高端制造装备的故障形成机理及可靠性提升关键技术研究

Due to low in reliability, the advanced manufacturing equipment is basically brought on aboard, which is serious obstacle to the development of manufacturing industry in China, even to the safety of national defense and industry. It is of great significance to increase the reliability of the equipment. Based on previous research on reliability technology, this project will focus on the network model-based reliability analysis, fault formation mechanism, reliability increasing maintenance. To address these problems, several new ideas are put forward: (1) A multi-scale system network model is proposed to optimize the system structural reliability by using survival signature, which provides a new idea for reliability analysis at system level. (2) A multi rigid body model with rigid, flexible, and thermal chains is proposed to compute deformations from various loads and thermal deformation, which usually cause degradation in machining accuracy and is a bottleneck to be addressed for precision improvement. The research results can provide a good way for the understanding and quality improvement of the advance equipment theoretically and practically. (3) Technique for the recognition of degradation by energy efficiency monitoring system is proposed for intelligent maintenance so that the failures can be known in time and be maintained by correct technology so that the health status of the system can be measured and predicted by the value of energy efficiency, and provides an efficient method for intelligent maintenance. Moreover, it is wished that the approaches and obtained results in this project will be applied to improve the reliability and quality of advanced mechanical equipments.

我国高端制造装备因可靠性问题基本依赖进口，严重制约着我国制造业发展、甚至影响国防和产业安全，提升高端制造装备的可靠性具有重大意义。本项目在前期可靠性技术研究的基础上，拟围绕系统可靠性建模分析、故障形成机理、面向可靠性提升的维护维修等问题展开深入研究。提出多项原创性的解决思路和方法：（1）通过建立多尺度系统网络模型，研究基于生存签名的结构可靠性优化方法，为系统级的可靠性优化提供理论依据。（2）通过建立集成刚柔热耦合特性的多体动力学模型，揭示由各种外载荷及热变形引起的系统精度衰减机理，突破数控机床精度保持性差的瓶颈，为高端制造装备的技术消化和质量可靠性提升提供理论和实验方法。（3）研究基于能效监测的系统退化状态辨识技术，实现故障的早发现早干预早维护，为智能维护维修奠定基础。期望研究成果能为大型复杂装备的可靠性提升和质量改进提供理论依据和实用技术。

该研究围绕高端装备的可靠性提升问题，分别从系统结构设计可靠性、服役过程的精度保持性、误差建模与误差补偿技术等展开研究。.（1）为了解决现有误差模型过于复杂、缺少规范化的分析和计算手段等问题，提出了一种改进的修正D-H参数法，将机床的构型误差分机床连杆的几何变形误差及关节的运动误差，通过对平行关节与垂直关节的变换矩阵的个性化处理，建立了包含连杆变形误差与关节运动误差的综合误差模型。该方法适用于所有正交关节机床的误差建模，期望该方法能够用于机床的构型设计，为高端机床的精度设计提供理论指导。.（2）围绕机床设计的精度可靠性提升问题，研究了基于生存签名的系统结构可靠性建模与分析技术，提出了一种适合于复杂系统可靠性评估的多尺度生存签名计算模型，并以制造系统的优化配置为例进行了实验验证，期望该方法能用于高端装备设计阶段的精度可靠性评估，以保证设计方案理论上的正确性。.（3）针对机床的精度保持性提升问题，围绕数控机床多元耦合误差建模与分析技术，提出了一种考虑数控机床几何误差、运动误差和热-力耦合误差的综合误差模型。并以机床的电主轴与进给系统为例，分析了变载荷下的热-力耦合作用对系统精度的影响。.（4）从提高机床精度保持性出发，针对数控机床结合面的动态误差特性，提出了一种基于风险等效因子的数控机床误差敏感度评估方法，通过对主要误差源的补偿或部件质量提升，提高系统精度。同时，针对动载荷下的机床精度可靠性评估问题，提出了一种基于加工误差超差量的精度可靠度计算模型，与传统方法相比，计算结果受检测点数量的影响较小，计算结果更为准确。.（5）为了定期保养和维护对机床服役可靠性的影响，提出一种基于SPC和Markov模型的预防性维修技术。通过引入故障递增和役龄递减的双因子修正故障率、以最小成本为目标函数，采用Markov状态转移概率矩阵进行故障模式预测和故障部件识别，实现精准维修，在提升服役可靠性的同时，节约维护成本。