摘要
机械产品在国内外市场中竞争力的强弱,在很大程度上取决于产品的质量,而且随着现代科学技术的快速发展与市场竞争的日益激烈,产品的技术含量和复杂程度正在不断增加。在知识经济时代的今天,本文所述的是包括:知识K(Knowledge)、质量Q(Quality)、价格C(Cost)、研发生产周期T(Time)、工作环境E(Environment)和售后服务S(Service)等用户对产品的各种要求的广义质量。而产品的广义质量在很大程度上取决于产品的研究与开发,最重要的就是产品的设计,产品的设计质量可赋予某种产品“先天性优劣”这种至关重要的本质特性。因此对绝大多数的产品来说,产品的设计工作在保证产品质量的过程中起着头等重要的作用。
为搞好产品设计,近百年来国内外科技工作者进行了大量的研究,提出了数十种设计理论与方法,但这些方法只能在一定范围内适用于特定产品或是产品开发的某些阶段,还没有一种可以很好地覆盖整个产品开发周期的设计理论与方法,因此,设计理论与方法仍存在很多不足和需要继续研究的问题。同时,面对纷繁复杂的设计理论与方法,如何在产品设计过程中加以有效的选择和运用,实现不同设计方法的有机组合和最佳匹配,也一直是设计理论与方法研究的热点和难点问题。
本文对以下问题进行了研究:
1.在已有理论的基础上,将产品设计分为四个阶段,即调研阶段(the stage ofresearch)、规划阶段(the stage of planning)、实施阶段(the stage of implementation)和检验阶段(the stage of test)。
(1)产品的调研阶段,主要完成产品市场情况调研和技术进步分析预测。
(2)产品设计规划阶段,采用8D产品总体规划理论完成产品设计的全程规划;
(3)产品设计实施阶段,采用以非线性动力学理论与方法、智能控制理论与技术和计算机技术为基础的,以“功能优化设计、动态优化设计、智能优化设计和可视优化设计”为核心的,以提高产品广义质量和综合性能为目标的、能够克服单一设计法局限性的、面向现代机械产品广义质量和综合性能的高层次的“1+3+X”综合设计法,来完成对产品的详细设计;
(4)产品设计检验阶段,采用3A质量检验与评估模型来完成对产品的评估和检验;从而构成了一个完整的设计系统。
2.将现代机械产品系统化设计理论与方法,应用于某型号空调用滚动转子式压缩机的设计中。本课题的研究除得到了国家自然科学基金重点项目(50535010)、还得到沈阳华润三洋压缩机有限公司的支持,应用方面的研究分以下五个方面展开:
(1)某型号空调用滚动转子式压缩机的设计调研阶段。从用户需求调研、产品环境调研和风险调研三方面对空调压缩机行业进行了设计调研,并最终确立了研发方向。
(2)某型号空调用滚动转子式压缩机的设计规划阶段。按照8D设计规划理论,从制定设计目标、明确设计思想、考虑设计环境、规划设计过程、选用设计方法,制定设计内容、规划质量评价与检验和编制设计规划书8个方面进行全程规划。
(3)某型号空调用滚动转子式压缩机的设计实施阶段。采用“1+3+X”综合设计法,对某型号空调用滚动转子式压缩机进行功能优化设计,建立了压缩机的功能结构,和功能实现策略,以此为基础完成了压缩机的方案设计;对某型号空调用滚动转子式压缩机进行了部分内容的动态优化设计,考虑压缩机的具体工作情况,并主要针对压缩机的振动和噪声方面进行了噪声源定位实验、模态振型实验的测试,对消声器的原理进行了研究,并对压缩机零部件进行了动力学分析和校核分析;对某型号空调用滚动转子式压缩机进行部分内容的智能优化设计,分析了压缩机电机的控制系统的结构和控制系统流程。对某型号空调用滚动转子式压缩机进行了部分内容的可视优化设计。建立了压缩机实体模型,从装配可视化和动力学可视化两方面对其进行设计。
(4)某型号空调用滚动转子式压缩机的设计检验阶段。采用3A质量检验与评估模型,首先对设计方案运用模糊理论对压缩机进行评价;然后对样机进行了性能试验、噪声试验、加速寿命试验;产品设计定型后,转入批量生产。抽检数据表明,该机型性能优越,质量稳定。从目前获得的客户反馈看,该机型很好地满足了市场需求。
The competitiveness of the echanical product in the domestic and international market is depended on its quality mostly. The products are more and more high technology and complicated with the modern science and technology developing rapidly and market competition increasingly fierce. In today's era of knowledge economy, the quality is generalization quality which the customers need and includes K(Knowledge) Q(Quality),C(Cost),T(Time),E(Environment) and S(Service). The generalization quality of product is depended on its research and development. The design of products is the most important. The design quality gives the products important essential characteristics which depends on its congenital superiority or inferiority. So it is very important to guarantee the quality for many products.
