大型离心压缩机产品精益设计研究与应用
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摘要
随着现代工业的迅猛发展,大型化、高效化、高速化、节能降噪成为大型压缩机发展的必然趋势。如何在科学发展观指导下,开发具有自主知识产权的大型压缩机研发技术,满足产品品质提升和产品创新的需求；以及如何在保证国计民生需求的同时,兼顾企业生存和发展的需要,降低研制成本,缩短研发周期,提高产品研发效率,已经成为大型压缩机制造行业所需要迫切解决的主要问题。
为此,本课题以闻邦椿教授提出的综合设计方法为基础,以“精益”技术做理论联系实际的结合点,以大型压缩机组的创新设计为背景,以满足用户对产品广义质量需求和企业对产品收益需求,提出一种适于大型复杂机械系统的创新设计实施方法,即大型压缩机精益设计方法。它从系统工程的角度出发,通过大型压缩机设计的总体规划、整机功能展开、以及具体功能区域内的性能研究和优化设计工作,完成用户给定功能条件下的大型压缩机结构创新和关键系统结构性能、工艺性能和工作性能的提升工作。同时,基于产品开发过程的成本模型,利用AHP方法和模糊集理论、CAX集成平台,对产品创新设计过程的规模、效率和时间消耗进行了约束和控制。
在课题的研究过程中,根据大型压缩机的结构特点和设计经验：①提出了深层次可视优化设计的基本方法,对其内容及实施流程进行了详细论述；②构建了用于缩减研发成本的设计对象精益筛选方法,并给出了具体的评价指标和实施方法；③给出了深层次动态优化设计在产品设计过程中,较为完整的具体实施方法及内容。并就如何应用精益筛选、深层次动态优化设计方法和深层次可视优化方法,在主功能区、辅助功能区关键结构,和主辅功能耦合区(即转子系统)的的概念化设计和详细设计阶段中,采用非线性动力学、结构力学、可靠性理论和非线性空气动力学理论等,对大型压缩机加气系统气动性能研究及优化设计方法、叶轮部装结构工艺性能和工作性能研究及优化设计方法、以及转子系统综合性能研究及优化设计方法,进行了详细论述。本文具体内容研究如下：
(1)通过文献收集和企业调研,对现代设计理论的研究现状和发展趋势、以及企业进行产品创新设计过程中存在的问题和需求,进行了概括和总结。并借鉴精益在生产体系中的成功经验,提出了精益设计概念。指明了精益设计中“精”和“益的具体含义,确定了精益设计的基本技术框架。
(2)对如何运用综合设计理论与方法完成复杂产品创新设计,进行了深入研究,形成了一套较为完整的大型压缩机精益设计实施方法。通过大型压缩机设计过程的总体规划、整机功能展开、以及主辅功能区和主辅功能耦合区的精益设计研究工作的开展,详细论述了如何在完成产品关键系统和结构设计、优化和设计质量评价工作的同时,兼顾成本控制的精益设计实施方法。并于样机试制完成后,在沈鼓集团的产品试车台位上通过单缸和三缸串联的机械运转试验,对产品的设计质量进行了检验。
(3)在研究大型压缩机精益设计实施方法的过程中,完成了4种主要精益设计实施工具的构建工作。这些工具包括：从系统角度出发的功能分解工具、用于大幅缩减新产品研发成本的设计对象精益筛选工具、以及用于提高产品设计质量的深层次动态设计工具和深层次可视优化优化工具。在这些工具创建过程中：①构造了8D总体规划模型和实施框架；②提出了深层次可视优化方法的概念和具体应用方法；③丰富了深层次动态优化设计方法的内涵；④通过构建质量贡献率和成本影响率两个评价指标,形成了设计对象的精益筛选方法。
(4)在主功能区的精益设计过程中,首先通过设计对象精益筛选,确立加气系统为首要研究对象,并利用深层次可视优化设计工具,完成其气动性能研究和概念化设计工作。其次,找到了原加气结构的设计缺陷,并根据对多种气动元件的分析和加气结构的分析,提出了一种带有进气涡壳的全新加气结构。在设计质量检验过程中,首次借助高性能计算平台,通过加气系统整流道模型(即包含加气结构及其相邻的两个模型级)的CFD分析工作,完成了引入加气结构后对周边气动元件的综合性能影响的评估工作。
(5)在辅助功能区的精益设计过程中,以工艺性能改善为目标,采用可视优化设计与深层次动态设计相结合的方法,完成了关键结构创新及详细设计工作。并在此基础上,利用CAX集成应用环境,结合非线性接触理论和结构动力学理论,完成了叶轮部装结构工艺性能和运行工况条件下的结构性能研究工作。之后利用深层次动态优化设计方法,对新结构的工艺性能、结构性能加以改善。并利用概率有限元分析技术,与非线性接触分析技术相结合的非线性可靠性分析方法,对原始结构和改进结构功能实现的可靠度进行了对比计算,初步讨论了输入参数的不确定因素,对原型叶轮和新叶轮部装结构的结构性能影响问题。
(6)在转子系统的精益设计过程中,详细论述了使用深层次动态设计工具,完成转子系统设计质量提升工作的具体操作方法和实施流程。从转子系统功能分析、综合性能优化以及设计质量的出厂验证和工作性能预估三个阶段入手,完成了大型压缩机转子系统综合性能研究、初始结构方案确定和最终结构详细设计工作。对大型压缩机转子系统单缸结构性能表现进行了深入研究。并使用三缸串联模型讨论了整个机组转子系统的结构性能表现。最后通过样机的机械运转试验和工作性能的非线性瞬态动力学预估手段,对产品的设计质量进行了评价。
With the rapid development of modern industry, Large-capacity, efficient operation, structure complication, energy saving and noise reduction becomes inevitable trend of large scale compressor development. How to develop super large compressor with indigenous intellectual property rights and meet the demands of upgrade quality and product creativity with the guidance of scientific development view. When the demand of the nation's economy and the people's livelihood is ensured, how to decrease research-and-development cost, reducing product development cycles, improve development efficiency will become key problems in large scale compressor manufacturing.
