【作者】 金鑫；

【导师】 苏建；

【作者基本信息】 吉林大学 ， 载运工具运用工程， 2013， 博士

【摘要】 随着经济和市场全球化的发展,汽车制造企业之间的市场竞争越来越激烈,如何更快、更准、低成本、高质量的生产出市场需要的汽车成为汽车制造企业的关键问题。先进的制造技术为这个关键问题提供了很好的解决方法,而数字化工厂是先进制造技术的核心技术。数字化工厂技术为工艺规划及最后的生产线布线带来了从规划流程到工艺实现的全方位的技术变革,能够有效地减少规划和设计周期,降低出错率,缩短生产制造周期,降低规划及生产成本,为柔性生产和快速市场供给提供了强有力的技术支持。目前国内还处于数字化工厂技术的局部应用阶段,而且仅仅停留在简单的技术应用,没有流程和技术上的深刻变革。无论是合资汽车制造企业还是自主汽车制造企业,很多企业都上了产品生命周期管理平台,但是没有一个企业据此实现了工作流程和方案实施上的质的变化。本文正是基于以上的原因,旨在基于工艺规划和方案实施的工作内容,以数字化工厂为技术平台,结合多个项目经验,提出可行的数字化工艺规划流程,并针对整个规划及实施过程的若干仿真关键参数及方法进行研究和阐述。全文的主要内容如下:1、数字化工厂技术为汽车制造工艺提供了三维可视化规划平台、工艺仿真平台和流程分析平台,为汽车制造提供了全套的虚拟制造技术支持。本文通过分析国内汽车制造工艺规划现行的流程,提出了基于数字化工厂技术的汽车制造工艺规划流程,以及保证新流程能够有效运转的软件保障和外部保障,并结合工艺规划进行的各个阶段,以实际项目经验为背景,阐述了数字化规划、工艺仿真和流程仿真等数字化工厂技术对各个阶段的技术支持。2、工艺仿真是连接工艺规划和生产线布线及调试的桥梁,为产品工艺性验证和工艺方案分析提供了虚拟化的仿真技术支持。本文结合多个工艺仿真项目,定义了工艺仿真概念、仿真介入点、仿真分析范围和仿真的输入输出,清晰的阐述工艺仿真的技术支持内容和形式,并对仿真流程、设备定义、仿真输入输出形式、人机仿真等方面进行详细的研究,以焊装工艺规划为背景提出了工艺仿真的实用的标准流程,定义了焊钳定义、夹具定义和人机仿真步骤,设定了仿真输入输出的内容及形式,并依托实际的焊装同步工程项目,具体阐述工艺仿真为产品设计和工艺规划带来的技术支持。3、汽车制造是流水线作业,而且现代装备技术的发展使生产线的自动化水平越来越高,机械带来了故障,带来了很多的机械性的不确定性,工艺物流仿真提供了生产运行系统整体流程分析的技术支持,本文通过分析工艺物流仿真的介入点、仿真分析范围、仿真的输入输出等,清晰的定义了工艺物流仿真的技术支持内容和形式。提出了基于目前的汽车制造系统特点的两种设定生产节拍方法和相应的数学模型,针对线间的自动化缓存区存储能力提出了初始化设置计算数学模型,并研究了如何用遗传算法对缓存区存储能力需求进行分析,给出了不同阶段的仿真的建模形式以及仿真的各类分析结果的最有效表达方式等,并结合多个实际项目进行了具体阐述。4、数字化工厂技术也可以为实物物流的规划及实际运行提供有效的仿真支持,本文首先分析实物物流仿真的介入点、仿真分析范围、仿真的输入输出等,定义出实物物流仿真的技术支持内容和形式,然后对仿真输入、仿真标准化建模、仿真的各类分析结果的最有效表达方式进行了研究,并定义了仿真的输入内容和仿真结果表到形式,提出了如何进行物流系统的标准化模块建模,最后以实际项目为依托具体阐述各个模块的模型表达形式。更多还原

【Abstract】 With the globalization development of economic and market the competition among the car manufacturers are more and more fierce.It is the key problem that how to produce the market needed high quality cars quickly and more accurately.Advanced manufacturing technology is a commendable method for this key problem,and the digital factory(DF)is the core technology of the advanced manufacturing technology.The digital factory technology produces all-wave technology transform of process planning and production line layout from planning flow to process realization.The digital factory technology can reduce the period of planning and designing,reduce error rate,reduce the period of produce,reduce the cost the planning and production.And then it provides strong technology support to flexibility production and rapid market supply.Currently we use the digital factory technology still in the local application stage in our country,there is no deep transform on procedure and technology.Some automobile manufactures use PLM platform,but nearly no one achieve nature change in work flow and implement,no matter joint investment automobile manufacture or our own automobile manufacture.Base on the above reasons this article proposes practicability procedure of process planning and implementation procedure base on the digital factory platform by some planning and implementation projects,and researches the parameters and methods of simulation technology during planning and implementation.The major content of this article is as follow:1.Digital factory technology provides a 3D visual planning platform,process simulation platform and pro for automotive manufacturing process analysis platform.DF provides a full range of virtual manufacturing technology support for automotive manufacturing.By analyzing the existing domestic automotive manufacturing process planning proceeding this paper propounds the process planning proceeding of automotive manufacturing based on digital factory,and the software security and the external security to keep the new proceeding effective functioning.This paper expounds the digital factory technical suppor,including digital technology planning,process simulation and plant simulation,to each stagecombined base on various stages of the process planning and the actual project experience.2.Process simulation is the bridge of process planning and production lines implementing.Process simulation provides a virtual simulation technology support for process validation and process solutions.This paper defines the concept of process simulation,simulation point of intervention,simulation scope of analysis and simulation input and output base on a number of process simulation projects,clearly articulateds process simulation content and form of technical support,and researches the simulation process,device definition,simulation input and output form,human-computer simulation in detail.This paper propounds a practical standard proceedingof process simulation base on body shop planning,and relying on the actual simultaneous engineering project of body shop expounds the technical support of process simulation for product design and process planning.3.Automobile manufacturing is pipeline operations,and the development of modern equipment and technology increases the level of automation of production lines.Machinery brings break down and a lot of mechanical uncertainty.Process logistics simulation provides a whole analyse technical support to the whole manufacture proceeding.This paper,by analyzing the process logistics simulation point of intervention,the scope of simulation analysis,simulation input and output,clearly defines the content and form of simulation technical support.This paper expounds two methods and corresponding formulas of setting cycle time and the formula of init setting for buffer capacity and researches how to use genetic algorithm to analyse buffer capacity.This paper put out some modeling forms of different stages and some effective forms of simulation analyse and explain in detail base on some practical projects.4.Digital factory technology can also provide effective simulation support for the physical logistics planning and actual operation.The paper first analyzes the physical logistics simulation point of intervention,the scope of analysis for the simulation,simulation input and output,defines the content and form of physical logistics simulation technology support,then researches the form of simulation input,standardized modeling simulation,the various types of simulation analysis results.This paper defines the form of simulation input and simulation results,and how to model standardized modules of the logistics system,and finally explains them in detail base on some actual projects.更多还原