面向可适应性的产品模块化设计方法与应用研究
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摘要
可适应设计(AD)是面向产品生命周期,将满足不同需求及需求变化的可适应性作为重要评价标准,以提供具有柔性、易定制性、可重用性、可扩展性的产品为目标的全新设计方法。通过可适应设计,用户不仅可以得到价格低廉、“一物多用”的新型产品,还能够通过零部件替换满足未来的需求。本文基于公理设计方法探讨如何从模块化的设计角度来研究和提高产品的可适应性。从需求分析出发,以公理设计方法中设计域之间的层级映射为框架,以设计结构矩阵为分析工具,采用优化聚类算法,从底层参数级到上层零部件级设计参数对产品的结构进行模块化可适应的设计研究,以开发和设计多样化的高可适应性新型产品。
首先,综述了目前模块化设计、产品族设计、可适应设计及相关领域的理论方法和研究现状,分析了可适应设计与模块化设计之间关系。
其次,以公理设计的设计域为研究主线,针对面向可适应性的模块化体系结构的设计探讨并提出了若干新方法。具体包括:
(1)针对产品可适应性评价问题,基于公理设计和功能模块独立条件矩阵分别从参数级和模块级分析了功能要求和设计参数的一一对应程度,并通过接口标准化程度、功能兼容性、拆卸可逆性三个指标评定接口的可适应性;基于Kano需求模型对产品通过适应性变化达到客户满足的程度进行了评价,并以台式打孔装订机为例进行了验证。结果表明:该方法不仅能从结构上对产品可适应性进行度量,更能反映出设计的不足,对进一步的改良设计提供有价值的借鉴。
(2)在模块划分方法方面,基于公理设计通过微分分析将设计矩阵转化成设计结构矩阵,并分别构建设计参数从功能域、过程域和结构域角度考虑的相关性设计结构矩阵;从考虑模块的加工效率出发,建立了设计参数关于过程域中过程变量的相似性矩阵,通过基于最小描述长度的遗传算法对其进行聚类分析,以打孔装订机的打孔装置为实例实现了模块的合理划分。结果表明,该方法考虑因素较以往方法更全面、更直观,设计者可以根据产品实际情况对各交互关系有所偏重,快速得到合理的定量化分析结果。
(3)针对模块划分过程中的耦合设计参数容易导致反复迭代的问题,基于公理设计和基于三角模糊数的层次分析法获得设计参数的量化设计结构矩阵,建立了工作量变化矩阵模型,给出了设计模态和关键设计参数的定义,并由此判断给定设计是否收敛和识别出关键设计参数。最后通过打孔装订机的切管装置实例验证表明,该方法可以判断给定设计的收敛性,并能识别出影响设计反复迭代的关键设计参数。
(4)针对现有两大产品平台设计方法提供平台定制能力有限的问题,提出了可适应平台的概念。基于灰色关联和模糊聚类相结合的方法对客户需求进行量化聚类分析,以对识别可适应平台的构成元素提供依据;基于公理设计推导出设计参数构成公共平台参数的数学模型,利用敏感设计结构矩阵对公共平台参数和定制参数进行了区分。最后,通过台式打孔装订机产品族可适应平台的分析实例验证表明,该方法弥补了现有两种平台设计方法的缺点,可以同时从横向和纵向上提高了平台的定制能力和可适应能力。
开发了面向产品可适应性的模块化设计系统MDSA,介绍了系统软件实现的体系结构、功能组成等,并给出了系统针对以上几个实例的运行界面及其结果表示。
最后对全文进行了总结,指出了进一步的研究方向。
Adaptable design (AD) is a new design methodology based on product life-cycle, and takes the adaptability that can meet various and changeable requirements as an important evaluation criterion. It aims to provide customer flexible, customizable, reusable, extensible and versatile product with a low price, which can satisfy potential requirements through simple replacement of parts. This dissertation focuses on how to improve the adaptability of product with modularization. Base on the hierarchical mapping between the design domains of axiomatic design method, analyses of customer requirements are first performed, design structure matrix is introduced as analytical tool, and modular and adaptable product architecture is researched from bottom to up design parameters with advanced and reasonable optimization algorithm in order to develop new product with high adaptability.
Firstly, the state quo of researching on the methodologies of modular design and adaptable design and other relative field is summarized and the connotation. Further on, the relationship of AD and modular design is expatiated.
