.虚拟制造及其体系结构研究[J].机床与液压,2004,5(1):94-96.
[14]李珊,李治邦.虚拟制造技术[J].计算机应用研究,2001.3:1-3.
[15]王宏典,张友良.虚拟制造技术及其体系结构[J].机械制造,2000.4,38(428):20-23
[16]魏安顺,周印等.虚拟现实技术及其在制造业的应用[J].模具技术,2004.5:54-58.
[17]Chetan Shukla etc.Virtual manufacturing:an overview,Computer Ind.Engng,1996 Vol.31(1-2):79-82.
[18]邵立,钟延修,严隽琪等.虚拟制造环境与仿真[J].中国机械工程,2000,5:919-922.
[19]陈雁飞,马建民,高丽.虚拟现实技术综述[J].机械制造与自动化,2004.10,33(5):5-7.
[20]马栋林.关于虚拟现实技术及其应用的研究[J].甘肃科技,2003.8,19(8):30.
[21]王国强,陈家新.虚拟制造可视化环境技术研究现状及发展趋势[J].河南科技大学学报,2004.8,25(4):20-24.
[22]徐晓峰,张浩,樊留群.基于集成化产品设计平台的虚拟制造及其仿真建模研究[J].制造业自动化,2004.7,26(7):47.
[23]金明霞,吴晓燕,朱昌葵.建模与仿真生命周期综述[J].计算机仿真,2003.8,20(8):46-48.
[24]刘庆鸿,陈得源,王子才.建模与仿真校核、验证与确认[J].系统仿真学报,11,15(7):925-930.
[25]Chetan Shukla etc.Virtual Manufacturing User Workshop.Technical Report.1994,15(9)
[26]Jean V.Owen.Virtual Manufacturing,Manufacturing Engineering,Oct.1997:84-90.
[27]彭丽华.机械制造仿真实体建模技术新论[J].太原师范学院学报,2004.6,3(2):56-58.
[28]李玉忠,陈泽琳,杨振野.基于知识的虚拟设计研究[J].中国机械工程,2004.5,15(9):809-812.
[29]Raymond E Chalmers,Going digital at Daimler Chrysler,Manufacturing Engineering,Dearborn,1999,Aug.,Vol.123(2):66-70.
[30]于会涛.虚拟制造技术分析及其环境的建立[D].西北工业大学硕士学位论 文2001.1:2-3,15-16.
[31]李珊.虚拟制造技术及其应用.指挥技术学院学报[J],2000.10,11(5):97-103.
[32]汪立亮,姬建伟.车用发动机气门材料的选用及新材料的开发[J].湖北汽车,2000,(2):37-42.
[33]赵明好.国内外内燃机气门现状和发展动向[J].内燃机配件,1998(5):14-16.
[34]高云.气门摩擦焊接及超声波探伤[J].内燃机配件,2000,(2):28-30.
[35]郭旭之.快速气门自动检测分选系统[J].今日科技,2000,(12):15-18.
[36]邵立,严隽琪,马登哲等.生产线的虚拟集成设计[J].工业工程与管理,2000(6):1-4
[37]赵骥,朱名铨,罗琦.虚拟生产线框架及其实现[J].中国机械工程,2000,(6):671-676
[38]肖田元等.虚拟制造[M].北京:清华大学出版社,2004
[39]朱名铨,张树生.虚拟制造系统与实现[M].西安:西北工业大学出版社,2001
[40]龚全胜,李世其.基于虚拟仿真的制造系统布局[J].机械科学与技术,2004(7):857-859
[41]赵骥,乐清洪,罗琦等.虚拟生产线模型研究[J].西北工业大学学报,2000,18(4):518-522
[42]孙连胜,宁汝新,王新永.虚拟制造中生产线可视化设计[J].北京理工大学报,2002,22(1):32-36
[43]陈立伟,张翔,李晓燕.基于VEGA的数字城市漫游系统设计[J].计算机工程,2003,29(20):31-33.
[44]Nancy S.Dorighi,Barry T.Sullivan.Future Flight Central:A Revolutionary Air Traffie Control Tower Simulation Facility.Ameriean Institute of Aeronauties and Astronautics(AIA),September 2003.
[45]杨桂华.基于PC的虚拟环境建模技术的研究[D].广东工业大学硕士学位论文,2002.
