基于健康演化和动态重构的广义制造系统维护建模研究

As an advanced manufacturing mode for diverse products, variable batches and quick delivery, the dynamic reconfigurable manufacturing, which can reform its system structure, has become a new trend in the transformation and development of the industry. The maintenance decision-making of dynamic reconfigurable manufacturing system (DRMS) is an essential aspect of its efficient system operation. Previous researches usually focus on maintenance models for special systems with static structure. In this project, the generalized system-level maintenance modelling (GSMM) technique for dynamic structure is developed. This comprehensive research focuses on the relationships and interactions of machine health evolution and predictive maintenance planning, machine maintenance opportunity and system downtime, and dynamic system configuration and maintenance optimization. In the proposed maintenance modelling methodology for DRMS, the predictive maintenance scheduling based on health evolution for various machines is studied as the support point; the reconfiguration mechanism of sequential system reconfigurations is utilized as the research line; while the system-level maintenance adjustment is researched as the optimization surface. This multi-level modelling framework shows the timeliness, dynamic and agility of the maintenance decision-making. This research will lead to a new scientific basis and practical tools for reliability engineering of advanced manufacturing modes. It will expand the existing theories for static system structures and form a new methodology of GSMM, and efficiently achieve rapid responsiveness and cost effectiveness for health management of dynamic reconfigurable manufacturing.

作为可实现多品种、变批量和快速交货的先进制造模式，具有系统结构重组能力的动态重构制造正逐渐成为制造业转型发展的新趋势，而维护决策是其运营管理中非常重要一环。现有研究多是面向静态结构的狭义系统维护模型，本研究提出一种面向动态结构的广义系统维护建模技术，从设备健康演化与维护规划、设备维护机会与系统停机、系统动态构形与维护优化的相互联系、相互作用中综合地开展研究。本项目所构建的动态结构维护建模的整体解决方案，以多类型设备的健康演化和预知维护规划为支撑点，以构形扩展机制和系统贯序重构为研究线，以基于动态结构的广义系统预知维护调度为优化面，在多层级的建模架构中体现维护决策的实时性、动态性和敏捷性。本项目所形成的技术方法将为先进制造模式的可靠性工程提供一种新的科学基础和实用工具，扩展静态结构狭义系统维护的现有理论，并建立广义系统维护建模的方法体系，实现动态重构制造健康管理的快速决策响应和成本显著降低。

制造系统运维决策是动态重构制造的重要任务，设备健康演化与维护规划、设备维护机会与系统停机、系统动态构形与维护优化之间本质上具有紧密的相互作用。本项目主要研究成果：1）提出基于健康演化规律的多目标维护规划模型，统筹内部维护效果因素和外部环境工况因素，形成综合衰退演化规则；2）形成重构构形拓展与动态系统维护的综合建模机制，根据系统构形和组成设备的信息更新，建立可有效克服模型重建复杂性且具有快速决策响应能力的广义系统机会维护思想和方法；3）提出面向可重构制造的动态重构维护时间窗策略，利用串、并联子系统内设备停机造成的维护机会，动态循环地实施系统层维护作业合并/分离优化调度；4）通过汽车动态重构制造系统的维护决策与实证分析，验证了本项目的广义系统维护调度策略及技术方法的经济有效性。本项目所形成的技术方法为先进制造模式的可靠性工程提供一种新的科学基础和实用工具，扩展静态结构狭义系统维护的现有理论，并建立广义系统维护建模的方法体系，实现动态重构制造健康管理的快速决策响应和成本显著降低，为我国先进制造业的动态系统重构、健康状态管理、机会维护决策等提供有效的科学指导。