面向并行工程的数控车床可靠性研究
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摘要
一、引言
    最近几年,随着电子技术、信息技术、精密机械技术等相关学科的迅速发展,数控车床的转速、快速移动速度、换刀时间、控制轴数、分辨率等许多性能指标都有很大提高,然而可靠性问题却是困扰数控车床发展的主要问题之一。数控车床故障频繁,不能完成规定的功能,无法发挥其在国民经济发展和国防建设中的保障作用,从而也就失去了数控车床自身的先进性。
    提高数控车床的可靠性已成为当前数控车床制造企业自身生存和发展的关键。在市场竞争日趋激烈的情况下,只有那些可靠性高的数控车床才能受到用户的青睐。用户固然注重机床的功能和先进性,但更关注功能和先进性的维持性,即可靠性。数控车床是否可靠已成为广大用户选购数控车床的重要标准。由于国产数控车床的整体可靠性水平与进口产品相比有较大差距,影响了其在用户中的声誉和信任度,严重冲击了我国数控车床产业的发展,所以迅速提高数控车床的可靠性是一个急需亟待解决的问题。
    本课题正是在这种背景下提出的,它是国家高技术研究发展计划(863计划)课题—数控装备与系统可靠性关键技术开发及应用的一部分。以某系列数控车床为工程背景,对面向并行工程和全寿命周期工程数控车床可靠性技术及其信息系统进行了研究,并应用于国产数控车床,促使产品的MTBF值(平均故障间隔时间:Mean Time Between Failures)接近国际先进水平。
    二、面向并行工程的数控车床可靠性工程
    并行工程(concurrent engineering)是近年来新出现的一种产品开发模式,它受到了国内外众多研究单位与制造企业的重视。并行工程是集成地、并行地设计产品及其相关过程的系统化方法。它要求产品开发人员从设计一开始就考虑产品生命周期中的各种因素。其重要目的是缩短产品开发周期,提高产品质量,降低产品成本,从而增强企业的竞争能力。
    本文全面分析了数控车床产品全寿命周期可靠性工作, 提出了可靠性工作是面向数控车床全寿命周期的思想。由于并行工程也是面向产品全寿命周期,因此提出了面向并行工程的数控车床可靠性分析的思想,并且充分分析了可靠性工程与数控车床并行工程环境中主要技术之间的关系,由此体现面向并行工程的数控车床可靠性分析的思想。基于面向并行工程的数控车床可
    
    
    靠性分析的思想,提出了面向并行工程的数控车床可靠性控制模型。为了利于数控车床可靠性分析,根据该面向并行工程的数控车床可靠性控制模型的分析,提出了渐进式可靠性分析。把人工神经元网络应用于数控车床可靠性分析中,提出了数控车床可靠性分析的神经元法,并且建立了基于神经元法的数控车床功能分解重组。为了进行数控车床故障分析,基于数控车床功能分解重组提出了面向并行工程的数控车床故障模式、影响分析方法。
    三、数控车床可靠性评价体系
    结合在国家“863”计划课题—数控装备与系统可靠性关键技术开发及应用研究中收集的大量某系列数控车床故障数据,对数控车床可靠性进行了系统的深入的研究,初步建立了数控车床可靠性评价体系并给出了相应的评价指标。运用数控机床可靠性信息管理系统分析给出了该系列数控车床的可靠度(R(t))、累积失效概率(F(t))、累积失效概率密度(f(t))、瞬时失效率(λ(t))四个基本函数的数学模型,平均故障间隔时间(MTBF)、平均维修时间(MTTR)、固有有效度()和使用有效度()。以数控车床的平均故障间隔时间、平均维修时间和使用有效度3个指标为基础,利用模糊加权综合平均方法求出了该系列数控车床的使用可靠度。
    四、数控车床故障分析
    本文建立了基于神经元法的数控车床神经元网络结构图,应用面向并行工程的数控车床可靠性分析的原理和方法,对考核的数控车床进行了故障统计分析,查清了数控车床各故障神经元、故障模式及故障原因的比率,从整体上掌握了该系列数控车床的故障发生情况。该系列数控车床的故障多发神经元主要是CNC系统(20.83%)、电气系统(18.06%)、转塔(16.67%)、装卡附件(11.11%)和液压系统(9.72%)。最频繁的故障模式是零部件损坏(16.67%)、元器件损坏(15.28%)、液、气、油渗漏(11.11%)、线路、电缆连接不良(8.33%)、锁紧部件松动(8.33%)、参数调整不当(5.56%)和定位精度超标(5.56%)。故障原因主要是零部件损坏(15.28%)、元器件损坏(13.89%)、渗漏(9.72%)、松动(8.33%)、磨损(6.94%)、误操作(6.94%)、调整不当(6.94%)、压力、流量不适(5.56%)、断裂(5.56%)和开关线路接触不良(4.17%)。该系列数控车床的故障以用户和外购、外协件为主,占到故障总数的73.61%,而装配、制造和设计等共占26.39%。
    
