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浙江大学学报(工学版)  2020, Vol. 54 Issue (11): 2233-2246    DOI: 10.3785/j.issn.1008-973X.2020.11.019
机械工程     
多重故障驱动的再制造并行拆卸序列规划方法
郭磊1(),张秀芬1,2,3,*()
1. 内蒙古工业大学 机械工程学院,内蒙古 呼和浩特 010051
2. 浙江大学 流体动力与机电系统国家重点实验室,浙江 杭州 310027
3. 康力电梯股份有限公司,江苏 苏州 215213
Remanufacturing parallel disassembly sequence planning method driven by multiple failures
Lei GUO1(),Xiu-fen ZHANG1,2,3,*()
1. College of Mechanical Engineering, Inner Mongolia University of Technology, Hohhot 010051, China
2. State Key Laboratory of Fluid Power Transmission and Control, Zhejiang University, Hangzhou 310027, China
3. Canny Elevator Co. Ltd, Suzhou 215213, China
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摘要:

为了克服由故障导致的连接失效、不可拆卸对拆卸序列的影响,提出多重故障驱动的再制造并行拆卸序列规划(RPDSP)方法. 通过分析零件的不可拆卸性以及故障特征,构建层次式多重故障传递链模型,描述产品零部间的故障类型、故障程度、报废程度、回收决策、拆卸模式等信息. 为了方便计算机编程,应用多色集合理论对模型进行数学描述,映射为多重故障信息传递多色模型,通过多色推理识别出零部件的拆卸模式. 将零件故障信息融入拆卸模型,建立可破坏性拆卸信息模型,并推导出可拆卸性条件. 为了表示零件可破坏信息,提出包含拆卸节点层和破坏约束层的多层染色体编码方法. 设计考虑零部件回收决策的初始种群获取方法以剔除不合理序列,通过选择、交叉、变异等进化机制实现多重故障驱动的可破坏再制造并行拆卸序列寻优. 以波轮式洗衣机为案例验证所提方法的可行性和有效性.

关键词: 多色集合再制造并行拆卸序列规划拆卸模式多重故障    
Abstract:

A remanufacturing parallel disassembly sequence planning (RPDSP) method driven by multiple failures was proposed in order to overcome the influence of connection failure and component non-disassembly caused by failures on the disassembly sequence. A hierarchical multiple failures transfer chain model was constructed through analyzing the non-detachability and failure characteristics of the parts to describe the relationship among the failure type, failure degree, scrap level, recycling decision, and disassembly mode of parts. Furthermore, the model was formally described in mathematically language and mapped into a polychromatic graph model of multiple failures information transfer chain based on the polychromatic sets theory, which is convenient for computer programming and manipulating. On this basis, the disassembly mode of parts can be identified by polychromatic reasoning. The information of part failure was integrated into the disassembly information model, and then a destructible disassembly information model was established, and the disassemblability formula was derived. A multi-layer chromosome coding method including disassembled node layer and destruction constraint layer was proposed to represent the partial destructive information of the product. An initial population acquisition method considering the part recycling decision was designed to eliminate unreasonable sequences. The RPDSP was realized by chromosome evolution rules such as selection, crossover and mutation operator. Finally, a case study of washing machine was used to demonstrate the feasibility and effectiveness of the proposed method.

Key words: polychromatic sets    remanufacturing    parallel disassembly sequence planning    disassembly mode    multiple failures
收稿日期: 2019-11-09 出版日期: 2020-12-15
CLC:  TH 122  
基金资助: 国家自然科学基金资助项目(51965049,51565044);内蒙古自治区自然科学基金资助项目(2017MS(LH)0510);内蒙古自治区高等学校青年科技英才支持计划资助项目(NJYT-17-B08)
通讯作者: 张秀芬     E-mail: 1499326118@qq.com;xxff6188@163.com
作者简介: 郭磊(1995—),男,硕士生,从事再制造拆卸规划与评价研究. orcid.org/0000-0002-1078-3462. E-mail: 1499326118@qq.com
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引用本文:

郭磊,张秀芬. 多重故障驱动的再制造并行拆卸序列规划方法[J]. 浙江大学学报(工学版), 2020, 54(11): 2233-2246.

Lei GUO,Xiu-fen ZHANG. Remanufacturing parallel disassembly sequence planning method driven by multiple failures. Journal of ZheJiang University (Engineering Science), 2020, 54(11): 2233-2246.