To improve the product quality, many researchers have done plenty of research work about the product design, and presented many new design theory and method. But these methods are only suitable for the certain product or certain development stages. The method which could cover the whole development period is inexistence. Many problems and deficiencies need to be studied continually about design theory and method. At the same time, the difficulty problems how to use such many methods in the design process and how to realize organic combination and match the different methods are the focus.
The following problems are researched in this paper
1. Base on the theory has been divided into fore stage which are the stage of research, the stage of planning, the stage of implementation, the stage of test.
(1) The finished product market analysis and forecasting research and technological progress are focused on in the stage of research.
(2) The 8D overall product planning theory is used to complete the entire in the stage of planning.
(3) In the stage of implementation, non-linear dynamics theory and methods, intelligent control theory and technology and computer technology-based are used to, overcome the limitations of a single design method-oriented macro-quality of modern machinery and integrated performance of high-level "1 +3 + X" integrated design method, to complete the detailed design of the product in order to "function optimal design, dynamic optimization design, intelligent design and visual optimization design" as the core of the in order to improve product quality and overall performance of broad objectives.
(4) In the stage of testing, the 3A quality inspection and evaluation of models is used to complete the product evaluation and testing; and thus constitute a complete design system.
2. Systematic design of modern mechanical products theories and methods are applied to a model air-conditioning rotary compressor design. The research is supported by the significant project of the National Natural Science Foundation of China (50535010), and Shenyang Sanyo Compressor Co. Ltd and the applied research should be started under the following five areas:
(1) In the stage of research in a certain model air-conditioning rotary compressor design, Research of the demand of the user is including, products, environmental research and risk research three aspects which have been designed air-conditioning compressor industry research, and ultimately established a research and development direction;
(2) The designing and planning stage of a certain type of air-conditioning rotary compressor. According to the 8D designing and planning theory, the paper makes the full planning in eight aspects. The eight aspects are as follows : formulating the designing object, ascertaining the design idea, considering the design environment, planning the design process, selecting the design methodology, formulating the design content, planning the quality evaluation and test and making the designing program.
(3) The design implementation phase of a certain model air-conditioning rotary compressor. With the "1+3+X" integrated design method, this paper made functional optimization design of a certain model air-conditioning rotary compressor, established the functional structure and functional implementation strategy of the compressor, and then completed the program design; this paper made part dynamic optimization design of a certain model air-conditioning rotary compressor, made positioning experiment of the noise source, testing of the modal vibration mode experiment of the air-conditioning rotary compressor taking into account of the specific work of the compressor. It also studied the principle of the muffler and made the dynamic analysis and checking analysis of the parts of the compressor; it made part intelligent optimal design of a certain model air-conditioning rotary compressor and analyzed the structure and process of the compressor motor control system. It made part visual optimal design of the compressor, established solid model of the compressor and designed it from the aspect of the assembly visualization and dynamics visualization.
(4) The designing and inspecting phrase of a certain type of air-conditioning rotary compressor. With the 3A quality inspection and evaluation models, at first the paper uses the fuzzy theory in the design of the compressor evaluation and then it makes the test of performance of the prototype besides the noise test, accelerating life testing. After the forming of the product design, it converts to mass production. Sampling data shows that the model is of superior performance and stabling quality and. Viewing from the customer's feedback, this prototype meets the market's needs perfectly.
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