复杂机电产品模块化设计若干关键技术及应用研究
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摘要
随着人们生活水平的提高、经济全球化和产品多样化的发展,客户需求呈现出多样化和个性化的特点,客户在低成本、高质量和个性化方面的要求已经成为当前制造业共同面临的严峻的挑战。模块化设计制造是迎接上述挑战的重要途径,基于合理的产品模块化体系,可以快速地组合成满足客户需求的个性化产品,同时又可以通过通用模块的批量生产和批量管理降低生产和管理成本。本文对复杂机电产品模块划分方法、模块相似性度量方法、模块化产品配置设计等模块化设计的关键技术进行了研究,并结合实际对某企业的轮式装载机进行了模块化设计的应用研究。具体研究内容包括：
(1)提出了基于最小最大划分的复杂产品模块划分方法。首先给出最小最大划分的定义,然后根据零部件之间的各种关联关系进行复杂产品的初步划分并计算出其最小最大划分。根据最大划分的子集将复杂产品的零部件进行分组并在各组内以最小划分的子集为计算单元进行模糊聚类分析,根据模块聚合度确定阂值而得到复杂产品的模块划分结果。该方法具有计算量小、最优的阈值和合理的权因子等优点。最后以轮式装载机的工作装置模块化设计为例来说明该方法的合理性和有效性。
(2)研究了基于BOM(产品物料清单)和最优模块化度的模块划分方法。首先基于复杂产品的BOM形成以零部件为结点的产品结构树(PST),然后通过分析同一结点内零部件的几何、功能和物理相关性等得到关联矩阵(CM)并生成关联图(CG),根据关联图计算在不同划分情况时的模块化度(DM),在结构树范围内通过选择最优的模块化度的最小值和平均值确定模块的划分。最后以轮式装载机的工作装置模块化设计为例说明了该方法的合理性和有效性。
(3)研究了轮式装载机进行模块划分的预处理要求及其进行模块划分的独特原则,并从多个层次应用本文相关模块划分方法对轮式装载机进行模块划分,将产品划分为17个一级模块和77个二级模块。
(4)研究了机电产品模块的结构相似性和参数相似性,并提出了模块结构相似性和参数相似性的度量方法和基于结构相似性的模块唯一性的判别方法。提出了模块装配类型编码方法和网络模型建模方法,并以典型模块为例建立其加权的网络模型。重点研究了比较交叉法,并给出了装配关系相似度度量及匹配方法。基于装配关系的相似度和匹配提出了加强网络的匹配和相似性度量方法,并将其应用于模块唯一性的判别。
(5)研究了模块的参数相似性度量方法及模块重用度优化方法。针对模块重用度不高,冗余实例过多的问题提出了一种模块库的聚类分析方法。首先给出了模块库、模块重用度、模块实例相似度、冗余矩阵和聚类中心等模块库的相关定义,并通过模块库相似度的计算构造相似度矩阵,然后对模块库进行聚类分析来消除冗余的模块实例,从而提高模块的重用度。最后以轮式装载机的铲斗模块库设计为例来说明该方法的合理性和有效性,在满足聚合要求的前提下,消除冗余模块12个,提高模块的重用率44.4%。
(6)根据模块化产品的特点提出了模块化产品多层次配置方法。首先将客户需求分为约束性需求和选择性需求两大类,然后提出基于客户需求分析从核心平台和定制模块等多个层次进行模块化产品的配置设计。重点研究了模块化产品核心平台的设计和配置方法、定制模块的配置方法。并以轮式装载机为例进行了模块化产品多层次配置的应用验证。
(7)研究了复杂机电产品模块化的系统设计方法,主要包括模块化准备、模块化规划、模块化过程和模块配置设计四个阶段。并对产品模块化准备工作、模块化规则、模块结构和接口设计方法、基于模块化的产品创新设计方法进行了论述,并分析了四种基于模块化的产品创新方法。
(8)研究了机电产品的模块和模块库设计方法,提出从模块结构和模块接口两个方面进行机电产品模块的设计,提出机电产品模块库的构建包括模块模型库建模和模块数据库建模,并对模块和模块库的设计过程和设计方法进行了研究。以轮式装载机的产品模块为例,对模块结构设计、模块变型设计方法和模块接口设计进行了分析。
(9)开发了面向轮式装载机的机电产品模块化设计平台,对相关研究成果进行了应用验证,完成了轮式装载机模块化设计的工程背景分析、机电产品模块化设计平台的总体设计以及相关组成系统设计。平台具备对产品及其零部件和模块进行编码管理、模块管理、需求管理等功能,同时基于轮式装载机的多层次配置方法实现了轮式装载机快速配置设计。
通过本论文研究,解决了复杂机电产品模块化设计中模块划分、模块相似性度量及应用、模块化产品配置等关键技术,主要成果有：提出了适合于复杂机电产品的模块划分方法,具有计算量小和模块划分结果更加客观、合理等特点；提出了模块相似性及其度量方法并应用于模块重复性判别和模块重用度优化；提出了模块化产品核心平台的定义和模块化产品的多层次配置方法,能有效提高产品的配置效率；并将研究成果成功应用于轮式装载机的模块化设计。
With the improvement of the people's living standard and development of economic globalization and product diversification, the customers'demands show a diversified and personalized features, the customers'demands in low-cost, high quality and personalization aspects have become the serious challenges jointly faced in current manufacturing industry, modular design and manufacture are the important approaches to meet these challenges. The modular design is used to quickly combine into the individuation products which can satisfy the demand of the customers by the reasonable product modularization system and also reduce cost due to the batch production and management of the universal modules so as to effectively resolve the contradiction between low cost and high quality of the products and satisfaction of the individuation demands. This paper conducts the research on key technologies of the modular design such as modular division method of complex mechantronic products, the metrics method of the module parameter similarity, configuration design of the modular products etc., and carries out the application research on the modular design of the wheel loaders of certain enterprise by combining the practice. The specific research contents include:
