退役机床再制造评价与再设计方法研究
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摘要
我国机床保有量世界第一，但整体技术水平落后，大量机床面临技术性或功能性淘汰。机床再制造是一种基于废旧资源循环利用的机床制造新模式，是解决我国量大面广的退役机床处理过程所存在问题的最有效途径，符合当前我国发展循环经济、实施节能减排、应对气候变化的战略需要。退役机床再制造评价与再设计是机床再制造的关键技术之一，迫切需要相关理论与方法的支持。
本文结合“十一五”国家科技支撑计划课题“机床再制造关键技术与应用”（课题编号：2006BAF02A20）及“十二五”国家科技支撑计划滚动课题“机床再制造成套技术及产业化”（课题编号：2011BAF11B09）等项目，集成现代机床设计理念、方法以及机床再制造经验，对退役机床再制造评价与再设计方法进行研究，为机床再制造产业化发展提供理论支撑。
首先，在分析比较机床再制造与机床维修及改造、新机床制造的共同点以及区别的基础上，阐述机床再制造的定义及内涵；从生命周期过程的角度出发，建立包括关键技术层、生命周期过程层、目标层的机床再制造过程模型，并分别从机床再制造的目标、再设计、工艺过程、技术框架、质量控制、资源消耗及环境影响等视图，全面分析机床再制造过程。
其次，提出面向过程的退役机床可再制造度评价总体流程，建立包括技术可行性、经济可行性、资源环境效益三方面的退役机床可再制造度评价指标体系，对各个指标的量化方法进行分析，并确定各准则下各指标的权重值，进而形成一种集成的面向机床再制造过程的退役机床可再制造度评价方法，并应用于B2025龙门刨床再制造评价过程。
再次，在分析退役机床再设计过程特点的基础上，引入公理化设计理论，建立基于公理化设计的退役机床定制化再设计总体流程框架，主要包括用户需求分析、概念再设计及再制造工艺设计等过程；重点从功能特性规划、结构再设计等方面分析退役机床概念再设计过程，并结合案例对某车床再制造过程进行分析；考虑退役机床再设计的定制化特点，建立一种面向定制化再设计的退役机床物料优化配置方法，以再加工时间，再制造效益，再制造工艺难易度为定制化再设计的目标，最终实现“被动式”定制需求与“主动式”定制需求之间的优化协调。
然后，阐述退役机床再制造工艺过程的特点，对机床再制造工艺方案设计过程进行分析，主要包括机械部分修复与再制造、数控及电气部分再设计，并从节能性、环境友好性、信息化等方面，对机床整机性能综合提升方案进行分析；建立包括经济性、技术性、资源性、环境友好性的机床再制造方案综合评价指标体系，形成一种基于熵权的指标权重确定方法，进而建立退役机床再设计方案综合评价模型。
最后，对重庆机床集团实施机床再制造的实践情况进行介绍；在对YX3120系列滚齿机再制造需求分析的基础上，形成YX3120系列滚齿机再制造设计方案，再制造效益显著。
The quantity of machine tools in China is about eight million and ranks first in theworld，however, most of the machine tools are backward in technique and areconfronted with retirement and scrapping due to technology or function. Machine toolremanufacturing, as a new manufacturing model of machine tool based on reusing theused resources, is the best solution for the problems of dispose of the numerous usedmachine tools all over our country, in line with China's strategic needs of developingrecycling economy, implementing energy saving and emission reducing, and addressingclimate change. Remanufacturability evaluation and redesign are key technologies ofmachine tool remanufacturing, requiring for support from related theories and methodsurgently.
With the support of the11th Five-YearNational Key Technology R&DProgram(2006BAF02A20),the12th Five-YearNational Key Technology R&D Program(NO.2011BAF11A09) and other projects, methods of remanufacturability evaluationand redesign for machine tool remanufacturing are studied integrated with advanceddesign theory of machine tool and the practice experience of machine toolremanufacturing, which can provide technology support for the industry development ofmachine tool remanufacturing.
