可重构石材台面板生产线的设计研究

发布时间：2018-05-23 14:23

本文选题：石材 + 台面板　；参考：《山东大学》2012年硕士论文

【摘要】：石材台面板制品的需求量日益增多,并呈现出向多品种大批量生产模式发展的趋势。由于缺乏足够的柔性和合理的设备布局,传统的固定串行生产线存在生产能力冗余或不足的现象,且搬运距离长,搬运次数多,劳动强度大,无法满足大批量定制的要求。因此,开发推广兼备高生产力和足够柔性的可重构石材台面板生产线,已成为我国石材企业扩大生产规模、开拓生存空间的关键。本文从生产线总体规划、产品族工序识别和划分、可重构石材台面板设备开发、物流系统设计、布局规划及建模仿真等几个方面对可重构台面板生产线进行了系统研究。通过对现行台面板生产方式中所存在问题的分析,构建了可重构石材台面板生产线系统的集成框架,从系统层和设备层两个层面详细阐述了系统设计过程中涉及的使能技术,并每个层面的应用层使能技术进行了研究。基于位置公差和κ-平均算法对石材台面板产品族进行工序划分,使可在同一设备上完成的工序分配在同一工序组合内,通过对各工序组合的合并和排序,得到了工序族的优化组合方案。以所得优化工序组合方案为基础,通过对各工序组合进行加工运动分析,获得了可重构石材台面板设备所需具备的基本功能。利用模块化设计方法,将可重构石材台面板设备的总体方案划分为机械、控制、冷却润滑和辅助四大模块,并将机械模块进一步划分为运动、动力、支撑和扩展四个子模块,进而对各子模块进行初步结构设计,通过各模块的组合生成可重构石材台面板设备的配置图,利用Solidworks构建了设备的三维模型。通过分析确定采用辊子输送机配以真空起重机组成具有一定柔性的物流传输系统,并分别对辊子输送机和真空起重机进行了结构改进。通过对直线型、U型和单元式三种布局形式的分析,结合石材台面板的生产特点,确定采用U型与单元式相结合的布局方式。为了使可重构石材台面板生产线具有足够的柔性,采用基于可重构单元的生产线结构,结合混合整数规划模型完成了可重构单元构建。基于以上研究内容,获得了可重构石材台面板生产线的规划图。由于物流设施的合理选择与布局,可重构石材台面板生产线的搬运距离和搬运时间仅为现行生产方式的1/2和1/5。为了了解可重构石材台面板生产线的系统性能,并与现行台面板生产方式形成直观对比,基于EM-Plant仿真软件对可重构石材台面板生产线系统进行了建模仿真研究。通过对生产线的性能指标和瓶颈分析,得出以下结论：用于两种不同产品加工时,生产线的月产值可以分别达到2784件和2726件,完全满足期望值；平衡率可以分别达到79.2%和84.6%,生产较稳定；负荷率较高的设备作业时间小于生产节拍,不存在生产瓶颈。山东省科技发展计划资助项目(2010GGX10405,2010GZX20604)。
[Abstract]:The demand of stone tabletop products is increasing day by day, and the trend of mass production is becoming more and more. Due to the lack of sufficient flexibility and reasonable equipment layout, the traditional fixed serial production line has the phenomenon of redundant or insufficient production capacity, and the long distance, the number of times of handling and the labor intensity can not meet the requirements of mass customization. Therefore, developing and popularizing the reconfigurable stone Mesa plate production line with high productivity and enough flexibility has become the key to expand the production scale and open up the living space for our country's stone enterprises. In this paper, the reconfigurable Mesa plate production line is systematically studied from the following aspects: production line master plan, product family process identification and division, reconfigurable stone Mesa equipment development, logistics system design, layout planning, modeling and simulation, and so on. Based on the analysis of the existing problems in the production of table plate, the integrated framework of the reconfigurable stone Mesa plate production line system is constructed, and the enabling technology involved in the system design process is described in detail from the two levels of system layer and equipment layer. At each level, the application layer enabling technology is studied. Based on the position tolerance and 魏 -average algorithm, the product family of stone Mesa plate is divided, so that the processes that can be completed on the same equipment are assigned in the same process combination, and the combination and sequencing of each process combination are carried out. The optimal combination scheme of working procedure family is obtained. Based on the optimized process combination scheme, the basic functions of the reconfigurable stone table plate equipment are obtained by analyzing the processing motion of each working procedure combination. Using the modular design method, the overall scheme of the reconfigurable stone table plate equipment is divided into four modules: machinery, control, cooling, lubrication and auxiliary, and the mechanical module is further divided into four sub-modules: motion, power, support and expansion. Then the structure of each sub-module is designed and the configuration diagram of the reconfigurable stone table plate equipment is generated by the combination of each module. The three-dimensional model of the equipment is constructed by using Solidworks. Through analysis, it is determined that the roller conveyer is equipped with a vacuum crane to form a flexible material flow transmission system, and the structure of the roller conveyor and the vacuum crane are improved respectively. Through the analysis of the three layout forms of linear U type and unit type and combined with the production characteristics of stone table plate, the layout mode of U type and unit type is determined. In order to make the reconfigurable stone Mesa plate production line flexible enough, the reconfigurable unit was constructed by using the production line structure based on the reconfigurable unit and the mixed integer programming model. Based on the above research content, the plan of reconfigurable stone Mesa plate production line is obtained. Due to the reasonable selection and layout of logistics facilities, the distance and time of the reconfigurable stone Mesa production line is only 1 / 2 and 1 / 5 of the current production mode. In order to understand the system performance of the reconfigurable stone Mesa plate production line and make a direct comparison with the current production mode of the Mesa plate, the modeling and simulation of the reconfigurable stone Mesa plate production line system based on EM-Plant simulation software was carried out. Through the performance index and bottleneck analysis of the production line, the following conclusions are drawn: when used in two different products processing, the monthly output value of the production line can reach 2784 pieces and 2726 pieces respectively, which fully meet the expected value; The balance rate can reach 79.2% and 84.6% respectively, the production is stable, the working time of the equipment with higher load rate is smaller than the production rhythm, and there is no production bottleneck. The Shandong Science and Technology Development Program supports the project 2010 GX10405 and 2010 GZX20604.
【学位授予单位】：山东大学
【学位级别】：硕士
【学位授予年份】：2012
【分类号】：TH165

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