机队航空发动机维修规划及其关键技术研究
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摘要
现代制造服务的发展和产品价值链的变化都表明装备维修工程管理正变得越来越重要。航空发动机是飞机的“心脏”。现代航空发动机具有结构复杂、工作环境恶劣、转动速度快、维修费用高等特点。为了提高管理效率和降低维修成本,航空公司一般对同一型号的所有航空发动机进行统一管理。本文的机队指的就是航空公司同一型号的所有航空发动机的总和。从航空公司的角度出发,研究机队航空发动机维修规划,对于提高航空公司的维修工程管理水平和综合竞争力具有重要的意义。本文在分析国内外机队发动机维修规划研究中存在问题的基础上,针对我国航空公司在发动机维修工程管理方面的需求,建立了包括维修数据管理、拆发期限预测、拆发计划制定、维修工作范围决策、维修成本预测、维修进度监控和维修效果评价等活动的机队发动机维修规划体系,并对相关模型的建立及关键技术进行了研究。
发动机维修数据管理是机队发动机维修规划的基础性工作。根据发动机维修数据具有多维性、可扩展性、演化性的特点,借鉴面向对象的思想,将发动机维修数据分为构型数据、对象相关数据和类相关数据。在发动机维修数据组织方面,建立了基于使用状态的维修数据组织模型,实现了发动机维修数据的统一管理。在发动机构型数据管理方面,建立了基于位置件的发动机维修BOM管理模型和基于物理状态的实例维修BOM管理模型,解决了数据冗余问题;提出了基于主要件的适航指令/服务通告状态控制方法,解决了适航指令/服务通告状态难以控制的问题。
机队中各台发动机的拆发期限预测是合理安排机队发动机送修时间的前提。为了提高发动机拆发期限预测的准确度,考虑到机队中各台发动机在性能衰退方面的差异性,提出了基于性能衰退模式的发动机拆发期限预测方法。在对送修时间和备发选择的影响因素进行分析的基础上,建立了机队发动机拆发计划多目标组合优化模型,提出了一种基于逐步构解策略的启发式算法进行模型的求解,研究了拆发计划方案集的构造方法和选择方法。最后采用实际数据验证了提出方法的有效性。
发动机送修时,航空公司都会根据机队整体情况给出送修目标。为了制定合理的发动机维修工作范围,在分析送修目标的基础上,提出了一种送修目标导向的发动机维修工作范围决策方法,从寿命件、部件损伤、软时限、适航指令/服务通告、排气温度裕度五个方面分两步进行发动机维修工作范围的制定。针对决策过程中单元体性能恢复值分配存在的难点,建立了确定条件下和不确定条件下以维修成本最小为目标的单元体性能恢复值分配优化模型,研究了模型求解的动态规划算法和启发式算法。通过求解结果的比较,给出了两种算法的适用环境,提升了发动机维修工作范围决策的科学化水平。
机队中各台发动机的车间维修成本预测是发动机年度维修成本预算制定的前提。为了准确预测发动机的车间维修成本,对发动机车间维修成本进行了分析,将其分为确定Ⅰ型成本、确定Ⅱ型成本、不确定Ⅰ型成本和不确定Ⅱ型成本,分别研究了有归集数据和无归集数据条件下的车间维修成本预测。当有归集数据时,建立了重要件的报废概率模型和其他器材费和修理费的成本概率模型。当无归集数据时,建立了信息扩散支持向量机预测模型,对模型的拓扑结构、建模步骤、参数选择进行了研究。对两种情况下的车间维修成本预测模型均采用实际数据进行了验证。
为了保证送修发动机能够按时出厂,给出了发动机维修工作分解结构和网络计划图,采用计划评审技术实现了维修进度的监控。针对传统计划评审技术在求取任务持续时间存在的问题,提出了一种新的多时估计法,然后采用近似方法获得了发动机维修完工时间的分布函数。为了对承修厂的选择提供决策支持,建立了发动机维修效果评价指标体系,采用数据包络分析实现了机队中各台发动机维修效果的评价。对于发动机维修进度监控和维修效果评价,分别给出了应用案例,验证了提出方法的有效性。
最后,以中国国际航空股份有限公司为案例企业,探讨了机队发动机维修规划及其关键技术在大型航空公司的应用,开发了航空发动机健康管理与维修决策支持系统。对中国国际航空股份有限公司的发动机维修工程管理的需求进行了分析,介绍了系统的体系结构、功能模型和信息模型,并给出了系统运行实例和应用情况,验证了本文模型与技术的正确性和有效性。
The development of modern manufacturing service and change of product value chain show that the equipment maintenance management is becoming increasingly important. An aeroengine is the heart of an aircraft. A modern aeroengine has a complex structure, bad operation environment, fast rotational speed, high maintenance cost and so on. To improve management efficiency and reduce maintenance cost, an airline generally manages all aeroengines with the same model uniformly. In this dissertation, the fleet is defined as all aeroengines with the same model in an airline. From the perspective of an airline, studying aeroengines in a fleet oriented maintenance programming is essential for improving an airline’s maintenance management and competitiveness. Based on the analysis of existing problems in studying aeroengines in a fleet oriented maintenance programming at home and abroad, a system of aeroengines in a fleet oriented maintenance programming, which includes maintenance data management, removal deadline prediction, removal scheduling, maintenance workscope decision-making, maintenance cost prediction, maintenance progress monitoring and maintenance effect evaluation is established and its related models and key technologies are studied, according to domestic airline’s needs in aeroengine maintenance management.