[46]Okino Computer Graphies Inc.PolyTrans User Manual And RefereneeGuide Guide.1998.
[47]MultiGen-Paradigm Inc.OPenFlight API User's Guide(Volume I)[M/CD].1998.
[48]赵骥,肖田元,韩向利等.制造系统虚拟环境行为建模研究[J].清华大学学 报(自然科学版),2001,42(3):369-372
[49]Lee.Y.G.and Malone M.F..Batch Proeess schedule optimization under parameter volatility[J].Journal of Production Research.2001,4:603-623.
[50]魏国前,卢全国,陈定方.物流系统仿真的三维可视化研究[J].湖北工业大学学报,2005,20(3):160-161.
[51]邹湘军,孙健,何汉武.虚拟环境下的生产线三维动态仿真及其建模[J].组合机床与自动化加工技术,2004,4:29-31.
[52]O.Felix Offodile,Layek L.Abdel.The virtual manuafeturing Paradigm:the impact of It/Is outsourcing on manufacturing strategy[J].Production Economies,2002,75:147-159.
[53]G.H.Lee.Design of components and layout of machines of material handling[J].the International Journal of Advanced Manuafeturing Technology,2001,17:371-382.
[2]刘凯,曾忠.虚拟制造技术研究及其发展[J].机械工程师,2007,(09):100-102.
[3]魏安顺,周印,谢叻.虚拟现实技术及其在制造业的应用[J].模具技术,2004,(05):54-58.
[4]邵立.基于虚拟制造技术的自动线设计研究[D].上海交通大学博士学位论文,2000.2:5-16.
[5]Kimura F.Product and Process Modeling as a Kemal for Virtual Manufacturing Environment[J].Annals of the CIRP,1993,42(1):147-154.
[6]Masahiko Onosato,Kazuaki Iwata et.al.,Development of VM System by Integrating Product Models and Factory Models[J].Annals of the CIRP,1993Vol.42(1)
[7]Kazuaki Iwata et.al.,Virtual Manufacturing Systems as Advanced Information Infrastructure for Integrating Resource and Activities[J].Annals of the CIRP,1997Vol.46(1):335-338.
[8]肖田元,郑会永,王新龙,韩向利.虚拟制造体系结构研究[J].计算机集成制造系统-CIMS,1999,(01):33-38
[9]S.Nahavandi.A virtual manufacturing environment with an element of reality.Factory 2000-Advanced Factory Automation,1994 October.
[10]Lin E.,Minis I.Nau D S,et.al.Contribution to Virtual Manufacturing Background Research.Technical report.The University of Maryland,1997.
[11]Gloria J.Wiens.An overview of virtual manufacturing[M].Virtual manufacturing-proceeding of 2nd agile manufacturing conference(AMC'95)
[12]肖田元,韩向利,张林煊.虚拟制造内涵及其应用研究[J].系统仿真学报,2001.1,13(1):118-123
[13]习俊杰,吴中.虚拟制造及其体系结构研究[J].机床与液压,2004,5(1):94-96.
[14]李珊,李治邦.虚拟制造技术[J].计算机应用研究,2001.3:1-3.
[15]王宏典,张友良.虚拟制造技术及其体系结构[J].机械制造,2000.4,38(428):20-23
[16]魏安顺,周印等.虚拟现实技术及其在制造业的应用[J].模具技术,2004.5:54-58.
[17]Chetan Shukla etc.Virtual manufacturing:an overview,Computer Ind.Engng,1996 Vol.31(1-2):79-82.
[18]邵立,钟延修,严隽琪等.虚拟制造环境与仿真[J].中国机械工程,2000,5:919-922.
[19]陈雁飞,马建民,高丽.虚拟现实技术综述[J].机械制造与自动化,2004.10,33(5):5-7.
[20]马栋林.关于虚拟现实技术及其应用的研究[J].甘肃科技,2003.8,19(8):30.
[21]王国强,陈家新.虚拟制造可视化环境技术研究现状及发展趋势[J].河南科技大学学报,2004.8,25(4):20-24.
[22]徐晓峰,张浩,樊留群.基于集成化产品设计平台的虚拟制造及其仿真建模研究[J].制造业自动化,2004.7,26(7):47.
