面向设计—制造—服役全周期的产品质量控制与优化技术及其在大型空分装备中的应用研究
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摘要
本文围绕产品质量控制的主要过程和关键技术,提出了面向设计-制造-服役全周期的产品质量控制与优化技术,对产品概念设计阶段的客户需求的处理、产品质量特性的提取方法、产品方案设计信息模型的优化求解、产品开发方案的多目标优化质量控制方法,产品加工制造阶段的质量特性稳健优化控制技术以及产品服役使用阶段的质量控制方案优化决策技术和产品服役质量的可靠性预测方法进行了深入研究。结合项目实施将上述方法和技术应用于大型空分装备的质量优化控制过程,取得良好的效果。
论文主要内容入下：
第一章概述了面向全生命周期的产品设计理论,阐述了产品质量控制的基本理论及产品质量控制方法的研究情况。在分析了现有产品质量控制技术的不足之后,提出了面向设计-制造-服役全周期的产品质量控制与优化技术的主要思想和研究背景。
第二章提出了基于需求满足的质量特性-功能-结构多域映射及方案设计求解技术。针对产品方案设计中质量特性向结构域映射的复杂性问题,引入功能域作为中介引导质量特性向产品结构域映射。首先利用模糊Kano模型筛选客户需求,然后根据客户需求对质量特性的影响及质量特性间的互相关性由网络关系分析法求得质量特性重要度。针对质量特性实行功能分解,继而对功能实行结构分解,从而实现质量特性-功能-结构多域映射。继而通过分析功构映射在概念与特性上与约束满足问题的相似性,将方案求解问题映射到约束满足框架中,并采用演化博弈算法求解该模型,以质量特性评价函数作为博弈的效用函数。上述方法在透平膨胀机方案设计中的应用验证了其可行性和有效性。
第三章提出了基于模糊概率约束规划的产品开发方案多目标优化质量控制方法。针对产品设计开发方案的时间、成本、质量的不确定优化问题,在模糊概率约束规划的框架下分别建立了基于关键路线的开发方案周期优化模型、基于资源使用的开发方案周期-成本优化模型和基于质量功能展开的产品周期-质量优化模型,在此基础上构建了开发方案周期-成本-质量多目标优化模型；使用模糊模拟技术处理三个目标函数约束的过程中,构建了一个基于遗憾度的适应度函数,然后利用离散微粒群算法对多目标优化模型进行求解。以空气压缩机产品开发方案优化为具体应用,验证了上述模型和算法的有效性。
第四章提出了基于约束满足的产品质量特性稳健优化控制方法。针对产品结构参数发生变差,导致产品在加工制造阶段的输出质量特性不稳定的问题,将参数变差形式化描述为量词约束满足问题框架中的普遍性变量,在其作用下求得目标函数和约束函数的上下界,依据设计者偏好设定稳健性指标。根据模型特点,采取区间分析-混合蛙跳组合式算法进行求解,最终获得满足稳健性指标的帕累托优化解,并使用基于信息熵理论的方法选择出最优解。应用该方法对透平压缩机扩压器进行质量特性稳健优化设计,证明了该方法在工程应用中的正确性和高效性。
第五章提出了基于直觉模糊集的产品质量控制方案的优化决策方法。针对当前产品质量控制方案优化决策方法存在的不足,引入直觉模糊理论表达信息的不确定性。在传统DEMATEL方法基础上引入拆分矩阵法以维持综合影响矩阵的直觉模糊特性,由改进DEMATEL法对产品质量控制方案决策系统中的评价指标进行量化分析,表达各评价指标的量化因果关系,并根据量化结果对指标集进行因果分类、重要度排序和权重分配；在VIKOR算法中改进理想解和负理想解的定义,以折中规划法为核心,提供最大化“群体效益”与最小化“个别遗憾”相妥协的备选方案最佳排序,得到距离理想解最近的折中可行方案。最后详细分析了空分装备的质量控制方案优化决策的应用案例。
第六章提出了基于非线性回归的产品服役质量可靠性参数的区间预测方法。针对当前产品服役质量可靠性预测方法的不足,首先构建可靠性参数预测神经网络模型,由极端学习机算法进行训练。在网络训练得到的预测点值和网络权重的基础上,基于非线性回归模型构建可靠性参数的区间预测值。结合预测值的覆盖率和平均区间比例长度提出一种新的综合评价指标CPLC以衡量预测值的质量。引入免疫优化算法优化区间预测值和网络结构。上述方法在某系列空分装备的可靠性参数MTBF预测的具体应用,证明所提方法是一种有效的质量性能指标预测方法。
第七章依托国家科研开发项目,结合企业实际应用,开发了空分装备质量优化控制系统(HY-ASEQCOS),阐述了系统的应用背景、实施策略,并给出了平台系统的体系结构和主要功能模块的应用实现。
第八章总结了本文的主要研究内容和成果,并对未来要进行的研究工作做了展望。
This paper focuses on the product quality control process and its key technologies. Product quality control and optimization technologies are proposed in this dissertation oriented to the design-manufacturing-sevice full cycle, which is mainly consisted of the analysis of customer requirements, the optimization extraction method of quality characteristics, the optimization method for solving product scheme design information model, the multi-objective optimization quality control of product development project, the robust optimization of product design parameters in product manufacturing stage, the optimization decision of product quality control scheme in service stage and the reliability prediction optimization of product service quality. Furthermore, the effective applications on the quality control of large air separation equipment proved advancement and validity of the proposed method and technology as well.
