机电产品服役状态监测与主动再制造时机决策的方法与技术研究

Nowadays, due to the disadvantages in wasted mechanical and electrical products remanufacturing, informed by multi-life cycle method, "active remanufacturing" is presented with its timing decision method and other technology. Since it is usually to remanufacture the "over-used" product, the multiple mapping relationships between functional performance and using time are established with analyzing the design parameters and strength coefficients for key parts in mechanical and electrical products, the bottom limit of time interval is expressed with the limen of remanufacturing feasibility. Meanwhile, to avoid the "previous remanufacturing", with gathering, analyzing and quantifying the factors which would affect the "using-remanufacturing" procedure, the multi-factors decision model is presented based on game theory for the upper limit of time interval. Thus, with current monitoring methods for mechanical and electrical products, the mapping between monitoring signal and remanufacturing eigenvector is studied for on-line identifying the remanufacturing ability, as well as the software tools for time interval decision in active remanufacturing is developed. Finally, the advantage metal forming machine-tools and large compressors are tested as the industrial applications to validate the method, software and equipments proposed in this study.

针对目前机电产品在其报废阶段时被动再制造的种种弊端，以大型机电产品中典型零部件为研究对象，开展基于多生命周期的主动再制造最佳时机决择方法及关键技术研究。针对再制造过程中经常出现的"过度使用后再制造"情况，分析零部件本身的设计及强度参数，构建机电产品中关键零部件的多项服役状态指标与服役时间的映射关系，预测再制造可行性阈值并建立再制造最佳时区下限的判定模型。另一方面为了避免"提前再制造"的情况，通过统计、分析及量化机电产品"使用-再制造"过程中的多类决策因素，构建面向主动再制造的多要素博弈模型，判定再制造多要素博弈点，合理判定主动再制造最佳时区上限。同时基于现有的机电产品监测技术，构建服役信号和再制造特征向量的映射，实现对机电产品服役时的再制造性的有效判别，开发主动再制造时域决择及判断辅助系统。最后结合高端金属成形装备及大型压缩机等典型大型机电产品对本项目所提出的理论方法和设备予以完善和验证。

在国家自然科学基金项目资助下，项目组基于再制造企业及文献调研，搭建了发动机主动监测实验平台，在此基础上，开展并完成了全生命周期下机电产品服役性能演化规律模型、多因素下产品与零部件主动再制造时域分析、匹配及抉择方法、发动机及其关键零部件的主动再制造时域分析案例，为机械产品服役状态监测与主动再制造时域抉择奠定了理论与方法基础。其主要研究成果为：（1）结合相关发动机再制造企业调研数据，参照相关标准利用发动机疲劳实验机搭建了主动监测实验平台；（2）基于主动监测实验数据以及零部件失效状态分析，构建了轴颈磨损量与轴心轨迹和振动信号特征量之间的映射关系；（3）结合产品全生命周期分析方法，构建机电产品在制造、服役、再制造、再生服役阶段中服役性能演化规律模型；（4）结合工程经济学、数值分析以及寿命匹配设计方法，提出多因素下产品与零部件主动再制造时域分析、匹配及抉择方法；（5）结合柴油发动机关键零部件（曲轴部件、连杆部件、活塞部件），分析了关键零部件（曲轴部件、连杆部件、活塞部件）主动再制造时域，提出了发动机主动再制造时域。