【作者】 陈建；

【导师】 李剑峰；

【作者基本信息】 山东大学 ， 机械制造及其自动化， 2007， 博士

【摘要】 大规模定制(MC,Mass Customization)作为21世纪最主要的一种生产模式,是解决目前企业发展过程中所面临如何以大规模生产方式生产个性化产品问题的有效途径。其中面向大规模定制设计(DFMC,Design for Mass Customization)是实施MC关键环节,而产品族设计(PFD,Product Family Design)是实现DFMC的重要、有效方法。由于缺乏系统性的理论、方法及工具支持,PFD作用还未能充分发挥出来,这已经成为实施、应用DFMC及MC的瓶颈。本文在综合国内外相关研究基础上,按照“理论探讨-方法技术研究-系统开发及工程应用”策略对“面向大规模定制的产品族设计关键技术”进行了重点研究。系统提出了PFD方法体系,深入探讨了PFD基本思想、PFD研究问题、PFD理论依据和PFD方法体系框架,为面向MC的PFD研究提供了理论、方法支持,形成了从理论到技术再到实际应用的完整PFD体系结构。针对PFD过程中模块定制性要求问题,把客户定制需求信息引入模块划分,提出了面向MC的PFD多约束模块划分方法(MCMPA,Multi-Constrained ModularPartition Approach)。从产品结构、功能和客户定制需求多个角度提出产品零部件模块划分准则,基于该准则分别构建产品结构、功能和客户定制三种相关性矩阵;采用AHP方法计算三种相关性矩阵之间的权重系数,依据公式对三种相关性予以整合,得到产品零部件两两之间模块化综合相关度数值,并构建综合相关度矩阵;建立产品零部件多约束模块划分算法流程,输入模块划分阈值,将综合相关度矩阵元素数值与阈值进行比较,根据结果生成相应模块划分方案。以装载机工作装置为例进行MCMPA应用分析,结果表明MCMPA使划分模块同时具备客户定制性、结构独立性和功能独立性,并把模块划分定性问题转化为可定量计算问题,提高了模块划分效率和合理性。针对PFD过程中产品通用平台辨识问题,在并行考虑产品结构、功能和客户定制需求基础上,提出了产品通用平台耦合空间跨域辨识方法(CDIPCP,Cross-Domain Identification of Product Common Platform)。通过提出产品通用平台辨识规则和当量距离概念,为产品通用平台跨域辨识提供了理论方法基础。把图论和矩阵有关理论应用到CDIPCP研究中,定义和构建了产品结构域无向图模型、功能域有向图模型、用户需求域向量表模型以及各模型对应关联矩阵,并在此基础上构建了多约束耦合空间模型,将产品零部件转化为空间中的点,通过计算、比较各点与原点当量距离大小进行CDIPCP。将CDIPCP方法应用于轮式装载机进行了分析验证,结果表明产品通用平台辨识规则、多约束耦合空间模型和多约束耦合空间矩阵是产品通用平台辨识的有效方法,能并行考虑产品结构、功能以及客户定制因素,并能把产品通用平台辨识定性问题转变为定量计算问题,有效地解决了产品通用平台在多域中统一、定量辨识问题。针对PFD过程中产品信息、客户定制信息和企业资源信息集成表达问题,提出了产品族结构无向图模型(UGMPFA,Undirected Graph Model for Product Family Architecture)。采用图论方法,以产品通用平台、差异化模块及其之间相互配置关系作为主要构成单元,定义了两类顶点和三类边,在充分考虑产品族模型内涵基础上把客户信息、产品信息和企业资源信息集成在一起。并以UGMPFA为基础提出了个性化产品定制算法流程,将客户定制需求信息作为驱动,通过平台选择和模块匹配定制个性化产品。以工程机械装载机为例进行UGMPFA建模研究,结果表明UGMPFA可合理表达企业生产能力、顾客个性化需求、差异化产品变型能力、系列相似产品之间关系以及个性化产品定制所蕴涵知识,筛选掉定制过程中冗余信息,为企业充分利用生产资源、快速响应细分市场和产品族设计软件系统的开发奠定基础。针对PFD辅助支持工具开发问题,以PFD方法及其关键技术为基础,把PFD思想和CAD技术相结合,提出面向MC的产品族设计软件系统(PFDSS,Product Family Design Software System)开发技术。以CAD系统为PFD开发平台,以UGMPFA为信息集成、传递桥梁,通过构建统一外部数据库并结合CAD内部数据库进行资源信息管理。在PFDSS中输入客户定制信息,将其转化、传递和映射为设计信息,通过平台选择、模块匹配,最终输出个性化定制方案和个性化产品。最后以工程机械装载机工作装置为例,对PFD方法及PFDSS进行实际应用研究,并取得了初步成效。更多还原