The main contents of this dissertation are as follows:
Chapter1gives the reviews of full-lifecycle-oriented product design technology. The connotation and current research of product quality control are discussed as well. Based on the analyzing the deficiencies in existing method of product quality control, the main ideas and research background of product quality control and optimization oriented to the design-manufacturing-service full cycleare given.
Chapter2analyzes the mapping relationship between product function and structure based on requirement satisfaction, and the product scheme solving technique. For the complex issue of the mapping between quality characteristics and structure domain in product scheme design, function domain is introduced as intermediary to guide this mapping. First, the customer requirements are filtered by fuzzy Kano model, then the importance degree of quality characteristics are calculated by analytic network process (ANP) accoding to the influence of customer requirements on quality characteristics and the correlation between quality characteristics. Quality characteristics are decomposed in functions, and functions are decomposed in structures. The similarity of concept and characteristics between product function-structure mapping and constraint satisfaction problem (constraint satisfaction problem, CSP) are analyzed, so the conceptual design problem is mapped to the CSP framework, evolutionary game algorithm was employed to solve the CSP model, and the evaluation function is mapped as utility function. The efficiency and effectiveness of the proposed method is illustrated by the scheme design of turbo-expander product.
Chapter3proposes the method of multi-objcetve optimization in product development project base on fuzzy chance constrained programming. The fuzzy chance constrained programming is applied to establish a project completion time optimization model based on critical path, a project time-cost optimization model based on employment of resources and a project time-quality optimization model by quality function deployment, then a time-cost-quality multi-objective optimization model is established based on these models. The discrete particle swarm algorithm is applied to solve the multi-objective optimization model, where the fitness function is constructed based on regret degrees of sub-objectives, which are handled by fuzzy simulation technique. The abovementioned approaches are applied to the case of air aompressor product development project optimization to demonstrate the advantage.
Chapter4proposes the method of product quality characteristics robust optimization based quantified constraint satisfaction problem (QCSP). When the product structure parameters fluctuate, the product exporting quality characteristcs will be unstable. The structure parameter variation is expressed as the universal variable in QCSP. The upper and lower bounds of the objective functions and constraint functions are calculated with the effect of the universal variable, and the robustness indicators are set according to designer's preference. Considering the model characteristics, a modular algorithm consisted of interval analysis and he shuffled frog-leaping algorithm is applied to solve the QCSP model, and the Pareto optimal solutions which satisfy the robustness indicators is gained, the optimal solution is selected by the information entropy theory-based approach. The efficiency and effectiveness of the proposed method are illustrated by the product quality characteristics robust optimization design of turbine compressor diffuser.
Chapter5proposes the method of product quality control shceme optimization decision based on hybrid model of advanced fuzzy DEMATEL-VIKOR algorithm. For the deficiencies of product quality control shceme evaluation methods, the uncertain information is expressed with intuitionistic fuzzy number. Splitting matrix method is applied in DEMATEL method to maintain the fuzzy characteristic for total-influence matrix. The relationship between evaluation criteria was analyzed using the improved DEMATEL method, which not only revealed causal relationship between criteria, but also carried out the causal classification, importance ranking and weights assignment. For VIKOR method, there is some modification on definition of positive-ideal solution and negtive-solution. The improved VIKOR method helps decision makers to achieve an acceptable compromise solution of a maximum "group utility" of the "majority" and a minimum of the individual regret of the "opponent". Finally, the scheme evaluation of air separation equipment is analyzed as an instance.
Chapter6proposes the method of interval prediction for product reliability criterion of service quality based on nonlinear regression. First, prediction neural network of reliability parameters is constructed, which is trained by ELM algorithm. Then, nonlinear regression model is used to construct prediction interval for reliability parameters based on its point value derived from the trained neural network and the weights of network. The immune algorithm is adopted to automate the neural network model selection and adjustment of the weight decay regularizing factor. Model selection and parameter adjustment are carried out through minimization of the prediction interval-based cost function called CPLC, which combines the coverage probability and the mean interval proportional length of PI. Finally, the proposed theory and method is applied to predict the reliability parameter MTBF of air separation equipment, which proved the feasibility and effectiveness of the method in engineering application.
