废旧机床再制造性评估与再制造工艺方案决策方法研究

发布时间：2018-04-17 06:57

本文选题：废旧机床 + 再制造　；参考：《武汉科技大学》2014年博士论文

【摘要】：我国是世界机床制造大国，机床消费量和保有量居世界第一，但我国机床服役周期长，，老化严重。仅在“十二五”期间，将有100多万台机床面临各种形式的报废。机床再制造是一种充分利用现有废旧机床资源的机床制造新模式，具有显著的节能、节材、减少环境排放的效果，是解决我国量大面广的废旧机床的有效方式，符合我国循环经济和低碳经济的发展要求。废旧机床再制造性评估与再制造工艺方案决策是机床再制造关键技术之一，迫切需要相关理论基础的支持。本文结合“十二五”国家科技支撑计划课题“中小型机床再制造生产技术开发及产业化应用示范”（课题编号：2006BAF02A20）及国家自然科学基金“多寿命特征驱动的废旧零部件再制造工艺资源配置”（基金编号：51205295）等项目对废旧机床再制造性评估和再制造工艺方案决策方法展开研究，为实施机床再制造提供技术支持。主要研究内容有：（1）在分析技术性、经济性和环境效益对机床再制造性的影响程度的基础上，结合我国机床再制造发展现状，得出再制造成本是影响机床再制造性的关键因素。其次，针对机床失效特征多样性导致再制造成本具有差异性的问题，运用作业成本法分析出不同失效特征机床的再制造成本，并将机床失效特征和对应的再制造成本作为案例进行存储。通过检测某回收机床的失效特征，运用实例推理技术在案例库中检索相似案例，预测机床再制造成本。最后，结合再制造机床的税费、运行保证成本等费用及设定的市场目标利润率，建立废旧机床再制造性评估模型。（2）以零部件失效数据和表征零部件性能退化的特征指标数据为基础，联合威布尔分布和人工神经网络模型来评估废旧零部件的剩余使用寿命。对于具有剩余使用寿命的废旧零部件，以定量的方式分析其第一次寿命末期和剩余寿命末期的可靠性，并结合企业制定的零部件可靠性阈值，确定废旧零部件的资源化策略，即再利用、再制造或再循环。（3）建立了基于质量功能展开、模糊线性回归及0-1目标规划的再制造工艺方案决策模型。以零部件再制造的加工效率（时间）（T）、加工质量（Q）、加工成本（C）、资源消耗（R）和环境排放（E）为决策目标，不同工艺阶段的工程技术参数为决策量，运用质量功能展开法建立决策目标与决策变量的关联函数以及决策变量之间的自相关函数，并运用模糊线性回归进行参数求解。在此基础上，通过0-1目标规划进行优化决策，得出最优的再制造工艺方案。（4）在以上理论和方法研究的基础上，开发了废旧机床再制造性评估与再制造工艺方案决策支持系统，对系统体系结构、功能模块设计及运行流程进行了阐述。（5）对广州机床厂实施机床再制造的实践情况进行介绍，重点以机床C6132A1为例，从再制造流程、再制造方案及再制造前后对比三个方面进行分析。
[Abstract]:Our country is a big country of machine tool manufacture in the world. The consumption and possession of machine tool are the first in the world, but the service period of machine tool in our country is long and the aging is serious.During the five-year Plan period alone, more than 1 million machine tools will be scrapped in various forms.Machine tool remanufacturing is a new mode of machine tool manufacturing, which makes full use of the existing waste machine tool resources. It has remarkable energy saving, material saving and environmental emission reduction effect. It is an effective way to solve the problem of waste machine tool with large quantity and wide range in our country.In line with China's circular economy and low carbon economy development requirements.Remanufacturing evaluation and remanufacturing process decision are one of the key technologies of machine tool remanufacturing, which urgently need the support of relevant theoretical basis.This paper combined with the "12th Five-Year Plan" of the National Science and Technology support Program, "small and medium-sized machine tool remanufacturing technology development and industrialization application demonstration" (subject number: 2006BAF02A20) and the National Natural Science Foundation of China "Multi-Life characteristics driven waste Zero"Projects such as Resource allocation for component Remanufacturing process (Fund No.: 51205295) have studied the remanufacturing evaluation of waste machine tools and the decision-making methods of remanufacturing process schemes.Provide technical support for the implementation of machine tool remanufacturing.The main research contents are as follows:1) on the basis of analyzing the influence of technology, economy and environmental benefit on the remanufacturing of machine tool, and combining with the present situation of machine tool remanufacturing in China, it is concluded that the cost of remanufacturing is the key factor affecting the remanufacturing of machine tool.Secondly, aiming at the problem that the cost of remanufacturing is different due to the diversity of failure characteristics of machine tools, the cost of remanufacturing of machine tools with different failure characteristics is analyzed by using activity-based costing method.And the machine tool failure characteristics and the corresponding remanufacturing costs are stored as a case.By detecting the failure characteristics of a recovery machine tool and using case-based reasoning technology to retrieve similar cases in the case base, the cost of machine tool remanufacture is predicted.Finally, the remanufacturing evaluation model of waste machine tool is established by combining the tax and fee of remanufacturing machine, the cost of operation guarantee and the set market target profit rate.(2) based on the failure data of parts and the characteristic index data of performance degradation of parts, Weibull distribution and artificial neural network model are combined to evaluate the remaining service life of waste parts.For waste parts with residual service life, the reliability of the end of the first life and the end of residual life is analyzed quantitatively, and combined with the reliability threshold of parts and components established by enterprises, the strategy of recycling waste parts and components is determined.Reuse, remanufacture or recycling.3) the decision model of remanufacturing process scheme based on quality function expansion, fuzzy linear regression and 0-1 objective programming is established.The process efficiency (time, quality, cost, resource consumption and environmental emission) of parts remanufacturing is taken as the decision objective, and the engineering technical parameters in different technological stages are the decision quantity.The correlation function between decision objective and decision variables and the autocorrelation function between decision variables are established by using the quality function expansion method, and the parameters are solved by fuzzy linear regression.On this basis, the optimal remanufacturing process scheme is obtained by 0-1 objective programming.4) on the basis of the above theories and methods, a decision support system for remanufacturing evaluation and remanufacturing process of waste machine tools is developed. The system architecture, function module design and operation flow are described.This paper introduces the practice of machine tool remanufacturing in Guangzhou Machine tool Factory, and analyzes the process of remanufacturing, the plan of remanufacturing and the comparison between before and after remanufacturing, taking C6132A1 of machine tool as an example.
【学位授予单位】：武汉科技大学
【学位级别】：博士
【学位授予年份】：2014
【分类号】：F426.4;TH16

【参考文献】