Firstly, the definition and connotation of machine tool remanufacturing arepresented based on the analysis of the common features and differences betweenmachine tool remanufacturing and machine tool repair or rebuild, new machine toolmanufacturing. Combined with the actual demand, a process model of machine toolremanufacturing oriented to life-cycle is established, and then the view models ofobjective, redesign, process, technology framework, quality control, resourceconsumption and environmental impact for machine tool remanufacturing are presentedto analyze the remanufacturing process.
Secondly, the process of remanufacturability evaluation of used machine tool ispresented, in which technology feasibility, economic feasibility and environmentalbenefits of machine tool remanufacturing are the evaluation indexes. In addition, thequantification methods for each index are proposed and the weights for each index aredetermined. Then, an integrated method for evaluating the remanufacturability of usedmachine tool oriented to remanufacturing process is proposed, and it is applied to the remanufacturing process of used planer B2025to examine its feasibility and validity.
Thirdly, based on the analysis of the features of reuse-oriented redesign, a novelreuse-oriented customized redesign method of used machine tools based on axiomaticdesign theory is presented, including the process of customer demand analysis,conceptual redesign and process design. In addition, the process of conceptual redesignis analyzed in detail, which is applied to lathe remanufacturing, such as the processes offunction feature planning based on QFD, structure redesign, etc. Then, an optimizationmodel is constructed based on unbalanced transportation problem to match and optimizethe reuse relationship between the cores and the designed module family for diversedemands.
Fourthly, the process of machine tool remanufacturing is introduced and theprocess scheme design of machine tool remanufacturing is analyzed, includingmechanical parts remanufacturing, NC and electrical systems retrofitting. In addition,the machine-based comprehensive upgrading scheme is analyzed from the views ofenergy-saving, environmental friendliness and informationization.Then, the evaluationindex system of machine tool remanufacturing that includes economy, technology,resource and environment is established, and the evaluation method of machine toolremanufacturing scheme based on entropy weight and analytic hierarchy process (AHP)is proposed.
Finally, the practices of machine tool remanufacturing in Chonqing Machine ToolGroup. is analyzed. The remanufacturing scheme of YX3120gear hobbing machine ispresented based on the customer demand analysis and the economic and social benefitsare analyzed.
本文结合“十一五”国家科技支撑计划课题“机床再制造关键技术与应用”（课题编号：2006BAF02A20）及“十二五”国家科技支撑计划滚动课题“机床再制造成套技术及产业化”（课题编号：2011BAF11B09）等项目，集成现代机床设计理念、方法以及机床再制造经验，对退役机床再制造评价与再设计方法进行研究，为机床再制造产业化发展提供理论支撑。
首先，在分析比较机床再制造与机床维修及改造、新机床制造的共同点以及区别的基础上，阐述机床再制造的定义及内涵；从生命周期过程的角度出发，建立包括关键技术层、生命周期过程层、目标层的机床再制造过程模型，并分别从机床再制造的目标、再设计、工艺过程、技术框架、质量控制、资源消耗及环境影响等视图，全面分析机床再制造过程。
其次，提出面向过程的退役机床可再制造度评价总体流程，建立包括技术可行性、经济可行性、资源环境效益三方面的退役机床可再制造度评价指标体系，对各个指标的量化方法进行分析，并确定各准则下各指标的权重值，进而形成一种集成的面向机床再制造过程的退役机床可再制造度评价方法，并应用于B2025龙门刨床再制造评价过程。
再次，在分析退役机床再设计过程特点的基础上，引入公理化设计理论，建立基于公理化设计的退役机床定制化再设计总体流程框架，主要包括用户需求分析、概念再设计及再制造工艺设计等过程；重点从功能特性规划、结构再设计等方面分析退役机床概念再设计过程，并结合案例对某车床再制造过程进行分析；考虑退役机床再设计的定制化特点，建立一种面向定制化再设计的退役机床物料优化配置方法，以再加工时间，再制造效益，再制造工艺难易度为定制化再设计的目标，最终实现“被动式”定制需求与“主动式”定制需求之间的优化协调。
然后，阐述退役机床再制造工艺过程的特点，对机床再制造工艺方案设计过程进行分析，主要包括机械部分修复与再制造、数控及电气部分再设计，并从节能性、环境友好性、信息化等方面，对机床整机性能综合提升方案进行分析；建立包括经济性、技术性、资源性、环境友好性的机床再制造方案综合评价指标体系，形成一种基于熵权的指标权重确定方法，进而建立退役机床再设计方案综合评价模型。
最后，对重庆机床集团实施机床再制造的实践情况进行介绍；在对YX3120系列滚齿机再制造需求分析的基础上，形成YX3120系列滚齿机再制造设计方案，再制造效益显著。