The dissertation studies implementation methods of modern design theory based on synthesis design theory created by professor Wen Bangchun in large scale complicated products. By making quality and benefit as objectives, lean technology as foundation and super-large compressor as research object, adopting nonlinear dynamics, structural mechanics, reliability and nonlinear aerodynamics, making development cost as constraint conditions, a lean design implementation method is presented based on system engineering thinking.
High-level viewable optimization design method is put forward in the process of studying this method. Evaluation index and operation method of screening method of design object are determined. Lean filtration and high-level dynamic optimization method and high-level viewable optimization method are introduced. And aerodynamic performance analysis, technological properties, working performance and optimization design of impeller components assembly structure and combination property and optimization design of rotor system are performed in main function domain, auxiliary function domain and coupling domain of both. The main research contents are as follows:
(1) Lean design concept is put forward by learning from successful experience of lean in product system. The detail meanings of "fine" and "benefit" of lean design are explained and basic frameworks of lean design are determined.
(2) Implementation method of a complete super large compressor lean design is offered based on synthesis design theory. General planning, function deployment of whole unit, lean design in main and auxiliary function domains and coupling domain of both are carried out in the design process of super large compressor. Lean design tools are selected based on synthesis design theory and lean thinking in detail. Lean design implementation method considering cost control is presented when design, optimization and evaluation of product key systems and structures are fulfilled.
(3) Four implementation tools for lean design are constructed in the process of studying the implementation method when design quality is improved and cost is controlled. These tools are as follows:function decomposition tool for system, lean screening tool of design object for reducing development cost, high-level dynamic tool and viewable tool for improving product design quality. These constructed tools include as follows:①8D overall plan model and its implementation framework are determined;②The concept of high-level viewable optimization method and its application method are presented;③Application scope of high-level dynamic optimization method is extended;④Lean design screening method is formed by constructing two evaluation indexes of quality contribute rate and cost influence ratio.
(4) In the process of lean design in main function domain, firstly, adding-gas system is determined as the most important research object by design object lean screening. And aerodynamic performance research and conceptualization design work are performed by using high-level viewable design tool. Design defects of the former adding-gas structure are discovered and a new adding-gas structure with inlet turbine casing is presented by analysis of many kinds of pneumatic components and adding-gas structure. In the checkup process of design quality, firstly, evaluation works about the adding-gas structure affecting on surrounding pneumatic components is completed after computational fluid dynamics of whole channel model of (including adding-gas structure and its adjacent two module levels) is analyzed by mean of high performance computing platform.
(5) In the lean design process of auxiliary function domain, making as objective and combining high-level dynamic optimization design method and high-level viewable optimization design method, key structure creation and detailed design method are completed. And CAX integrated environment is constructed on the basis of above method. By combining nonlinear contact theory and structure dynamic theory, technological property of impeller assembly structure and structure performance at operating condition are completed. Then the initial design proposal of new impeller hub is presented by using viewable optimization method. Technological property and structure performance optimization are performed by using high-level dynamic optimization design method. Finally, combining stochastic finite element method and nonlinear reliability method, reliability of initial and improved structures are computed and function effect on both is discussed for different random parameters.
