面向复杂工况的定制装备精准设计理论、方法及其应用研究

In view of the complex and various conditions of the customized equipment, and the existing design methods lack the accurate design methods for complex conditions and so on, and the lack of precise design methods for complex conditions at present, the theory and method of precise design for customized equipment in complex conditions is presented. Based on the composition mode and time probability distribution of the customized equipment condition, the multi-dimensional space of the process parameters space is constructed, and the rules of interval distribution and variation of the process parameters and the boundary interception method are studied. According to the accumulation mapping rules between the interval and segment-continuous process parameters and the multi-point discrete design parameters, the section aggregation and division method of multi-point design parameters based on the weight and distribution characteristics are researched. The multi-level module design rules of the adjusting, replacing and serializing driven by the design parameters, and the construction method of dynamic model driven by the process parameters are established. The model evolution and the deviation mechanism in conditions transition are studied. Based on the deviation feedback rules of the mapping between process parameters and design parameters, the iterative correction and reconstruction method and process driven by deviation for the model are established. A prototype system of precise design for customized equipment in complex conditions is developed based on the theories and methods of the research, and implemented in the design of large-scale air separation equipment and industrial steam turbine.

定制装备的工况具有条件复杂、形态多变的特点，现有设计方法缺乏面向复杂工况的准确设计手段，项目针对这一问题提出面向复杂工况的定制装备精准设计理论和方法。研究定制装备工况构成模式，分析工况时间概率分布特点，构建基于工艺参数表达的多维工况空间，研究工艺参数区间分布规律与边界截取方法；建立区间化分段连续的工艺参数向多点离散设计参数的积聚映射规则，研究基于重要度与疏离度特征的多点设计参数区段聚合与划分方法；建立设计参数驱动的模块可调节、可更换和系列化多层级设计规则，研究工艺参数驱动的适应性模型构造方法；研究工况变迁的模型演化方法，分析模型演化过程中的偏移产生机理，研究基于工艺-设计参数映射的偏差反馈规则，建立偏差驱动的模型迭代修正重构方法与流程。根据项目研究的理论方法，开发面向复杂工况的定制装备精准设计原型系统，在大型空分装备和工业汽轮机等装备设计中应用。

随着制造业的多样化和精细化要求的日益提高，定制装备得到了越来越广泛的应用，然而生产工况的复杂多变，要求定制装备能够保持高效稳定运行。如何根据复杂工况进行定制装备的精准设计，对于提高生产效率和质量具有重要作用。目前应对复杂多变工况的方法主要是以极限工况作为定制装备设计的基本条件，通过满足极限工况来覆盖其它各种工况。这虽然能够满足使用要求，但装备的体积、重量增加，加工能力和性能指标的余量过大，严重浪费了能源、材料以及加工能力，造成“大材小用”的局面。因此，研究面向复杂工况的精准设计方法，是定制装备研发中亟待解决的一个重要问题。项目提出了面向复杂工况的定制装备精准设计方法，从设计前的工况分析、设计中的参数映射和模型构建以及设计后的偏差修正三个阶段展开研究。在定制装备复杂工况分析与工艺参数计算方面，研究了基于信息熵的工业汽轮机工况表征指标分析与计算方法；在工艺-设计参数映射与求解方面，研究了基于工业汽轮机运行工艺参数的叶片预变形设计参数迭代求解方法；在设计参数驱动的适应性模型构造方面，研究了非平衡载荷驱动的低压级叶片的变刚度热态叶型构造方法；在多工况变迁的修正重构设计方面，研究了基于载荷-空间混合补偿的低压级叶片的冷态叶型修正重构方法；在多工况设计方案优化方面，研究了基于Vague集的低压级叶片的预变形设计方案组合优化方法；在定制装备精准设计应用方面，实现了工业汽轮机变工况条件下低压级叶片的预变形设计与优化。发表学术论文18篇，获得国家发明专利授权8项，培养研究生8名。