(1) A min-max partition modularity method suiting complex product is proposed in this paper. Firstly, present the definition of min-max partition, then execute the primarily partition of complex products according to various complex relationships between parts and components to obtain its min and max partitions, thirdly, with these min and max partitions classify the parts and components of the complex products into different groups, then in these groups carry out the fuzzy clustering analysis using the min partition subsets as calculating unit, finally obtain the results-critical value according to the modularity polymerization degree. This method has the advantage of minimum calculation, optimum critical value and reasonable weighting coefficient. At the end, this method is applied to a wheel loaders to demonstrate its rationality and effectiveness.
(2) A new modular division method based on Bill of Material (BOW) and degree of modularization (DM) is proposed in this paper. Product structure tree (PST) consisted of nodes (part or parts) is formed based on the BOM of complex products, correlation matrix (CM) and correlation graph (CG) is calculated through an analysis of relativity of geometric structure, functional and physics, the degree of modularization (DM) is defined and calculated based on CM and CG. With the optimization of DM (include the minimum and average of DM), the modular is divided in the range of PST. As an example, the methods were applied to the working unit of loaders, and the method was verified.
(3) The pretreatment requirement of the module division of the wheel loaders and its unique principle of the module division are researched, the module division is performed for the wheel loaders by using the relevant module division method in this paper from multiple levels, the product is divided into17one-level modules and77two-level modules.
(4) The structure similarity and parameter similarity of the electromechanical product module are researched, the metrics method of the similarities of the module structure and parameter and the module uniqueness discrimination method based on the structure similarity are proposed. The coding method and network modeling method of the module assembly type are proposed, the weighted network model is established by taking typical module for an example. The comparative intersection method is focused on research, the similarity metrics and matching method of the assembly relationship are given. Based on the similarity and matching of the assembly relationship, the method to strengthen the network matching and similarity measure is proposed and used to discriminate the module uniqueness.