Chapter7develops the air separation equipment quality control and optimization system (HY-ASEQCOS) with practical project..The background of system application, implementation scheme, the technical implementation and main functions of the system is elaborated.
Chapter8summarizes the key research contents and achievements, and gives conclusions along with recommendations for future research.
论文主要内容入下：
第一章概述了面向全生命周期的产品设计理论,阐述了产品质量控制的基本理论及产品质量控制方法的研究情况。在分析了现有产品质量控制技术的不足之后,提出了面向设计-制造-服役全周期的产品质量控制与优化技术的主要思想和研究背景。
第二章提出了基于需求满足的质量特性-功能-结构多域映射及方案设计求解技术。针对产品方案设计中质量特性向结构域映射的复杂性问题,引入功能域作为中介引导质量特性向产品结构域映射。首先利用模糊Kano模型筛选客户需求,然后根据客户需求对质量特性的影响及质量特性间的互相关性由网络关系分析法求得质量特性重要度。针对质量特性实行功能分解,继而对功能实行结构分解,从而实现质量特性-功能-结构多域映射。继而通过分析功构映射在概念与特性上与约束满足问题的相似性,将方案求解问题映射到约束满足框架中,并采用演化博弈算法求解该模型,以质量特性评价函数作为博弈的效用函数。上述方法在透平膨胀机方案设计中的应用验证了其可行性和有效性。
第三章提出了基于模糊概率约束规划的产品开发方案多目标优化质量控制方法。针对产品设计开发方案的时间、成本、质量的不确定优化问题,在模糊概率约束规划的框架下分别建立了基于关键路线的开发方案周期优化模型、基于资源使用的开发方案周期-成本优化模型和基于质量功能展开的产品周期-质量优化模型,在此基础上构建了开发方案周期-成本-质量多目标优化模型；使用模糊模拟技术处理三个目标函数约束的过程中,构建了一个基于遗憾度的适应度函数,然后利用离散微粒群算法对多目标优化模型进行求解。以空气压缩机产品开发方案优化为具体应用,验证了上述模型和算法的有效性。
第四章提出了基于约束满足的产品质量特性稳健优化控制方法。针对产品结构参数发生变差,导致产品在加工制造阶段的输出质量特性不稳定的问题,将参数变差形式化描述为量词约束满足问题框架中的普遍性变量,在其作用下求得目标函数和约束函数的上下界,依据设计者偏好设定稳健性指标。根据模型特点,采取区间分析-混合蛙跳组合式算法进行求解,最终获得满足稳健性指标的帕累托优化解,并使用基于信息熵理论的方法选择出最优解。应用该方法对透平压缩机扩压器进行质量特性稳健优化设计,证明了该方法在工程应用中的正确性和高效性。
第五章提出了基于直觉模糊集的产品质量控制方案的优化决策方法。针对当前产品质量控制方案优化决策方法存在的不足,引入直觉模糊理论表达信息的不确定性。在传统DEMATEL方法基础上引入拆分矩阵法以维持综合影响矩阵的直觉模糊特性,由改进DEMATEL法对产品质量控制方案决策系统中的评价指标进行量化分析,表达各评价指标的量化因果关系,并根据量化结果对指标集进行因果分类、重要度排序和权重分配；在VIKOR算法中改进理想解和负理想解的定义,以折中规划法为核心,提供最大化“群体效益”与最小化“个别遗憾”相妥协的备选方案最佳排序,得到距离理想解最近的折中可行方案。最后详细分析了空分装备的质量控制方案优化决策的应用案例。
第六章提出了基于非线性回归的产品服役质量可靠性参数的区间预测方法。针对当前产品服役质量可靠性预测方法的不足,首先构建可靠性参数预测神经网络模型,由极端学习机算法进行训练。在网络训练得到的预测点值和网络权重的基础上,基于非线性回归模型构建可靠性参数的区间预测值。结合预测值的覆盖率和平均区间比例长度提出一种新的综合评价指标CPLC以衡量预测值的质量。引入免疫优化算法优化区间预测值和网络结构。上述方法在某系列空分装备的可靠性参数MTBF预测的具体应用,证明所提方法是一种有效的质量性能指标预测方法。
第七章依托国家科研开发项目,结合企业实际应用,开发了空分装备质量优化控制系统(HY-ASEQCOS),阐述了系统的应用背景、实施策略,并给出了平台系统的体系结构和主要功能模块的应用实现。
第八章总结了本文的主要研究内容和成果,并对未来要进行的研究工作做了展望。
This paper focuses on the product quality control process and its key technologies. Product quality control and optimization technologies are proposed in this dissertation oriented to the design-manufacturing-sevice full cycle, which is mainly consisted of the analysis of customer requirements, the optimization extraction method of quality characteristics, the optimization method for solving product scheme design information model, the multi-objective optimization quality control of product development project, the robust optimization of product design parameters in product manufacturing stage, the optimization decision of product quality control scheme in service stage and the reliability prediction optimization of product service quality. Furthermore, the effective applications on the quality control of large air separation equipment proved advancement and validity of the proposed method and technology as well.