    
    利用FMECA方法对数控车床故障数据进行了详细、深入的可靠性定性分析,给出了FMECA分析结果。分析出了数控车床发生故障的各个神经元及其具体故障模式,各故障模式的典型故障现象,发生属于该故障模式时故障的可能原因,故障模式发生的概率等级和严酷度类别。同时对发生故障较多的CNC系统和电气系统也建立了它们的神经元网络结构图,进行了它们的故障模式、影响分析(FMEA)。通过以上工作,较全面地分析了该系列数控车床故障的分布情况,并且深入
1.INTRODUCTION
    Recent years, with rapid development of information technique, electronic technique and mechanical technique, Many performances of NC lathe, such as rotational speed, fast moving speed, controlling axis number, exchanging tool time and resolving power have gotten some improvement. However reliability is one of primary problems puzzling NC lathe development. NC lathe occur faults frequently, so it is unable to accomplish required performance and play a secure role in economic development and defense construction, thus NC lathe lose its advanced capability.
    Enhancing NC lathe reliability has become the key of survival and development for machine tool building corporation. Today machine tool market compete drastically, it is higher reliability NC lathe that can get consumer favor. Though consumers pay attention to advanced performance, they even pay attention to holding of advanced performance, i.e. reliability. Because of the whole reliability level of homemade NC lathe not to be compared with the import product, it affects its at the good reputation in the customer with the trustful of degree, impacts seriously the development of our national NC equipment. Therefore ,quickly increasing the reliability of NC lathe is a problem for urgently needing the solution.
    This thesis is just put forward under this kind of background .it is a part of development plan of national high-tech research(863 Progrom)-key technic development and application of reliability of NC equipment and its system.Regard NC lathe as project background, to face cocurrent engineering and the whole life cyclr project NC lathe reliability technology and its information system carry on research,and apply to the homemade NC lathe , enhance MTBF of the products(Mean Time Between Failures)close to the international most advanced level.
    2.CONCURRENT ENGINEERING-ORIENTED NC LATHE RELIABILITY PROJECT
    Concurrent engineering is a kind of product development mode appearing newly in recent years, it receives the attention of numerous domestic and international research units and manufacturing company. Concurrent engineering is the systematized methods to design products and its relevant courses concurrent
    
    
    and integrately. It requires that products developer should consider various kinds of factors in the cycle of the life of the products at the beginning of design. Its important purpose is to shorten the exploitation cycle of products and improve product quality, reduce the cost of products, thus strengthen the competitive power of enterprises.
    This paper has analysed the reliability work of the whole life cycle of NC lathe, and proposed that reliability work is to oriente the whole of life cycle of NC lathe. Because cocurrent engineering is to oriente the whole life cycle of products, too, I have put forward the thought of reliability analysing about concurrent engineering-oriented NC lathe. I have fully analysed the relation between reliability project and main technologies in NC lathe cocurrent engineering environment. they reflect the thought of reliability analysing in cocurrent engineering-oriented NC lathe. On the basis of the thought of reliability analysing about concurrent engineering-oriented NC lathe . I have improved and perfected the reliability controlling model about concurrent engineering-oriented NC lathe..For benefit reliability analysing of NC lathe, according to this control analysis of model, I have put forward concepts of progressive reliability analysis, I apply nerve cell in reliability analysis of NC lathe, and set up some concepts and basic methods about function resolve and recombinate of NC lathe For carry on l fault analysis of NC lathe, based on function resolve and recombinate of NC lathe I put forward fault mode effect analysis of concurrent engineering-oriented NC lathe.
    3.RELIABILITY APPRAISAL SYSTEM OF NC LATHE
    Combining with a large number of failure data of some serial NC lathe that credibility research institute collected during '863' Program, the author carries on the research of NC lathe
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