有限时间区间内制造系统预防性机会维护策略研究
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摘要
现代企业中制造系统的维修对生产型企业的经济效益和市场竞争力有重要影响,是企业的制造成本和生产运营成本决定性的影响因素之一维修策略是对设备和制造系统的维修工作进行定量描述及分析,利用数学建模和各种工具对使维修计划进行优化,从而使维修工作水平得到提高,最终实现提高设备保障水平和企业效益。因此通过对故障和维修运行规律的研究,提出更有效、更符合实际的故障描述模型和维修决策策略,对现代制造企业具有重要的现实意义。
维修计划的生成是与制造系统本身的构成密切相关的,特别是在多设备构成的复杂制造系统中,系统结构包含了生产任务的因素,不同的生产任务使得同一组生产设备之间的相互影响是不同的。针对复杂制造系统的特点,机会维护策略是一种非常有效的手段,能够充分利用系统组成部分之间的相关性进行维修计划的优化,从而降低维修总成本。本论文针对制造系统在有限时间区间内的预防性机会维护策略进行了研究,根据制造系统需要控制的运行目标的不同,设定相应的状态参数作为维修阈值和并对维修阈值进行优化从而获得最优预防性维修计划,从而有效避免系统维修过剩和维修不足。本文主要研究内容如下：
首先以多部件构成的单设备为研究对象,在可靠性理论基础上引入机会维护策略,提出了基于可靠度的多部件单设备预防性机会维护策略,以有限时间区间内总维护成本最优为目标,综合考虑了设备的维修成本和可靠性保障,以费效比作为多种维护方式选择的决策指标,并推导了在不同维护方式下设备可靠度的演化过程。
在基于可靠度的预防性机会维护策略基础上,拓展其应用对象,以随机故障可能导致严重后果的制造设备为研究对象,通过构建系统风险评价函数描述其随机故障的后果,建立了以在有限运行时间区间内总维护成本最优为目标的预防性机会维护策略模型,该模型以故障风险为机会维护阈值,综合考虑事后维修和预防性维修,以经济性为维护方式的选择指标,并推导了不同维护方式的情况下系统风险的演化过程。以具有多个可监测状态的制造设备为研究对象,引入相对劣化度概念,结合制造系统的风险模型,构建了在有限时间区间内基于相对劣化度的预防性机会维护模型。
在上述研究的基础上,将预防性机会维护模型应用于多设备组成的混联制造系统,为其为研究对象,通过分析系统维护机会产生的机理,建立了一种基于可靠度的以有限时间区间内维护成本为优化目标的多设备混联制造系统的机会维护模型,并在此基础上继续探讨了考虑风险的多设备混联预防性机会维护策略。
最后,基于本文所提出的预防性机会维护模型进行了“制造系统预防性维护系统”的设计和开发,并通过在某汽车零部件制造企业中的具体应用实例,对本文所提出的制造系统预防性机会维护策略进行了实际应用,并验证了其有效性和实用性。
Production systems maintenance work have very important impact onthe economic efficiency and the market competitiveness of the enterprisesand which are the important decisive factors of the manufacturing costs andoperating costs. Maintenance policy is used to analyze the maintenance jobsof equipment and production systems through the quantitative descriptionand to optimize the maintenance plans by the mathematical models and othertools and to improve the performance of maintenance work and theequipments security.
The decision of maintenance plans of the production systems areassociated with the production systems structure especially in the multipleequipments systems. And the production plan will make the relationship tochange in different of the equipments. The opportunistic maintenance policyis a very effective means to decrease the maintenance cost of multipleequipments production system which can sufficiently utilize the relativityof equipments in production system. In this paper the production systemspreventive opportunistic maintenance policies are be proposed to avoidinsufficient maintenance or excess maintenance by selecting the suitableopportunistic thresholds and the values.In this paper, an reliability-basedsingle equipment opportunistic maintenance in finite time horizon policy is proposed which consider the maintenance cost and the equipmentsreliability, and use effective-cost ratio to determine maintenance job typesand the evolutionary processes of equipment reliability are deduced.
The multiple unit equipment preventive opportunistic maintenancepolicy model is constructed consider with the system risk level. The risklevels of the equipments are used to be the opportunistic thresholds in thismodel. the minimized maintenance cost is optimized by choosing the moreeconomical efficiency maintenance method type. and the risk evolutionaryprocesses of are deduced the relative inferiority degree concept is combinedwith system risk model to construct the equipment preventive opportunisticmaintenance policy model.
The multiple equipment production system preventive opportunisticmaintenance policy model is constructed by the basis of analyzing theformation mechanism rules of the maintenance opportunities in this modelthe production system is the research objective and the minimization ofmaintenance cost is the optimization objective.
