定制生产下工艺可重用理论、方法及关键技术研究与应用
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摘要
随着制造企业由少品种、大批量的大规模生产模式向多品种、小批量的定制生产模式转变，传统的工艺设计系统已不能适应定制生产模式下复杂多变的制造环境，提高设计的快速响应能力是定制生产对工艺设计技术提出的迫切要求。本文系统地研究了定制生产下工艺可重用理论和方法，提出了回转体、箱体零件工艺可重用的解决方案，并开发了工艺可重用设计系统，在国家863/CIMS应用推广计划项目(863-511-910-211/02)——“宁波华翔集团公司CIMS应用示范工程”中得到了有效的应用。
第一章在分析定制生产特点的基础上，论述了定制生产下工艺可重用的关键技术。详细分析了工艺过程设计中系统结构和工艺方案重用技术的研究现状和存在的不足，提出了本文付诸研究的问题和采用的技术方法。最后给出了本文的组织结构。
第二章提出了支持设计重用的面向制造结构单元建模方法，将加工工艺和制造数据封装于结构单元中，为零件结构设计和工艺设计重用提供了基本模块。借鉴成组工艺的思想，提出了工艺可重用的层次化设计方法，将该方法应用到产品建模的不同层次，以及不同的零件对象。在此基础上，提出了适应定制生产的工艺可重用设计系统的工作模式，为回转体零件和箱体类零件的工艺设计奠定了应用基础。
第三章以机械产品中典型零件为例，总结了回转体、箱体类零件的加工工艺特点。详细分析了零件加工工艺多样性形成的原因，并给出了多工艺方案的描述方法。提出了“类型层+实例层”的层次型可重用工艺库索引模型，建立了类型层成组分类编码结构，给出了成组分类方法。
第四章建立了回转体零件层次结构的信息模型，给出了零件信息的框架描述。针对固定编码方式存在的不足，提出了基于零件结构单元特征和加工工艺性的变位数柔性编码方法。为了相似工艺的检索，以零件柔性编码为基础，提出了相似性判定准则和三级检索策略，使检索出的实例在几何及工艺上更符合当前零件的设计要求。对不存在相似实例的零件，提出了结构退化——匹配算法，并结合推理机制自动生成零件工艺。
第五章针对复杂结构的箱体类零件，建立了基础结构单元与方位结构单元树信息描述方法，定义了层次结构的箱体零件信息模型。基于工艺可重用层次性思想，应用结构单元层次的相似性进行零件结构单元的工艺链设计，提出了结构单元编码规则以及进级匹配的搜索策略，对检索出的相似工艺修改和新结构单元工艺的生成给出了相应的算法。将基因遗传/禁忌混合算法应用于加工工序的聚合问题，以工序聚合中的约束规则为基础，建立了
摘 要
遗传算法的适应度函数，通过实例验证了混合算法的有效性。
第六章在本文理论研究基础上，开发了工艺可重用设计系统。介绍了系统的结构、特
点以及主要模块的功能。提出了资源引用导航和工序图递归化生成技术，并在工艺可重用
设计系统中得到应用。
第七章总结了全文的主要研究成果，并展望了今后的研究工作。
With productive manufacturing model changing from large-scale mode to customization mode, conventional CAPP system could not fit to multivariate manufacturing environment any longer. The ability of fast response is the insistent requirement of the customization manufacture mode. This dissertation presents the reuse theory of process plans and correlative methods. Based on the reuse theory, the process planing schemes are put forward for rotational and case parts. A system of process planning design is developed, and is applied effective to CIMS promotion subject (863-511-910-211/02) of state 863 high-tech program.
In the 1st chapter, on the basis of analysis of the characteristic of customization production, the technical demand of reusing process plans for customization manufacture is discussed. The present research situation of system structure and process plans reusing technology in process planning are summarized in detail. Then, the background and content of this dissertation are described briefly.
In the 2nd chapter, the modeling method of manufacture-oriented structure unit is put forward, and has been used to implement design reuse. The structure unit encapsulates manufacturing and planning data, and provides basic modular for product design and process planning reuse. With the discussion of application mode of group process , the layering design method of process plans reuse is introduced. This method is applied to different level of product modeling and different parts. To obtain the theory base of process planning design of rotational and case parts, the work fashion of process plans reuse system is built.
In the 3rd chapter, by analyzing typical parts of mechanical product, the processing technical characteristics of rotational and case parts are generalized. The reason that causes multiplicity of process planning is analyzed in detail, and the descriptive method for multi-planning is provided. The hierarchical indexing model of process plans reuse base is composed of type level and case level, and the encoding rule and sorting method for type level are provided.
In the 4th chapter, the hierarchical information model of rotational part is built. In order to overcome the shortage of rigid-coding, flexible-coding rule is put forward based on the part processing property. Similarity decision rule and three level retrieval strategy are presented based on part flexible code, which provides accurate cases matching. In order to generate process plan for dissimilar parts, structure degenerating match algorithm is provided. The algorithm and
inference rule combine to generate part plan.
In the 5th chapter, aiming at the case part of complex structure, the information description method based on foundation-structure-unit and azimuth-structure-unit-tree is presented, and hierarchical information model of case part is defined. Based on process plan reuse layering, unit-based similarity is applied to process plan design of structure unit, and the coding architecture of structure unit and grading matching strategy are presented. The modification algorithms for similar plan and method of process planning reasoning generating for new structure unit are provided. The sufficiency function is built for genetic algorithm based on constraint rule, and the genetic /tabu algorithm is introduced to process aggregating. The feasibility and efficiency of the algorithm are verified by the result of example.