[23]金明霞,吴晓燕,朱昌葵.建模与仿真生命周期综述[J].计算机仿真,2003.8,20(8):46-48.
[24]刘庆鸿,陈得源,王子才.建模与仿真校核、验证与确认[J].系统仿真学报,11,15(7):925-930.
[25]Chetan Shukla etc.Virtual Manufacturing User Workshop.Technical Report.1994,15(9)
[26]Jean V.Owen.Virtual Manufacturing,Manufacturing Engineering,Oct.1997:84-90.
[27]彭丽华.机械制造仿真实体建模技术新论[J].太原师范学院学报,2004.6,3(2):56-58.
[28]李玉忠,陈泽琳,杨振野.基于知识的虚拟设计研究[J].中国机械工程,2004.5,15(9):809-812.
[29]Raymond E Chalmers,Going digital at Daimler Chrysler,Manufacturing Engineering,Dearborn,1999,Aug.,Vol.123(2):66-70.
[30]于会涛.虚拟制造技术分析及其环境的建立[D].西北工业大学硕士学位论 文2001.1:2-3,15-16.
[31]李珊.虚拟制造技术及其应用.指挥技术学院学报[J],2000.10,11(5):97-103.
[32]汪立亮,姬建伟.车用发动机气门材料的选用及新材料的开发[J].湖北汽车,2000,(2):37-42.
[33]赵明好.国内外内燃机气门现状和发展动向[J].内燃机配件,1998(5):14-16.
[34]高云.气门摩擦焊接及超声波探伤[J].内燃机配件,2000,(2):28-30.
[35]郭旭之.快速气门自动检测分选系统[J].今日科技,2000,(12):15-18.
[36]邵立,严隽琪,马登哲等.生产线的虚拟集成设计[J].工业工程与管理,2000(6):1-4
[37]赵骥,朱名铨,罗琦.虚拟生产线框架及其实现[J].中国机械工程,2000,(6):671-676
[38]肖田元等.虚拟制造[M].北京:清华大学出版社,2004
[39]朱名铨,张树生.虚拟制造系统与实现[M].西安:西北工业大学出版社,2001
[40]龚全胜,李世其.基于虚拟仿真的制造系统布局[J].机械科学与技术,2004(7):857-859
[41]赵骥,乐清洪,罗琦等.虚拟生产线模型研究[J].西北工业大学学报,2000,18(4):518-522
[42]孙连胜,宁汝新,王新永.虚拟制造中生产线可视化设计[J].北京理工大学报,2002,22(1):32-36
[43]陈立伟,张翔,李晓燕.基于VEGA的数字城市漫游系统设计[J].计算机工程,2003,29(20):31-33.
[44]Nancy S.Dorighi,Barry T.Sullivan.Future Flight Central:A Revolutionary Air Traffie Control Tower Simulation Facility.Ameriean Institute of Aeronauties and Astronautics(AIA),September 2003.
[45]杨桂华.基于PC的虚拟环境建模技术的研究[D].广东工业大学硕士学位论文,2002.
[46]Okino Computer Graphies Inc.PolyTrans User Manual And RefereneeGuide Guide.1998.
[47]MultiGen-Paradigm Inc.OPenFlight API User's Guide(Volume I)[M/CD].1998.
[48]赵骥,肖田元,韩向利等.制造系统虚拟环境行为建模研究[J].清华大学学 报(自然科学版),2001,42(3):369-372
[49]Lee.Y.G.and Malone M.F..Batch Proeess schedule optimization under parameter volatility[J].Journal of Production Research.2001,4:603-623.
[50]魏国前,卢全国,陈定方.物流系统仿真的三维可视化研究[J].湖北工业大学学报,2005,20(3):160-161.
[51]邹湘军,孙健,何汉武.虚拟环境下的生产线三维动态仿真及其建模[J].组合机床与自动化加工技术,2004,4:29-31.
[52]O.Felix Offodile,Layek L.Abdel.The virtual manuafeturing Paradigm:the impact of It/Is outsourcing on manufacturing strategy[J].Production Economies,2002,75:147-159.
[53]G.H.Lee.Design of components and layout of machines of material handling[J].the International Journal of Advanced Manuafeturing Technology,2001,17:371-382.