(5) The metrics method of the module parameter similarity and module reuse degree optimization method are researched. An optimization method of module reuse degree of module-base is proposed based on the calculation of the similarity. Firstly, the definitions of module-base, module reuse degree, similarity of module-case, similarity matrix and cluster center are introduced, and the similarity matrix are obtained by the calculation of the similarity. Then, the redundant case of module was eliminated through cluster analysis of module-base to improve the reuse degree of the module. Lastly, this method is applied to the module-base of bucket of wheel loader to demonstrate its rationality and effectiveness. With the demand of cluster analysis,12kinds of redundant case can be eliminated from the module-base while the initial number of cases is39, and the reuse degree was raised to44.4%.
(6) Multi-level configuration method of the modular products is demonstrated according to the characteristics of the modular products. First, the customers'demands are divided into two types namely binding demand and selective demand, then configuration design of the modular products is presented from the multiple levels such as core platform and customized module etc. based on the analysis of the customers'demands. This paper focuses on research on the design and configuration method of core platform of the modular products, customized module and configuration method. The application research is conducted on the modular design taking the wheel loaders as the application objects.
(7) The modular system design approach of the complex mechantronic products has been researched, the stages such as modular preparation of the modular design of the complex mechantronic products, modular planning, modular process and module configuration design etc. are analyzed. The four types innovation method of the products based on modularization is demonstrated.
(8) The design methods of the module and module library of the electromechanical products are researched, the module design of the electromechanical products is proposed from two aspects namely module structure and module interface, construction of the module library of the electromechanical products is proposed, including module library modeling and module library database modeling, the design process and design method of the module and module library are researched. Taking the product module of the wheel loaders for an example, the module structure design, module variant design method and module interface design are analyzed.
(9) The modular design platform of the electromechanical products for the wheel loaders is developed, the application verification is performed on the related research findings, engineering background analysis of the modular design of the wheel loaders, overall design of the modular design platform of the electromechanical products and the relevant design of the composition system are completed. The platform has the functions of coding management, module management and demand management etc. for the products and its components and modules, at the same time, based on multi-level configuration method of the wheel loaders, the rapid configuration design method of the wheel loaders is realized.
Key technologies such as module division, the metrics method of the module parameter similarity and its application, modular product configuration etc. are solved in the modular design of complex mechantronic products by research of this paper, main results are:modular division method suited to the complex mechantronic products is presented, the characteristics such as small calculation amount, more objective and reasonable module division results etc. are possessed; the module similarity and metrics method are proposed and applied to discriminate the module repeatability and module reuse optimization; the definition of the core platform of the modular products and multi-level configuration method of the modular products are presented to effectively improve the configuration efficiency of the products. The research results have been successfully applied to the modular design of the wheel loaders.