Secondly, several new methods addressing how to design modular product architecture for adaptability are proposed with design domains of axiomatic design as leading clue, including:
(1) In view of the problem of that the current evaluation method for adaptability cannot provide effective feedback to product redesign, the corresponding degree of functional requirements and design parameters is analyzed based on axiomatic design and independent matrix of functional modules from parameter and module hierarchy respectively. The adaptability of interfaces and the performance of adaptive requirements are estimated with three criteria and Kano requirement model respectively, and bookbinding machine is selected as an illustration. The results show that the method can not only evaluate the adaptability of product according to architecture, but also reflect the shortcomings in the design and provide valuable reference for redesign.
(2) Because most current modularization methods address the problem with unilateral consideration and lack of generality, the design matrix is transformed into design structure matrix of the design parameters utilizing total differential calculation, and correlation matrices of design parameters about function, process and structure are established based on design matrices. The similarity matrix of design parameters about process variable in process domain is also constructed with the consideration of the manufacturing efficiency. At last, genetic algorithm combined with the minimal description length is employed to solve the modularization optimization problem. The modularization illustration of the bookbinding shows that the proposed method is more comprehensive and clear, and the designer can set different weights to each interaction relationship and get reasonable result with quantification means.
(3)In order to solve the coupling problem in the modularization process, the quantified design structure matrix of design parameters is obtained based on axiomatic design. Subsequently, work transform matrix model is established to judge whether the design is convergent and identify key coupled parameters that cause design iterations mostly. An illustrative example of the cutting set of bookbinding machine shows that the presented method can judge the given design convergent or not, and identify the key coupled parameters and design modes that mostly lead to long development cycle.
(4) Because the two existing product platform design methods both have the disadvantage of limited customization ability, the concept of adaptable platform is presented, and the composing and character also are analyzed. In order to provide reasonable reference for the identification of components of adaptable platform, customer requirements are quantified and clustered with the combination of grey relational analysis and fuzzy clustering. The mathematic condition model for design parameters to be common platform parameters is deduced based on axiomatic design, and sensitivity design structure matrix is adopted to distinguish common platform parameters and customization parameters. The layout illustration of bookbinding machine shows that the presented method can make up the shortcomings of current platform design methods, and can improve the customization ability and adaptability transversely and longitudinally.
Then, the support system of MDSA is developed. The system architecture and functional modules are introduced, followed on with the presentation of some main implementation interfaces.
Finally, a conclusion is drawn and the trend on AD is anticipated.
首先,综述了目前模块化设计、产品族设计、可适应设计及相关领域的理论方法和研究现状,分析了可适应设计与模块化设计之间关系。
其次,以公理设计的设计域为研究主线,针对面向可适应性的模块化体系结构的设计探讨并提出了若干新方法。具体包括:
(1)针对产品可适应性评价问题,基于公理设计和功能模块独立条件矩阵分别从参数级和模块级分析了功能要求和设计参数的一一对应程度,并通过接口标准化程度、功能兼容性、拆卸可逆性三个指标评定接口的可适应性;基于Kano需求模型对产品通过适应性变化达到客户满足的程度进行了评价,并以台式打孔装订机为例进行了验证。结果表明:该方法不仅能从结构上对产品可适应性进行度量,更能反映出设计的不足,对进一步的改良设计提供有价值的借鉴。
(2)在模块划分方法方面,基于公理设计通过微分分析将设计矩阵转化成设计结构矩阵,并分别构建设计参数从功能域、过程域和结构域角度考虑的相关性设计结构矩阵;从考虑模块的加工效率出发,建立了设计参数关于过程域中过程变量的相似性矩阵,通过基于最小描述长度的遗传算法对其进行聚类分析,以打孔装订机的打孔装置为实例实现了模块的合理划分。结果表明,该方法考虑因素较以往方法更全面、更直观,设计者可以根据产品实际情况对各交互关系有所偏重,快速得到合理的定量化分析结果。
(3)针对模块划分过程中的耦合设计参数容易导致反复迭代的问题,基于公理设计和基于三角模糊数的层次分析法获得设计参数的量化设计结构矩阵,建立了工作量变化矩阵模型,给出了设计模态和关键设计参数的定义,并由此判断给定设计是否收敛和识别出关键设计参数。最后通过打孔装订机的切管装置实例验证表明,该方法可以判断给定设计的收敛性,并能识别出影响设计反复迭代的关键设计参数。
(4)针对现有两大产品平台设计方法提供平台定制能力有限的问题,提出了可适应平台的概念。基于灰色关联和模糊聚类相结合的方法对客户需求进行量化聚类分析,以对识别可适应平台的构成元素提供依据;基于公理设计推导出设计参数构成公共平台参数的数学模型,利用敏感设计结构矩阵对公共平台参数和定制参数进行了区分。最后,通过台式打孔装订机产品族可适应平台的分析实例验证表明,该方法弥补了现有两种平台设计方法的缺点,可以同时从横向和纵向上提高了平台的定制能力和可适应能力。
开发了面向产品可适应性的模块化设计系统MDSA,介绍了系统软件实现的体系结构、功能组成等,并给出了系统针对以上几个实例的运行界面及其结果表示。
最后对全文进行了总结,指出了进一步的研究方向。