(6) In the lean design process of rotor system, detailed operation method and implementation flow for improving design quality are completed by using high-level dynamic optimization tools. Starting with system function analysis, synthesis performance optimization, trial run and working performance forecast, synthesis performance analysis, initial scheme determination and final structure detail design work of super large compressor rotor system are completed. The dynamic characteristics of every single cylinder and whole series rotor system are studied. Evaluation work is performed for lean design method by using trail run of prototype and forecast method of nonlinear transient dynamic for working performance.
为此,本课题以闻邦椿教授提出的综合设计方法为基础,以“精益”技术做理论联系实际的结合点,以大型压缩机组的创新设计为背景,以满足用户对产品广义质量需求和企业对产品收益需求,提出一种适于大型复杂机械系统的创新设计实施方法,即大型压缩机精益设计方法。它从系统工程的角度出发,通过大型压缩机设计的总体规划、整机功能展开、以及具体功能区域内的性能研究和优化设计工作,完成用户给定功能条件下的大型压缩机结构创新和关键系统结构性能、工艺性能和工作性能的提升工作。同时,基于产品开发过程的成本模型,利用AHP方法和模糊集理论、CAX集成平台,对产品创新设计过程的规模、效率和时间消耗进行了约束和控制。
在课题的研究过程中,根据大型压缩机的结构特点和设计经验：①提出了深层次可视优化设计的基本方法,对其内容及实施流程进行了详细论述；②构建了用于缩减研发成本的设计对象精益筛选方法,并给出了具体的评价指标和实施方法；③给出了深层次动态优化设计在产品设计过程中,较为完整的具体实施方法及内容。并就如何应用精益筛选、深层次动态优化设计方法和深层次可视优化方法,在主功能区、辅助功能区关键结构,和主辅功能耦合区(即转子系统)的的概念化设计和详细设计阶段中,采用非线性动力学、结构力学、可靠性理论和非线性空气动力学理论等,对大型压缩机加气系统气动性能研究及优化设计方法、叶轮部装结构工艺性能和工作性能研究及优化设计方法、以及转子系统综合性能研究及优化设计方法,进行了详细论述。本文具体内容研究如下：
(1)通过文献收集和企业调研,对现代设计理论的研究现状和发展趋势、以及企业进行产品创新设计过程中存在的问题和需求,进行了概括和总结。并借鉴精益在生产体系中的成功经验,提出了精益设计概念。指明了精益设计中“精”和“益的具体含义,确定了精益设计的基本技术框架。
(2)对如何运用综合设计理论与方法完成复杂产品创新设计,进行了深入研究,形成了一套较为完整的大型压缩机精益设计实施方法。通过大型压缩机设计过程的总体规划、整机功能展开、以及主辅功能区和主辅功能耦合区的精益设计研究工作的开展,详细论述了如何在完成产品关键系统和结构设计、优化和设计质量评价工作的同时,兼顾成本控制的精益设计实施方法。并于样机试制完成后,在沈鼓集团的产品试车台位上通过单缸和三缸串联的机械运转试验,对产品的设计质量进行了检验。
(3)在研究大型压缩机精益设计实施方法的过程中,完成了4种主要精益设计实施工具的构建工作。这些工具包括：从系统角度出发的功能分解工具、用于大幅缩减新产品研发成本的设计对象精益筛选工具、以及用于提高产品设计质量的深层次动态设计工具和深层次可视优化优化工具。在这些工具创建过程中：①构造了8D总体规划模型和实施框架；②提出了深层次可视优化方法的概念和具体应用方法；③丰富了深层次动态优化设计方法的内涵；④通过构建质量贡献率和成本影响率两个评价指标,形成了设计对象的精益筛选方法。
(4)在主功能区的精益设计过程中,首先通过设计对象精益筛选,确立加气系统为首要研究对象,并利用深层次可视优化设计工具,完成其气动性能研究和概念化设计工作。其次,找到了原加气结构的设计缺陷,并根据对多种气动元件的分析和加气结构的分析,提出了一种带有进气涡壳的全新加气结构。在设计质量检验过程中,首次借助高性能计算平台,通过加气系统整流道模型(即包含加气结构及其相邻的两个模型级)的CFD分析工作,完成了引入加气结构后对周边气动元件的综合性能影响的评估工作。
(5)在辅助功能区的精益设计过程中,以工艺性能改善为目标,采用可视优化设计与深层次动态设计相结合的方法,完成了关键结构创新及详细设计工作。并在此基础上,利用CAX集成应用环境,结合非线性接触理论和结构动力学理论,完成了叶轮部装结构工艺性能和运行工况条件下的结构性能研究工作。之后利用深层次动态优化设计方法,对新结构的工艺性能、结构性能加以改善。并利用概率有限元分析技术,与非线性接触分析技术相结合的非线性可靠性分析方法,对原始结构和改进结构功能实现的可靠度进行了对比计算,初步讨论了输入参数的不确定因素,对原型叶轮和新叶轮部装结构的结构性能影响问题。
(6)在转子系统的精益设计过程中,详细论述了使用深层次动态设计工具,完成转子系统设计质量提升工作的具体操作方法和实施流程。从转子系统功能分析、综合性能优化以及设计质量的出厂验证和工作性能预估三个阶段入手,完成了大型压缩机转子系统综合性能研究、初始结构方案确定和最终结构详细设计工作。对大型压缩机转子系统单缸结构性能表现进行了深入研究。并使用三缸串联模型讨论了整个机组转子系统的结构性能表现。最后通过样机的机械运转试验和工作性能的非线性瞬态动力学预估手段,对产品的设计质量进行了评价。
With the rapid development of modern industry, Large-capacity, efficient operation, structure complication, energy saving and noise reduction becomes inevitable trend of large scale compressor development. How to develop super large compressor with indigenous intellectual property rights and meet the demands of upgrade quality and product creativity with the guidance of scientific development view. When the demand of the nation's economy and the people's livelihood is ensured, how to decrease research-and-development cost, reducing product development cycles, improve development efficiency will become key problems in large scale compressor manufacturing.
