机械产品质量损失建模与公差体系优化设计方法研究

发布时间：2018-07-01 09:05

本文选题：机械产品 + 质量特征　；参考：《中南大学》2013年博士论文

【摘要】：机械产品质量和成本是影响其竞争力的重要因素。本文从产品级的角度出发,面向具有多元性、动态性、复杂性的质量特征,深入分析产品质量特征与其零部件质量特征之间的关系,提出产品质量损失建模和公差优化设计方法,提高产品质量,降低产品成本,快速响应市场需求变化。 (一)提出了面向多质量特征的产品质量损失三层次建模方法。充分利用产品生产全过程历史检测数据,应用神经网络、层次分析方法,确定产品零件质量、产品质量特征、产品质量之间的权重；考虑零部件加工生产过程中的返修成本和报废成本,采用分段函数理论改进了田口质量损失函数,并根据质量特征服从不同的分布,导出了相应的零件质量损失；建立了多元产品质量损失模型。以微型电动机为例,对具有多质量特征的产品质量损失进行了计算与分析,验证了该方法的有效性,为多质量特征产品质量综合评价提供了解决途径。 (二)提出了基于服役寿命分布的质量损失建模方法。面向产品全寿命周期,定义产品质量损失为其投入服役后因产品质量特征超出规定范围而导致报废所造成的损失现值；在此质量观基础上,应用资金折现原理建立了基于服役寿命分布的产品质量损失模型；针对服从不同分布的质量特征,提出了基于质量特征公差要求的产品服役寿命分布密度函数计算方法。结合三个实例,分别对基于服役寿命分布的望目特征、望小特征和望大特征的产品质量损失进行计算与分析,深入讨论了产品特征分布参数和质量要求对质量损失的影响,并与田口质量损失模型、Teran质量损失模型进行了比较分析。结果表明：该产品质量损失模型描述了一种产品投入服役后因质量特征超出其技术规范要求而报废给社会带来的实际损失,能够反映不同产品在不同服役条件和环境下产生的质量损失,将产品质量从设计制造阶段扩展到运行服役阶段,为产品质量在全寿命周期的变化规律研究提供了新的视角。 (三)提出了基于数据挖掘的产品公差体系优化设计方法。从产品广义公差出发,分析产品各层次质量特征的相互影响关系,建立产品公差体系模型；利用产品制造检验过程中的历史数据,建立了基于支持向量非线性回归机的产品质量特征偏差与零部件质量特征偏差关系模型,并以微电机为例,构建了产品质量特征偏差与零部件质量特征偏差关系支持向量非线性回归机(SVNR)模型,并与RegressFunction方法进行了比较分析；分析了非尺寸公差与产品成本的关系,建立了基于产品广义公差的产品制造成本模型；以产品成本最小为目标,建立了产品公差体系优化设计模型。结果表明：所提出的产品公差体系优化方法行之有效,为实现产品公差设计提供了新途径。 (四)提出了面向用户性能需求的产品公差体系再设计方法。针对用户对产品性能需求不断变化或增加新的用户需求,在基于数据挖掘的产品公差体系优化设计方法的基础上,建立面向产品用户性能需求的产品公差体系再设计优化模型；并以微电机为实例,分析了微电机的装配关系以及性能影响因素,建立微电机公差体系模型,再以微电机制造成本最低为目标,用户性能需求为约束,建立微电机公差体系再设计优化模型,根据用户对微电机产品性能的不同需求,进行了微电机公差体系再设计优化,分析探讨了微电机公差和成本的变化规律。所提出的公差体系再设计优化方法能够根据用户性能需求变化直接对产品公差体系进行改进优化,缩短了产品设计与制造周期,快速响应市场变化,生产企业只需在原产品生产系统的基础上适当调整生产制造系统和质量检验体系,就能使产品既能满足用户需求而制造成本又最低,实现了产品公差设计从产品开发阶段到产品全市场周期的扩展。
[Abstract]:The quality and cost of mechanical products are the important factors that affect their competitiveness. From the point of view of product level, this paper is oriented to the quality characteristics of multiple, dynamic and complex. This paper analyzes the relationship between the quality characteristics of product and the quality characteristics of parts, and puts forward the method of product quality loss modeling and tolerance optimization design to improve the product. Quality, reduce product cost and respond quickly to market demand changes.
(1) the three level modeling method of product quality loss oriented to multi quality features is put forward, which makes full use of the whole process historical detection data of product production, applies neural network and analytic hierarchy process to determine the weight between product parts quality, product quality characteristics and product quality, and considers the repair costs and reports in the process of parts processing and production. The quality loss function of Taguchi is improved by the piecewise function theory, and the quality loss of the parts is derived according to the quality characteristics. The mass loss model of multiple products is established. The quality loss of the product with multi quality characteristics is calculated and analyzed with the micro motor as an example, and the results are verified. The effectiveness of the method provides a solution for the comprehensive evaluation of product quality with multiple quality characteristics.
(two) a quality loss modeling method based on service life distribution is proposed. The product quality loss is defined as the present value of the loss caused by the discarding of the product quality loss due to the quality characteristics of the product beyond the specified range. Based on this quality concept, the service life span based on the principle of discounted funds is established. In view of the quality characteristics of the cloth, a method for calculating the distribution density function of service life based on the quality characteristic tolerance is proposed in accordance with the quality characteristics of different distribution. Three examples are used to calculate and divide the product quality loss based on the service