(1)提出了基于最小最大划分的复杂产品模块划分方法。首先给出最小最大划分的定义,然后根据零部件之间的各种关联关系进行复杂产品的初步划分并计算出其最小最大划分。根据最大划分的子集将复杂产品的零部件进行分组并在各组内以最小划分的子集为计算单元进行模糊聚类分析,根据模块聚合度确定阂值而得到复杂产品的模块划分结果。该方法具有计算量小、最优的阈值和合理的权因子等优点。最后以轮式装载机的工作装置模块化设计为例来说明该方法的合理性和有效性。
(2)研究了基于BOM(产品物料清单)和最优模块化度的模块划分方法。首先基于复杂产品的BOM形成以零部件为结点的产品结构树(PST),然后通过分析同一结点内零部件的几何、功能和物理相关性等得到关联矩阵(CM)并生成关联图(CG),根据关联图计算在不同划分情况时的模块化度(DM),在结构树范围内通过选择最优的模块化度的最小值和平均值确定模块的划分。最后以轮式装载机的工作装置模块化设计为例说明了该方法的合理性和有效性。
(3)研究了轮式装载机进行模块划分的预处理要求及其进行模块划分的独特原则,并从多个层次应用本文相关模块划分方法对轮式装载机进行模块划分,将产品划分为17个一级模块和77个二级模块。
(4)研究了机电产品模块的结构相似性和参数相似性,并提出了模块结构相似性和参数相似性的度量方法和基于结构相似性的模块唯一性的判别方法。提出了模块装配类型编码方法和网络模型建模方法,并以典型模块为例建立其加权的网络模型。重点研究了比较交叉法,并给出了装配关系相似度度量及匹配方法。基于装配关系的相似度和匹配提出了加强网络的匹配和相似性度量方法,并将其应用于模块唯一性的判别。
(5)研究了模块的参数相似性度量方法及模块重用度优化方法。针对模块重用度不高,冗余实例过多的问题提出了一种模块库的聚类分析方法。首先给出了模块库、模块重用度、模块实例相似度、冗余矩阵和聚类中心等模块库的相关定义,并通过模块库相似度的计算构造相似度矩阵,然后对模块库进行聚类分析来消除冗余的模块实例,从而提高模块的重用度。最后以轮式装载机的铲斗模块库设计为例来说明该方法的合理性和有效性,在满足聚合要求的前提下,消除冗余模块12个,提高模块的重用率44.4%。
(6)根据模块化产品的特点提出了模块化产品多层次配置方法。首先将客户需求分为约束性需求和选择性需求两大类,然后提出基于客户需求分析从核心平台和定制模块等多个层次进行模块化产品的配置设计。重点研究了模块化产品核心平台的设计和配置方法、定制模块的配置方法。并以轮式装载机为例进行了模块化产品多层次配置的应用验证。
(7)研究了复杂机电产品模块化的系统设计方法,主要包括模块化准备、模块化规划、模块化过程和模块配置设计四个阶段。并对产品模块化准备工作、模块化规则、模块结构和接口设计方法、基于模块化的产品创新设计方法进行了论述,并分析了四种基于模块化的产品创新方法。
(8)研究了机电产品的模块和模块库设计方法,提出从模块结构和模块接口两个方面进行机电产品模块的设计,提出机电产品模块库的构建包括模块模型库建模和模块数据库建模,并对模块和模块库的设计过程和设计方法进行了研究。以轮式装载机的产品模块为例,对模块结构设计、模块变型设计方法和模块接口设计进行了分析。
(9)开发了面向轮式装载机的机电产品模块化设计平台,对相关研究成果进行了应用验证,完成了轮式装载机模块化设计的工程背景分析、机电产品模块化设计平台的总体设计以及相关组成系统设计。平台具备对产品及其零部件和模块进行编码管理、模块管理、需求管理等功能,同时基于轮式装载机的多层次配置方法实现了轮式装载机快速配置设计。
通过本论文研究,解决了复杂机电产品模块化设计中模块划分、模块相似性度量及应用、模块化产品配置等关键技术,主要成果有：提出了适合于复杂机电产品的模块划分方法,具有计算量小和模块划分结果更加客观、合理等特点；提出了模块相似性及其度量方法并应用于模块重复性判别和模块重用度优化；提出了模块化产品核心平台的定义和模块化产品的多层次配置方法,能有效提高产品的配置效率；并将研究成果成功应用于轮式装载机的模块化设计。
With the improvement of the people's living standard and development of economic globalization and product diversification, the customers'demands show a diversified and personalized features, the customers'demands in low-cost, high quality and personalization aspects have become the serious challenges jointly faced in current manufacturing industry, modular design and manufacture are the important approaches to meet these challenges. The modular design is used to quickly combine into the individuation products which can satisfy the demand of the customers by the reasonable product modularization system and also reduce cost due to the batch production and management of the universal modules so as to effectively resolve the contradiction between low cost and high quality of the products and satisfaction of the individuation demands. This paper conducts the research on key technologies of the modular design such as modular division method of complex mechantronic products, the metrics method of the module parameter similarity, configuration design of the modular products etc., and carries out the application research on the modular design of the wheel loaders of certain enterprise by combining the practice. The specific research contents include:
(1) A min-max partition modularity method suiting complex product is proposed in this paper. Firstly, present the definition of min-max partition, then execute the primarily partition of complex products according to various complex relationships between parts and components to obtain its min and max partitions, thirdly, with these min and max partitions classify the parts and components of the complex products into different groups, then in these groups carry out the fuzzy clustering analysis using the min partition subsets as calculating unit, finally obtain the results-critical value according to the modularity polymerization degree. This method has the advantage of minimum calculation, optimum critical value and reasonable weighting coefficient. At the end, this method is applied to a wheel loaders to demonstrate its rationality and effectiveness.