The production system preventive maintenance information system isdesigned and developed and it is applied in the motor vehicle partsmanufacturing enterprise which is designed on the basis of the productionsystem preventive opportunistic maintenance policy models which isproposed in this paper.
维修计划的生成是与制造系统本身的构成密切相关的,特别是在多设备构成的复杂制造系统中,系统结构包含了生产任务的因素,不同的生产任务使得同一组生产设备之间的相互影响是不同的。针对复杂制造系统的特点,机会维护策略是一种非常有效的手段,能够充分利用系统组成部分之间的相关性进行维修计划的优化,从而降低维修总成本。本论文针对制造系统在有限时间区间内的预防性机会维护策略进行了研究,根据制造系统需要控制的运行目标的不同,设定相应的状态参数作为维修阈值和并对维修阈值进行优化从而获得最优预防性维修计划,从而有效避免系统维修过剩和维修不足。本文主要研究内容如下：
首先以多部件构成的单设备为研究对象,在可靠性理论基础上引入机会维护策略,提出了基于可靠度的多部件单设备预防性机会维护策略,以有限时间区间内总维护成本最优为目标,综合考虑了设备的维修成本和可靠性保障,以费效比作为多种维护方式选择的决策指标,并推导了在不同维护方式下设备可靠度的演化过程。
在基于可靠度的预防性机会维护策略基础上,拓展其应用对象,以随机故障可能导致严重后果的制造设备为研究对象,通过构建系统风险评价函数描述其随机故障的后果,建立了以在有限运行时间区间内总维护成本最优为目标的预防性机会维护策略模型,该模型以故障风险为机会维护阈值,综合考虑事后维修和预防性维修,以经济性为维护方式的选择指标,并推导了不同维护方式的情况下系统风险的演化过程。以具有多个可监测状态的制造设备为研究对象,引入相对劣化度概念,结合制造系统的风险模型,构建了在有限时间区间内基于相对劣化度的预防性机会维护模型。
在上述研究的基础上,将预防性机会维护模型应用于多设备组成的混联制造系统,为其为研究对象,通过分析系统维护机会产生的机理,建立了一种基于可靠度的以有限时间区间内维护成本为优化目标的多设备混联制造系统的机会维护模型,并在此基础上继续探讨了考虑风险的多设备混联预防性机会维护策略。
最后,基于本文所提出的预防性机会维护模型进行了“制造系统预防性维护系统”的设计和开发,并通过在某汽车零部件制造企业中的具体应用实例,对本文所提出的制造系统预防性机会维护策略进行了实际应用,并验证了其有效性和实用性。
Production systems maintenance work have very important impact onthe economic efficiency and the market competitiveness of the enterprisesand which are the important decisive factors of the manufacturing costs andoperating costs. Maintenance policy is used to analyze the maintenance jobsof equipment and production systems through the quantitative descriptionand to optimize the maintenance plans by the mathematical models and othertools and to improve the performance of maintenance work and theequipments security.
The decision of maintenance plans of the production systems areassociated with the production systems structure especially in the multipleequipments systems. And the production plan will make the relationship tochange in different of the equipments. The opportunistic maintenance policyis a very effective means to decrease the maintenance cost of multipleequipments production system which can sufficiently utilize the relativityof equipments in production system. In this paper the production systemspreventive opportunistic maintenance policies are be proposed to avoidinsufficient maintenance or excess maintenance by selecting the suitableopportunistic thresholds and the values.In this paper, an reliability-basedsingle equipment opportunistic maintenance in finite time horizon policy is proposed which consider the maintenance cost and the equipmentsreliability, and use effective-cost ratio to determine maintenance job typesand the evolutionary processes of equipment reliability are deduced.
The multiple unit equipment preventive opportunistic maintenancepolicy model is constructed consider with the system risk level. The risklevels of the equipments are used to be the opportunistic thresholds in thismodel. the minimized maintenance cost is optimized by choosing the moreeconomical efficiency maintenance method type. and the risk evolutionaryprocesses of are deduced the relative inferiority degree concept is combinedwith system risk model to construct the equipment preventive opportunisticmaintenance policy model.
The multiple equipment production system preventive opportunisticmaintenance policy model is constructed by the basis of analyzing theformation mechanism rules of the maintenance opportunities in this modelthe production system is the research objective and the minimization ofmaintenance cost is the optimization objective.
The production system preventive maintenance information system isdesigned and developed and it is applied in the motor vehicle partsmanufacturing enterprise which is designed on the basis of the productionsystem preventive opportunistic maintenance policy models which isproposed in this paper.
引文
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