Aeroengine maintenance data management is the basis for aeroengines in a fleet oriented maintenance programming. According to its multi-dimensional, scalable and evolutionary characteristics, aeroengine maintenance data is divided into configuration data, object-related data and class-related data with the help of object-oriented thinking. In the organization of aeroengine maintenance data, usage state based aeroengine maintenance data organization model are established to achieve a unified management of aeroengine maintenance data. In the management of aeroengine configuration data, position part based aeroengine maintenance BOM management model and physical state based instance maintenance BOM management model are established to solve data redundancy, and major part based Airworthiness Directive (AD) / Service Bulletin (SB) status control method is put forward to solve AD / SB status difficult to control.
Each aeroengine removal deadline prediction in a fleet is the premise for scheduling aeroengine removal time reasonably. To predict the aeroengine removal deadline more accurately, a prediction method based on aeroengine performance deterioration pattern is put forward considering the differences of each aeroengine’s performance deterioration in a fleet. A multi-objective combinatorial optimization model of aeroengines in a fleet oriented removal scheduling is constructed after analyzing influencing factors of aeroengine removal date and spare aeroengine selection, and then a heuristic algorithm based on the progressive structure is put forward to solve the model. The method of the solution set construction and selection for removal scheduling problem is also studied. Finally, the practical data is adopted to verify the effectiveness of this algorithm.
When an aeroengine has a shop vist, objectives of shop visit will be always given based on the overall situation of the fleet by the airline. To make a reasonable aeroengine maintenance workscope, an objective-oriented method for aeroengine maintenance workscope decision-making is proposed after analyzing objectives of aeroengine shop visit. Aeroengine maintenance workscope is made through two steps from five aspects of life limited part, component damage, soft time, AD / SB and exhaust gas temperature margin using the method. To solve the problem that module performance restoration value is difficult to distribute in the decision-making process, optimization models based on minimum shop visit cost with certain or uncertain condition are put forward, and dynamic programming and heuristic algorithm are respectively studied to solve optimization models. By comparing their results, the applicable environment of the two algorithms is given. Therefore, aeroengine maintenance workscope decision-making becomes more scientific.
Each aeroengine shop visit cost prediction in a fleet is the premise for making annual aeroengine maintenance budget. To predict it accurately, aeroengine shop visit cost is analyzed and divided into the determinacy cost of typeⅠ, the determinacy cost of typeⅡ, the indeterminacy cost of typeⅠand the indeterminacy cost of typeⅡ. On this basis, aeroengine shop visit cost prediction is studied with having historical cost breakdown data or not. When having historical cost breakdown data, the scrap probability model of important part and the cost probability model of other material and repair are established. When having no historical cost breakdown data, a prediction model named information diffusion support vector machine is proposed. The topology, modeling process and selection of parameters of the model are also studied. The practical data is adopted to verify the effectiveness of models with having historical cost breakdown data or not.
To ensure that an aeroengine for shop visit leaves a MRO company on time, aeroengine maintenance work breakdown structure and network planning are presented, and PERT is adopted to monitor aeroengine maintenance progress. To solve existing problems in acquiring the task duration using the traditional PERT, a new multi-point approximation method is presented, and then obtained aeroengine maintenance completion time distribution function using an approximate method. To provide decision-making support for selection of aeroengine MRO company, the aeroengine maintenance effect evaluation system is established, and then data envelopment analysis is adopted to achieve the evaluation of each aeroengine maintenance effect in a fleet. Application cases for aeroengine maintenance progress monitoring and maintenance effect evaluation are presented to verify the effectiveness of methods.