Adaptable design (AD) is a new design methodology based on product life-cycle, and takes the adaptability that can meet various and changeable requirements as an important evaluation criterion. It aims to provide customer flexible, customizable, reusable, extensible and versatile product with a low price, which can satisfy potential requirements through simple replacement of parts. This dissertation focuses on how to improve the adaptability of product with modularization. Base on the hierarchical mapping between the design domains of axiomatic design method, analyses of customer requirements are first performed, design structure matrix is introduced as analytical tool, and modular and adaptable product architecture is researched from bottom to up design parameters with advanced and reasonable optimization algorithm in order to develop new product with high adaptability.
Firstly, the state quo of researching on the methodologies of modular design and adaptable design and other relative field is summarized and the connotation. Further on, the relationship of AD and modular design is expatiated.
Secondly, several new methods addressing how to design modular product architecture for adaptability are proposed with design domains of axiomatic design as leading clue, including:
(1) In view of the problem of that the current evaluation method for adaptability cannot provide effective feedback to product redesign, the corresponding degree of functional requirements and design parameters is analyzed based on axiomatic design and independent matrix of functional modules from parameter and module hierarchy respectively. The adaptability of interfaces and the performance of adaptive requirements are estimated with three criteria and Kano requirement model respectively, and bookbinding machine is selected as an illustration. The results show that the method can not only evaluate the adaptability of product according to architecture, but also reflect the shortcomings in the design and provide valuable reference for redesign.
(2) Because most current modularization methods address the problem with unilateral consideration and lack of generality, the design matrix is transformed into design structure matrix of the design parameters utilizing total differential calculation, and correlation matrices of design parameters about function, process and structure are established based on design matrices. The similarity matrix of design parameters about process variable in process domain is also constructed with the consideration of the manufacturing efficiency. At last, genetic algorithm combined with the minimal description length is employed to solve the modularization optimization problem. The modularization illustration of the bookbinding shows that the proposed method is more comprehensive and clear, and the designer can set different weights to each interaction relationship and get reasonable result with quantification means.
(3)In order to solve the coupling problem in the modularization process, the quantified design structure matrix of design parameters is obtained based on axiomatic design. Subsequently, work transform matrix model is established to judge whether the design is convergent and identify key coupled parameters that cause design iterations mostly. An illustrative example of the cutting set of bookbinding machine shows that the presented method can judge the given design convergent or not, and identify the key coupled parameters and design modes that mostly lead to long development cycle.
(4) Because the two existing product platform design methods both have the disadvantage of limited customization ability, the concept of adaptable platform is presented, and the composing and character also are analyzed. In order to provide reasonable reference for the identification of components of adaptable platform, customer requirements are quantified and clustered with the combination of grey relational analysis and fuzzy clustering. The mathematic condition model for design parameters to be common platform parameters is deduced based on axiomatic design, and sensitivity design structure matrix is adopted to distinguish common platform parameters and customization parameters. The layout illustration of bookbinding machine shows that the presented method can make up the shortcomings of current platform design methods, and can improve the customization ability and adaptability transversely and longitudinally.
Then, the support system of MDSA is developed. The system architecture and functional modules are introduced, followed on with the presentation of some main implementation interfaces.
Finally, a conclusion is drawn and the trend on AD is anticipated.
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