The main contents of this dissertation are as follows:
Chapter1gives the reviews of full-lifecycle-oriented product design technology. The connotation and current research of product quality control are discussed as well. Based on the analyzing the deficiencies in existing method of product quality control, the main ideas and research background of product quality control and optimization oriented to the design-manufacturing-service full cycleare given.
Chapter2analyzes the mapping relationship between product function and structure based on requirement satisfaction, and the product scheme solving technique. For the complex issue of the mapping between quality characteristics and structure domain in product scheme design, function domain is introduced as intermediary to guide this mapping. First, the customer requirements are filtered by fuzzy Kano model, then the importance degree of quality characteristics are calculated by analytic network process (ANP) accoding to the influence of customer requirements on quality characteristics and the correlation between quality characteristics. Quality characteristics are decomposed in functions, and functions are decomposed in structures. The similarity of concept and characteristics between product function-structure mapping and constraint satisfaction problem (constraint satisfaction problem, CSP) are analyzed, so the conceptual design problem is mapped to the CSP framework, evolutionary game algorithm was employed to solve the CSP model, and the evaluation function is mapped as utility function. The efficiency and effectiveness of the proposed method is illustrated by the scheme design of turbo-expander product.
Chapter3proposes the method of multi-objcetve optimization in product development project base on fuzzy chance constrained programming. The fuzzy chance constrained programming is applied to establish a project completion time optimization model based on critical path, a project time-cost optimization model based on employment of resources and a project time-quality optimization model by quality function deployment, then a time-cost-quality multi-objective optimization model is established based on these models. The discrete particle swarm algorithm is applied to solve the multi-objective optimization model, where the fitness function is constructed based on regret degrees of sub-objectives, which are handled by fuzzy simulation technique. The abovementioned approaches are applied to the case of air aompressor product development project optimization to demonstrate the advantage.
Chapter4proposes the method of product quality characteristics robust optimization based quantified constraint satisfaction problem (QCSP). When the product structure parameters fluctuate, the product exporting quality characteristcs will be unstable. The structure parameter variation is expressed as the universal variable in QCSP. The upper and lower bounds of the objective functions and constraint functions are calculated with the effect of the universal variable, and the robustness indicators are set according to designer's preference. Considering the model characteristics, a modular algorithm consisted of interval analysis and he shuffled frog-leaping algorithm is applied to solve the QCSP model, and the Pareto optimal solutions which satisfy the robustness indicators is gained, the optimal solution is selected by the information entropy theory-based approach. The efficiency and effectiveness of the proposed method are illustrated by the product quality characteristics robust optimization design of turbine compressor diffuser.
Chapter5proposes the method of product quality control shceme optimization decision based on hybrid model of advanced fuzzy DEMATEL-VIKOR algorithm. For the deficiencies of product quality control shceme evaluation methods, the uncertain information is expressed with intuitionistic fuzzy number. Splitting matrix method is applied in DEMATEL method to maintain the fuzzy characteristic for total-influence matrix. The relationship between evaluation criteria was analyzed using the improved DEMATEL method, which not only revealed causal relationship between criteria, but also carried out the causal classification, importance ranking and weights assignment. For VIKOR method, there is some modification on definition of positive-ideal solution and negtive-solution. The improved VIKOR method helps decision makers to achieve an acceptable compromise solution of a maximum "group utility" of the "majority" and a minimum of the individual regret of the "opponent". Finally, the scheme evaluation of air separation equipment is analyzed as an instance.
Chapter6proposes the method of interval prediction for product reliability criterion of service quality based on nonlinear regression. First, prediction neural network of reliability parameters is constructed, which is trained by ELM algorithm. Then, nonlinear regression model is used to construct prediction interval for reliability parameters based on its point value derived from the trained neural network and the weights of network. The immune algorithm is adopted to automate the neural network model selection and adjustment of the weight decay regularizing factor. Model selection and parameter adjustment are carried out through minimization of the prediction interval-based cost function called CPLC, which combines the coverage probability and the mean interval proportional length of PI. Finally, the proposed theory and method is applied to predict the reliability parameter MTBF of air separation equipment, which proved the feasibility and effectiveness of the method in engineering application.
Chapter7develops the air separation equipment quality control and optimization system (HY-ASEQCOS) with practical project..The background of system application, implementation scheme, the technical implementation and main functions of the system is elaborated.
Chapter8summarizes the key research contents and achievements, and gives conclusions along with recommendations for future research.
引文
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