链接本文:

http://www.zjujournals.com/eng/CN/10.3785/j.issn.1008-973X.2020.11.019        http://www.zjujournals.com/eng/CN/Y2020/V54/I11/2233

图 1  某摩擦驱动装置示意图
图 2  某摩擦驱动装置拆卸混合图
故障特征 故障程度 报废原因 回收决策
老化( ${f_1}$ 轻微故障( ${c_1}$ 尺寸不合格( ${b_1}$ 废弃( ${h_1}$
磨损( ${f_2}$ 一般故障( ${c_2}$ 残余价值低( ${b_2}$ 材料回收( ${h_2}$
腐蚀( ${f_3}$ 中等故障( ${c_3}$ 性能不足( ${b_3}$ 再制造( ${h_3}$
变形( ${f_4}$ 严重故障( ${c_4}$ 无法修复( ${b_4}$ 重用( ${h_4}$
无失效( ${f_5}$ ? 材料缺失( ${b_5}$ ?
断裂( ${f_6}$ ? 配对零件丢失( ${b_6}$ ?
孔洞( ${f_7}$ ? 无( ${b_7}$ ?
烧伤( ${f_8}$ ? ? ?
其他( ${f_9}$ ? ? ?
表 1  零件故障信息及回收决策信息
图 3  层次式多重故障传递链
图 4  层次式多重故障传递链映射机制
序号 名称 回收决策 拆卸模式
1 安装台 重用 非破坏操作
2 弹簧 再制造 非破坏操作
3 螺栓1 报废 破坏操作
4 调节轴 再制造 非破坏操作
5 主动臂 再制造 非破坏操作
6 螺栓2 报废 破坏操作
7 主动轮 再制造 非破坏操作
表 2  摩擦装置回收决策与拆卸模式
图 5  可破坏拆卸步骤与染色体编码的映射过程
图 6  融入零部件回收决策的初始种群获取
图 7  染色体交叉过程示例
编码 名称 tb /s td /s 拆卸方向 Cu /元 Cd /元
1 前盖板 112 46 ?X 0.160 0.310
2 配重 30 12 ?X 0.080 5.110
3 进水管 200 40 +Z 0.320 0.760
4 进水控制阀 132 34 +Z 0.310 0.370
5 外筒盖 314 88 ? 0.510 3.760
6 上盖板 80 32 +Z 0.220 0.286
7 内筒 304 64 +Y 0.290 0.840
8 叉形架 2 2 +Y 0.006 0.006
9 平衡块 10 4 +Y 0.028 0.170
10 大带轮 10 4 +Y 0.028 0.170
11 后盖板 128 52 +Y 0.360 0.360
12 小带轮 100 20 +Y 0.280 0.280
13 电机 114 28 +Y 0.250 0.450
14 外筒主体 440 102 ? 0.570 0.170
15 洗衣机排水管 402 84 +Y 0.340 1.120
16 箱体 150 60 ? 0.320 0.420
17 排水泵 40 16 ?Y 0.110 0.110
18 阻尼器 40 16 ?Y 0.110 0.170
19 外筒排水管 110 24 ?Y 0.230 0.310
20 温控器 40 16 ?Y 0.110 3.210
21 加热器 100 20 ?Y 0.280 3.190
表 3  零件原始拆卸信息表
图 8  某波轮式洗衣机爆炸图
序号 名称 回收决策 拆卸模式
3 进水管 报废 破坏操作
5 外筒盖 报废 破坏操作
7 内筒 再制造 非破坏操作
8 叉形架 再制造 非破坏操作
11 后盖板 报废 破坏操作
14 外筒主体 材料回收 破坏操作
15 排水管 再制造 非破坏操作
表 4  波轮洗衣机回收决策数据
类型 目标组件 t /s 最优序列
无故障
影响
零部件7 1632 (6)?(1, 11)?(9, 10)?(14, 15)?(8)?
(4, 18)?(3, 17)?(9, 8)?(7)
考虑故
障影响
破坏零件11 1388 (10, 6)?(3, 1)?(9)?(14, 15)?(8, 18)?
(17)?(19, 7)?(5)
考虑故
障影响
破坏零件5 884 (11)?(10, 9)?(14)?(8)?(7)
表 5  波轮式洗衣机不同类型拆卸序列规划结果
图 9  可破坏模式下的产品再制造并行拆卸序列规划
图 10  可破坏拆卸序列规划时间
图 11  可破坏拆卸下总拆卸时间随迭代次数的变化规律
图 12  可破坏拆卸并行度与拆卸时间的关系
图 13  种群规模与拆卸序列规划结果的关系
图 14  迭代次数与拆卸序列规划结果的关系
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