Finally, the application of aeroengines in a fleet oriented maintenance programming and its key technologies at a large-scale airline is discussed, by developing an aeroengine health management and maintenance decision-making support system for Air China. Based on analyzing aeroengine maintenance management requirements of Air China, the system architecture, the function model and the information model are introduced. Operation examples and application results of the system are also presented, demonstrating that the proposed models and technologies are correct and effective.
发动机维修数据管理是机队发动机维修规划的基础性工作。根据发动机维修数据具有多维性、可扩展性、演化性的特点,借鉴面向对象的思想,将发动机维修数据分为构型数据、对象相关数据和类相关数据。在发动机维修数据组织方面,建立了基于使用状态的维修数据组织模型,实现了发动机维修数据的统一管理。在发动机构型数据管理方面,建立了基于位置件的发动机维修BOM管理模型和基于物理状态的实例维修BOM管理模型,解决了数据冗余问题;提出了基于主要件的适航指令/服务通告状态控制方法,解决了适航指令/服务通告状态难以控制的问题。
机队中各台发动机的拆发期限预测是合理安排机队发动机送修时间的前提。为了提高发动机拆发期限预测的准确度,考虑到机队中各台发动机在性能衰退方面的差异性,提出了基于性能衰退模式的发动机拆发期限预测方法。在对送修时间和备发选择的影响因素进行分析的基础上,建立了机队发动机拆发计划多目标组合优化模型,提出了一种基于逐步构解策略的启发式算法进行模型的求解,研究了拆发计划方案集的构造方法和选择方法。最后采用实际数据验证了提出方法的有效性。
发动机送修时,航空公司都会根据机队整体情况给出送修目标。为了制定合理的发动机维修工作范围,在分析送修目标的基础上,提出了一种送修目标导向的发动机维修工作范围决策方法,从寿命件、部件损伤、软时限、适航指令/服务通告、排气温度裕度五个方面分两步进行发动机维修工作范围的制定。针对决策过程中单元体性能恢复值分配存在的难点,建立了确定条件下和不确定条件下以维修成本最小为目标的单元体性能恢复值分配优化模型,研究了模型求解的动态规划算法和启发式算法。通过求解结果的比较,给出了两种算法的适用环境,提升了发动机维修工作范围决策的科学化水平。
机队中各台发动机的车间维修成本预测是发动机年度维修成本预算制定的前提。为了准确预测发动机的车间维修成本,对发动机车间维修成本进行了分析,将其分为确定Ⅰ型成本、确定Ⅱ型成本、不确定Ⅰ型成本和不确定Ⅱ型成本,分别研究了有归集数据和无归集数据条件下的车间维修成本预测。当有归集数据时,建立了重要件的报废概率模型和其他器材费和修理费的成本概率模型。当无归集数据时,建立了信息扩散支持向量机预测模型,对模型的拓扑结构、建模步骤、参数选择进行了研究。对两种情况下的车间维修成本预测模型均采用实际数据进行了验证。
为了保证送修发动机能够按时出厂,给出了发动机维修工作分解结构和网络计划图,采用计划评审技术实现了维修进度的监控。针对传统计划评审技术在求取任务持续时间存在的问题,提出了一种新的多时估计法,然后采用近似方法获得了发动机维修完工时间的分布函数。为了对承修厂的选择提供决策支持,建立了发动机维修效果评价指标体系,采用数据包络分析实现了机队中各台发动机维修效果的评价。对于发动机维修进度监控和维修效果评价,分别给出了应用案例,验证了提出方法的有效性。
最后,以中国国际航空股份有限公司为案例企业,探讨了机队发动机维修规划及其关键技术在大型航空公司的应用,开发了航空发动机健康管理与维修决策支持系统。对中国国际航空股份有限公司的发动机维修工程管理的需求进行了分析,介绍了系统的体系结构、功能模型和信息模型,并给出了系统运行实例和应用情况,验证了本文模型与技术的正确性和有效性。
The development of modern manufacturing service and change of product value chain show that the equipment maintenance management is becoming increasingly important. An aeroengine is the heart of an aircraft. A modern aeroengine has a complex structure, bad operation environment, fast rotational speed, high maintenance cost and so on. To improve management efficiency and reduce maintenance cost, an airline generally manages all aeroengines with the same model uniformly. In this dissertation, the fleet is defined as all aeroengines with the same model in an airline. From the perspective of an airline, studying aeroengines in a fleet oriented maintenance programming is essential for improving an airline’s maintenance management and competitiveness. Based on the analysis of existing problems in studying aeroengines in a fleet oriented maintenance programming at home and abroad, a system of aeroengines in a fleet oriented maintenance programming, which includes maintenance data management, removal deadline prediction, removal scheduling, maintenance workscope decision-making, maintenance cost prediction, maintenance progress monitoring and maintenance effect evaluation is established and its related models and key technologies are studied, according to domestic airline’s needs in aeroengine maintenance management.