The dissertation studies implementation methods of modern design theory based on synthesis design theory created by professor Wen Bangchun in large scale complicated products. By making quality and benefit as objectives, lean technology as foundation and super-large compressor as research object, adopting nonlinear dynamics, structural mechanics, reliability and nonlinear aerodynamics, making development cost as constraint conditions, a lean design implementation method is presented based on system engineering thinking.
High-level viewable optimization design method is put forward in the process of studying this method. Evaluation index and operation method of screening method of design object are determined. Lean filtration and high-level dynamic optimization method and high-level viewable optimization method are introduced. And aerodynamic performance analysis, technological properties, working performance and optimization design of impeller components assembly structure and combination property and optimization design of rotor system are performed in main function domain, auxiliary function domain and coupling domain of both. The main research contents are as follows:
(1) Lean design concept is put forward by learning from successful experience of lean in product system. The detail meanings of "fine" and "benefit" of lean design are explained and basic frameworks of lean design are determined.
(2) Implementation method of a complete super large compressor lean design is offered based on synthesis design theory. General planning, function deployment of whole unit, lean design in main and auxiliary function domains and coupling domain of both are carried out in the design process of super large compressor. Lean design tools are selected based on synthesis design theory and lean thinking in detail. Lean design implementation method considering cost control is presented when design, optimization and evaluation of product key systems and structures are fulfilled.
(3) Four implementation tools for lean design are constructed in the process of studying the implementation method when design quality is improved and cost is controlled. These tools are as follows:function decomposition tool for system, lean screening tool of design object for reducing development cost, high-level dynamic tool and viewable tool for improving product design quality. These constructed tools include as follows:①8D overall plan model and its implementation framework are determined;②The concept of high-level viewable optimization method and its application method are presented;③Application scope of high-level dynamic optimization method is extended;④Lean design screening method is formed by constructing two evaluation indexes of quality contribute rate and cost influence ratio.
(4) In the process of lean design in main function domain, firstly, adding-gas system is determined as the most important research object by design object lean screening. And aerodynamic performance research and conceptualization design work are performed by using high-level viewable design tool. Design defects of the former adding-gas structure are discovered and a new adding-gas structure with inlet turbine casing is presented by analysis of many kinds of pneumatic components and adding-gas structure. In the checkup process of design quality, firstly, evaluation works about the adding-gas structure affecting on surrounding pneumatic components is completed after computational fluid dynamics of whole channel model of (including adding-gas structure and its adjacent two module levels) is analyzed by mean of high performance computing platform.
(5) In the lean design process of auxiliary function domain, making as objective and combining high-level dynamic optimization design method and high-level viewable optimization design method, key structure creation and detailed design method are completed. And CAX integrated environment is constructed on the basis of above method. By combining nonlinear contact theory and structure dynamic theory, technological property of impeller assembly structure and structure performance at operating condition are completed. Then the initial design proposal of new impeller hub is presented by using viewable optimization method. Technological property and structure performance optimization are performed by using high-level dynamic optimization design method. Finally, combining stochastic finite element method and nonlinear reliability method, reliability of initial and improved structures are computed and function effect on both is discussed for different random parameters.
(6) In the lean design process of rotor system, detailed operation method and implementation flow for improving design quality are completed by using high-level dynamic optimization tools. Starting with system function analysis, synthesis performance optimization, trial run and working performance forecast, synthesis performance analysis, initial scheme determination and final structure detail design work of super large compressor rotor system are completed. The dynamic characteristics of every single cylinder and whole series rotor system are studied. Evaluation work is performed for lean design method by using trail run of prototype and forecast method of nonlinear transient dynamic for working performance.
引文
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