(2) A new modular division method based on Bill of Material (BOW) and degree of modularization (DM) is proposed in this paper. Product structure tree (PST) consisted of nodes (part or parts) is formed based on the BOM of complex products, correlation matrix (CM) and correlation graph (CG) is calculated through an analysis of relativity of geometric structure, functional and physics, the degree of modularization (DM) is defined and calculated based on CM and CG. With the optimization of DM (include the minimum and average of DM), the modular is divided in the range of PST. As an example, the methods were applied to the working unit of loaders, and the method was verified.
(3) The pretreatment requirement of the module division of the wheel loaders and its unique principle of the module division are researched, the module division is performed for the wheel loaders by using the relevant module division method in this paper from multiple levels, the product is divided into17one-level modules and77two-level modules.
(4) The structure similarity and parameter similarity of the electromechanical product module are researched, the metrics method of the similarities of the module structure and parameter and the module uniqueness discrimination method based on the structure similarity are proposed. The coding method and network modeling method of the module assembly type are proposed, the weighted network model is established by taking typical module for an example. The comparative intersection method is focused on research, the similarity metrics and matching method of the assembly relationship are given. Based on the similarity and matching of the assembly relationship, the method to strengthen the network matching and similarity measure is proposed and used to discriminate the module uniqueness.
(5) The metrics method of the module parameter similarity and module reuse degree optimization method are researched. An optimization method of module reuse degree of module-base is proposed based on the calculation of the similarity. Firstly, the definitions of module-base, module reuse degree, similarity of module-case, similarity matrix and cluster center are introduced, and the similarity matrix are obtained by the calculation of the similarity. Then, the redundant case of module was eliminated through cluster analysis of module-base to improve the reuse degree of the module. Lastly, this method is applied to the module-base of bucket of wheel loader to demonstrate its rationality and effectiveness. With the demand of cluster analysis,12kinds of redundant case can be eliminated from the module-base while the initial number of cases is39, and the reuse degree was raised to44.4%.
(6) Multi-level configuration method of the modular products is demonstrated according to the characteristics of the modular products. First, the customers'demands are divided into two types namely binding demand and selective demand, then configuration design of the modular products is presented from the multiple levels such as core platform and customized module etc. based on the analysis of the customers'demands. This paper focuses on research on the design and configuration method of core platform of the modular products, customized module and configuration method. The application research is conducted on the modular design taking the wheel loaders as the application objects.
(7) The modular system design approach of the complex mechantronic products has been researched, the stages such as modular preparation of the modular design of the complex mechantronic products, modular planning, modular process and module configuration design etc. are analyzed. The four types innovation method of the products based on modularization is demonstrated.
(8) The design methods of the module and module library of the electromechanical products are researched, the module design of the electromechanical products is proposed from two aspects namely module structure and module interface, construction of the module library of the electromechanical products is proposed, including module library modeling and module library database modeling, the design process and design method of the module and module library are researched. Taking the product module of the wheel loaders for an example, the module structure design, module variant design method and module interface design are analyzed.
(9) The modular design platform of the electromechanical products for the wheel loaders is developed, the application verification is performed on the related research findings, engineering background analysis of the modular design of the wheel loaders, overall design of the modular design platform of the electromechanical products and the relevant design of the composition system are completed. The platform has the functions of coding management, module management and demand management etc. for the products and its components and modules, at the same time, based on multi-level configuration method of the wheel loaders, the rapid configuration design method of the wheel loaders is realized.
Key technologies such as module division, the metrics method of the module parameter similarity and its application, modular product configuration etc. are solved in the modular design of complex mechantronic products by research of this paper, main results are:modular division method suited to the complex mechantronic products is presented, the characteristics such as small calculation amount, more objective and reasonable module division results etc. are possessed; the module similarity and metrics method are proposed and applied to discriminate the module repeatability and module reuse optimization; the definition of the core platform of the modular products and multi-level configuration method of the modular products are presented to effectively improve the configuration efficiency of the products. The research results have been successfully applied to the modular design of the wheel loaders.
引文
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