life distribution. The effect of product characteristics distribution parameters and quality requirements on quality loss is discussed, and the Teran mass loss model is compared with Taguchi mass loss model. The result shows that the product quality loss model describes a product abandonment to society due to the quality characteristic of the product beyond its technical specification. The actual loss can reflect the quality loss of different products in different service conditions and environment, and expand the product quality from the design and manufacturing stage to the operation service stage, which provides a new perspective for the study of the product quality in the life cycle.
(three) the optimization design method of product tolerance system based on data mining is proposed. From the generalized tolerance of product, the interaction relationship between the quality characteristics of the product is analyzed, the product tolerance system model is established, and the product quality based on the support vector nonlinear regression machine is established by using the historical data in the process of product manufacturing inspection. The model of the relationship between characteristic deviation and the quality characteristic deviation of parts is built, and a support vector nonlinear regression machine (SVNR) model is constructed by using the micro motor as an example. The model of support vector nonlinear regression machine (SVNR) is constructed. The relationship between the non dimensional tolerance and the product cost is analyzed and the relationship between the non-dimensional tolerance and the product cost is analyzed, and the relationship between the product cost and the non dimensional tolerance is analyzed. The product manufacturing cost model based on product generalized tolerance is established. The optimization design model of product tolerance system is set up with the goal of minimum product cost. The result shows that the optimization method of product tolerance system is effective and provides a new way to realize product tolerance design.
(four) the redesign method of product tolerance system for user performance needs is proposed. Based on the optimization design method of product tolerance system based on data mining, the product tolerance system redesign optimization model is established on the basis of the product tolerance system optimization design method based on data mining. With the micro motor as an example, the assembly relationship and the factors affecting the performance of micro motor are analyzed, and the tolerance system model of micromotor is set up, and the minimum manufacturing cost of micro motor is the goal, and the user performance requirement is restricted, and the redesign optimization model of the micro motor tolerance system is set up. According to the user's different requirements for the performance of Micromotor products, the model is carried out. The tolerance system of micro motor is redesigned and optimized, and the variation of tolerance and cost of micro motor is analyzed and discussed. The proposed optimization method of tolerance system redesign can improve the product tolerance system directly according to the changes of user's performance requirements, shorten the product design and manufacture cycle, quickly respond to market changes, and only produce enterprises. The production system and quality inspection system should be properly adjusted on the basis of the production system of the original product. The product can meet the needs of the user and make the lowest manufacturing cost. The product tolerance design has been expanded from the product development stage to the whole market cycle of the product.
【学位授予单位】：中南大学
【学位级别】：博士
【学位授予年份】：2013
【分类号】：TH122;O213.2

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