In the 6th chapter, on the basis of theoretic research above, a process plans reuse design system is developed. The system's architecture, characteristics and main modular are introduced. Resource guidance and recursive generation techniques of process picture sheet are presented, and have been applied to this system.
In the 7th chapter, all achievements of this dissertation are summarized, and the further work in the future is given.
第一章在分析定制生产特点的基础上，论述了定制生产下工艺可重用的关键技术。详细分析了工艺过程设计中系统结构和工艺方案重用技术的研究现状和存在的不足，提出了本文付诸研究的问题和采用的技术方法。最后给出了本文的组织结构。
第二章提出了支持设计重用的面向制造结构单元建模方法，将加工工艺和制造数据封装于结构单元中，为零件结构设计和工艺设计重用提供了基本模块。借鉴成组工艺的思想，提出了工艺可重用的层次化设计方法，将该方法应用到产品建模的不同层次，以及不同的零件对象。在此基础上，提出了适应定制生产的工艺可重用设计系统的工作模式，为回转体零件和箱体类零件的工艺设计奠定了应用基础。
第三章以机械产品中典型零件为例，总结了回转体、箱体类零件的加工工艺特点。详细分析了零件加工工艺多样性形成的原因，并给出了多工艺方案的描述方法。提出了“类型层+实例层”的层次型可重用工艺库索引模型，建立了类型层成组分类编码结构，给出了成组分类方法。
第四章建立了回转体零件层次结构的信息模型，给出了零件信息的框架描述。针对固定编码方式存在的不足，提出了基于零件结构单元特征和加工工艺性的变位数柔性编码方法。为了相似工艺的检索，以零件柔性编码为基础，提出了相似性判定准则和三级检索策略，使检索出的实例在几何及工艺上更符合当前零件的设计要求。对不存在相似实例的零件，提出了结构退化——匹配算法，并结合推理机制自动生成零件工艺。
第五章针对复杂结构的箱体类零件，建立了基础结构单元与方位结构单元树信息描述方法，定义了层次结构的箱体零件信息模型。基于工艺可重用层次性思想，应用结构单元层次的相似性进行零件结构单元的工艺链设计，提出了结构单元编码规则以及进级匹配的搜索策略，对检索出的相似工艺修改和新结构单元工艺的生成给出了相应的算法。将基因遗传/禁忌混合算法应用于加工工序的聚合问题，以工序聚合中的约束规则为基础，建立了
摘 要
遗传算法的适应度函数，通过实例验证了混合算法的有效性。
第六章在本文理论研究基础上，开发了工艺可重用设计系统。介绍了系统的结构、特
点以及主要模块的功能。提出了资源引用导航和工序图递归化生成技术，并在工艺可重用
设计系统中得到应用。
第七章总结了全文的主要研究成果，并展望了今后的研究工作。
With productive manufacturing model changing from large-scale mode to customization mode, conventional CAPP system could not fit to multivariate manufacturing environment any longer. The ability of fast response is the insistent requirement of the customization manufacture mode. This dissertation presents the reuse theory of process plans and correlative methods. Based on the reuse theory, the process planing schemes are put forward for rotational and case parts. A system of process planning design is developed, and is applied effective to CIMS promotion subject (863-511-910-211/02) of state 863 high-tech program.
In the 1st chapter, on the basis of analysis of the characteristic of customization production, the technical demand of reusing process plans for customization manufacture is discussed. The present research situation of system structure and process plans reusing technology in process planning are summarized in detail. Then, the background and content of this dissertation are described briefly.
In the 2nd chapter, the modeling method of manufacture-oriented structure unit is put forward, and has been used to implement design reuse. The structure unit encapsulates manufacturing and planning data, and provides basic modular for product design and process planning reuse. With the discussion of application mode of group process , the layering design method of process plans reuse is introduced. This method is applied to different level of product modeling and different parts. To obtain the theory base of process planning design of rotational and case parts, the work fashion of process plans reuse system is built.
In the 3rd chapter, by analyzing typical parts of mechanical product, the processing technical characteristics of rotational and case parts are generalized. The reason that causes multiplicity of process planning is analyzed in detail, and the descriptive method for multi-planning is provided. The hierarchical indexing model of process plans reuse base is composed of type level and case level, and the encoding rule and sorting method for type level are provided.
In the 4th chapter, the hierarchical information model of rotational part is built. In order to overcome the shortage of rigid-coding, flexible-coding rule is put forward based on the part processing property. Similarity decision rule and three level retrieval strategy are presented based on part flexible code, which provides accurate cases matching. In order to generate process plan for dissimilar parts, structure degenerating match algorithm is provided. The algorithm and
inference rule combine to generate part plan.
In the 5th chapter, aiming at the case part of complex structure, the information description method based on foundation-structure-unit and azimuth-structure-unit-tree is presented, and hierarchical information model of case part is defined. Based on process plan reuse layering, unit-based similarity is applied to process plan design of structure unit, and the coding architecture of structure unit and grading matching strategy are presented. The modification algorithms for similar plan and method of process planning reasoning generating for new structure unit are provided. The sufficiency function is built for genetic algorithm based on constraint rule, and the genetic /tabu algorithm is introduced to process aggregating. The feasibility and efficiency of the algorithm are verified by the result of example.
In the 6th chapter, on the basis of theoretic research above, a process plans reuse design system is developed. The system's architecture, characteristics and main modular are introduced. Resource guidance and recursive generation techniques of process picture sheet are presented, and have been applied to this system.
In the 7th chapter, all achievements of this dissertation are summarized, and the further work in the future is given.
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