【Abstract】 As a main manufacturing mode in 21 century,MC(Mass Customization)is an effective method to solve the difficulties how to produce personal products using mass production method which companies have confronted now.One of the key activities in the application in MC is DFMC(Design for Mass Customization),wherein PFD (Product Family Design)is of critically significant.However,the power of PFD has not been fully released due to lack of systematic theories and tools,which has already become the bottleneck of implementing DFMC and MC.In this study,based on the synthesis and refining of relevant researches at home and abroad,main efforts have been made on the methodology and key technologies of PFD,based on the strategy of "Theory-Technology-Software Development-Engineering Application".Methodology of PFD was proposed systematically and relevant ideas,scientific problems,theoretical basis and frame were also discussed deeply.It provides theoretical support for application of PFD,which combines PFD theory,technology and application together as a whole system.Focusing on customization problem in PFD,Multi-Constrained Module Partition Approach(MCMPA)of PFD for MC was proposed within which the customized information is introduced.Combined with product structure,function and customer demand,the criteria for MCMPA was proposed,and three correlation matrixes were built based on product customization correlation,function correlation and structure correlation,respectively.The weights of customization,function and structure are determined with AHP method,through which the comprehensive degree of correlations between two arbitrary parts may be further determined.According to the comprehensive degree of correlations and threshold value of modular partition,the approach for module partition is formed.The MCMPA was applied on the working equipment of loader.It is proved that,taking the correlation of customization,correlation of function and that of structure as initial conditions,the qualitative analysis of module partition was transformed into quantitative calculation and its efficiency and rationality was improved. The partitioned module has the features of customization,independence of structure and independence of function,which can be more suitable for PFD for MC.With the parallel incorporation of product structure,function and customization,the cross-domain coupling space identification approach for product common platform was proposed.The rules and models for identification were constructed and the concept of equivalent distance was presented.By virtue of graph theory and matrix theory,various identification models of product common platform were set up,such as structure-domain undirected graph model,function-domain directed graph model and customization-domain vector table model.When the parts are mapped into the points in space,the identification of common platform can be achieved through the distance from these points to original point.It makes the identification quantitative and unified in cross-domain coupling space.Through the application of wheel loader,it is verified that the approach for identification of product common platform,multi-constraint coupling space model and multi-constraints coupling matrix are effective on cross-domain identification of product common platform.In view of the description of information from product,customization and enterprise resource,the Undirected Graph Model for Product Family Architecture (UGMPFA)was built.The product common platform,customization module and their configuration relationship were taken as main elements,and two kinds of vertexes and three kinds of edges were defined.The UGMPFA was built based on the information integration of customization,product and enterprise resource.Moreover,the algorithm flow of product customization was proposed by UGMPFA.The UGMPFA was applied in wheel loader analysis as an example.It is verified that UGMPFA can appropriately describe company’s production capacity,individualized customer demand,product’s variation capacity,similarity between series of products and knowledge in customization without increasing redundant information,which can make full use of enterprise resource and quickly respond to customer demand.To develop the assistant tools for PFD,the techniques for the PFD system was studied based on combination of CAD and PFD with the foundation of methodology of PFD,.CAD system is used as the platform of system development tool,and UGMPFA acts as the bridges of information communication and integration.The information was managed through inner database in CAD and outer database.The information of customization was transformed,transmitted and mapped into parts,modules and common platforms.Then,the customized solutions and products were formed through choice of platforms and match of modules.Finally,the methodology and prototype system of PFD were applied for the working equipment of wheel loader,and the preliminary effects were achieved.更多还原