Aeroengine maintenance data management is the basis for aeroengines in a fleet oriented maintenance programming. According to its multi-dimensional, scalable and evolutionary characteristics, aeroengine maintenance data is divided into configuration data, object-related data and class-related data with the help of object-oriented thinking. In the organization of aeroengine maintenance data, usage state based aeroengine maintenance data organization model are established to achieve a unified management of aeroengine maintenance data. In the management of aeroengine configuration data, position part based aeroengine maintenance BOM management model and physical state based instance maintenance BOM management model are established to solve data redundancy, and major part based Airworthiness Directive (AD) / Service Bulletin (SB) status control method is put forward to solve AD / SB status difficult to control.
Each aeroengine removal deadline prediction in a fleet is the premise for scheduling aeroengine removal time reasonably. To predict the aeroengine removal deadline more accurately, a prediction method based on aeroengine performance deterioration pattern is put forward considering the differences of each aeroengine’s performance deterioration in a fleet. A multi-objective combinatorial optimization model of aeroengines in a fleet oriented removal scheduling is constructed after analyzing influencing factors of aeroengine removal date and spare aeroengine selection, and then a heuristic algorithm based on the progressive structure is put forward to solve the model. The method of the solution set construction and selection for removal scheduling problem is also studied. Finally, the practical data is adopted to verify the effectiveness of this algorithm.
When an aeroengine has a shop vist, objectives of shop visit will be always given based on the overall situation of the fleet by the airline. To make a reasonable aeroengine maintenance workscope, an objective-oriented method for aeroengine maintenance workscope decision-making is proposed after analyzing objectives of aeroengine shop visit. Aeroengine maintenance workscope is made through two steps from five aspects of life limited part, component damage, soft time, AD / SB and exhaust gas temperature margin using the method. To solve the problem that module performance restoration value is difficult to distribute in the decision-making process, optimization models based on minimum shop visit cost with certain or uncertain condition are put forward, and dynamic programming and heuristic algorithm are respectively studied to solve optimization models. By comparing their results, the applicable environment of the two algorithms is given. Therefore, aeroengine maintenance workscope decision-making becomes more scientific.
Each aeroengine shop visit cost prediction in a fleet is the premise for making annual aeroengine maintenance budget. To predict it accurately, aeroengine shop visit cost is analyzed and divided into the determinacy cost of typeⅠ, the determinacy cost of typeⅡ, the indeterminacy cost of typeⅠand the indeterminacy cost of typeⅡ. On this basis, aeroengine shop visit cost prediction is studied with having historical cost breakdown data or not. When having historical cost breakdown data, the scrap probability model of important part and the cost probability model of other material and repair are established. When having no historical cost breakdown data, a prediction model named information diffusion support vector machine is proposed. The topology, modeling process and selection of parameters of the model are also studied. The practical data is adopted to verify the effectiveness of models with having historical cost breakdown data or not.
To ensure that an aeroengine for shop visit leaves a MRO company on time, aeroengine maintenance work breakdown structure and network planning are presented, and PERT is adopted to monitor aeroengine maintenance progress. To solve existing problems in acquiring the task duration using the traditional PERT, a new multi-point approximation method is presented, and then obtained aeroengine maintenance completion time distribution function using an approximate method. To provide decision-making support for selection of aeroengine MRO company, the aeroengine maintenance effect evaluation system is established, and then data envelopment analysis is adopted to achieve the evaluation of each aeroengine maintenance effect in a fleet. Application cases for aeroengine maintenance progress monitoring and maintenance effect evaluation are presented to verify the effectiveness of methods.
Finally, the application of aeroengines in a fleet oriented maintenance programming and its key technologies at a large-scale airline is discussed, by developing an aeroengine health management and maintenance decision-making support system for Air China. Based on analyzing aeroengine maintenance management requirements of Air China, the system architecture, the function model and the information model are introduced. Operation examples and application results of the system are also presented, demonstrating that the proposed models and technologies are correct and effective.
引文
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