The quantity of machine tools in China is about eight million and ranks first in theworld，however, most of the machine tools are backward in technique and areconfronted with retirement and scrapping due to technology or function. Machine toolremanufacturing, as a new manufacturing model of machine tool based on reusing theused resources, is the best solution for the problems of dispose of the numerous usedmachine tools all over our country, in line with China's strategic needs of developingrecycling economy, implementing energy saving and emission reducing, and addressingclimate change. Remanufacturability evaluation and redesign are key technologies ofmachine tool remanufacturing, requiring for support from related theories and methodsurgently.
With the support of the11th Five-YearNational Key Technology R&DProgram(2006BAF02A20),the12th Five-YearNational Key Technology R&D Program(NO.2011BAF11A09) and other projects, methods of remanufacturability evaluationand redesign for machine tool remanufacturing are studied integrated with advanceddesign theory of machine tool and the practice experience of machine toolremanufacturing, which can provide technology support for the industry development ofmachine tool remanufacturing.
Firstly, the definition and connotation of machine tool remanufacturing arepresented based on the analysis of the common features and differences betweenmachine tool remanufacturing and machine tool repair or rebuild, new machine toolmanufacturing. Combined with the actual demand, a process model of machine toolremanufacturing oriented to life-cycle is established, and then the view models ofobjective, redesign, process, technology framework, quality control, resourceconsumption and environmental impact for machine tool remanufacturing are presentedto analyze the remanufacturing process.
Secondly, the process of remanufacturability evaluation of used machine tool ispresented, in which technology feasibility, economic feasibility and environmentalbenefits of machine tool remanufacturing are the evaluation indexes. In addition, thequantification methods for each index are proposed and the weights for each index aredetermined. Then, an integrated method for evaluating the remanufacturability of usedmachine tool oriented to remanufacturing process is proposed, and it is applied to the remanufacturing process of used planer B2025to examine its feasibility and validity.
Thirdly, based on the analysis of the features of reuse-oriented redesign, a novelreuse-oriented customized redesign method of used machine tools based on axiomaticdesign theory is presented, including the process of customer demand analysis,conceptual redesign and process design. In addition, the process of conceptual redesignis analyzed in detail, which is applied to lathe remanufacturing, such as the processes offunction feature planning based on QFD, structure redesign, etc. Then, an optimizationmodel is constructed based on unbalanced transportation problem to match and optimizethe reuse relationship between the cores and the designed module family for diversedemands.
Fourthly, the process of machine tool remanufacturing is introduced and theprocess scheme design of machine tool remanufacturing is analyzed, includingmechanical parts remanufacturing, NC and electrical systems retrofitting. In addition,the machine-based comprehensive upgrading scheme is analyzed from the views ofenergy-saving, environmental friendliness and informationization.Then, the evaluationindex system of machine tool remanufacturing that includes economy, technology,resource and environment is established, and the evaluation method of machine toolremanufacturing scheme based on entropy weight and analytic hierarchy process (AHP)is proposed.
Finally, the practices of machine tool remanufacturing in Chonqing Machine ToolGroup. is analyzed. The remanufacturing scheme of YX3120gear hobbing machine ispresented based on the customer demand analysis and the economic and social benefitsare analyzed.
引文
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