衰退流驱动的多工序制造系统维护调度研究

This project makes a deep research on the Stream of Degradation (SoD) enabled preventive maintenance scheduling for multistage manufacturing systems. First, the effect mechanism of SoD on maintenance scheduling is analyzed, and the maintenance modeling policy and the decision-making mechanism are given both for the equipment level and the system level. Then, with considering the maintenance scheduling demand of the system level on parameter configuration and degradation trend modeling, a hybrid reliability model combining the production quality and the equipment reliability is proposed based on the extended definition of failure. The maintenance scheduling model for equipment level is then established where a classified repair policy is applied on the quality degradation sources. Besides, a mathematical model of SoD is proposed to reveal the process mechanism on how maintenance decreases the degradation of equipment and then improves the quality of product. Subsequently, the maintenance scheduling model for system level is built up with the system SoD, the hybrid reliability of equipment and the economic efficiency of maintenance involved. Finally, an experiment is applied on the multistage machining process for wind turbine gearbox to ensure the availability of the proposed maintenance scheduling theory and the maintenance decision model. This project integrates the SoD into maintenance scheduling, which not only can extend the maintenance theory but also can promote the cross-coupling between the maintenance scheduling and the quality control.

针对多工序制造系统，开展衰退流驱动下系统整体预防维护活动的调度建模与决策研究。首先，分析衰退流对维护调度各层面的影响机制，提出衰退流驱动下设备层及系统层维护调度的建模策略和决策机制。然后，结合系统层维护调度的参数构成和状态趋势建模等需求，扩展故障定义，提出基于比例故障率的质量与可靠性集成建模方法，并对质量衰退源采用分类修复策略，实现设备层的维护调度建模与优化。之后，提出基于数据驱动的衰退流传递模型，揭示维护改善设备性能进而提升产品质量的过程机理，并据此建立融合系统衰退流、设备集成可靠性和维护经济性的多工序制造系统维护调度模型，实现衰退流驱动下系统层维护调度的整体决策优化。最后，以风电齿轮箱多工序制造过程为例，通过实验分析、仿真运行和对比研究，验证提出的维护调度理论和决策模型的有效性。本研究把衰退流导入维护调度，不仅可扩展现有的维护调度理论，而且可促进维护调度和质量控制两个领域的交叉与耦合。

针对多工序制造系统，开展了衰退流驱动下系统整体预防维护活动的调度建模与决策研究。首先，分析了衰退流对维护调度各层面的影响机制，提出了衰退流驱动下设备层及系统层维护调度的建模策略和决策机制。然后，结合系统层维护调度的参数构成和状态趋势建模等需求，扩展故障定义，提出了基于比例故障率的质量与可靠性集成建模方法，并对质量衰退源采用分类修复策略，实现了设备层的维护调度建模与优化。之后，提出了基于数据驱动的衰退流传递模型，揭示维护改善设备性能进而提升产品质量的过程机理。在此基础上，分别针对串行系统、串并混联系统、质量衰退源监测下的多工序制造系统开展研究，建立了融合系统衰退流、设备集成可靠性和维护经济性的多工序制造系统维护调度模型，实现了衰退流驱动下各类型系统维护调度的整体决策优化。最后，以由机床组成的机械多工序加工系统为例，通过实验分析、仿真运行和对比研究，验证了所提出的维护调度理论和决策模型的有效性。实验表明，本研究提出的维护调度策略及模型在降低多工序制造系统维护相关成本方面相比传统策略更具优势。