加工特征/机床运动耦合条件下的工艺规划与机床重构协同优化方法研究

In view of the process design and resource allocation's rapidity and flexibility requirements proposed by reconfigurable manufacturing environment, this project studys a collaborative optimization theory and method of process planning and machine tools reconfiguring. Through analyzing of the coupling relationships between the features and machine tools motions, internal information transmission mechanism will be established between process elements and machine tool reconfiguration. By fusing of fuzzy logic and polychromatic sets theory, the uncertainty relations of process elements and process constraint will be modeled for integrating traditional process knowledge towards basic information. Process will be extracting and optimizing based on the part features forming mode to generate alternative process initial solutions for the collaborative optimization. Through clustering analysis of the tools reconfiguration modules, motions coupling relations of the unit modules will be established to form a bidirectional coupling mechanism of homologous constraint with process planning model. And then, collaborative optimization model of process planning and machine tools reconfiguring will be established. Optimization goal and strategy will be confirmed. Based on two-dimension gene, genetic algorithm will be designed to optimize the problem. Process route and machine reconfiguration scheme will be parsed from optimizing result, and the second combining for the process route will be completed. The transformation from theoretical models to the two-dimensional relational database models will be carried out, and simulation system platform will be set up to verify the theory methods. On the whole, this research can effectively reveal the information transmission mechanism of resources and their relationships in the reconfigurable manufacturing mode, reduce manufacturing system operating costs through the collaborative optimization.

本项目针对可重构制造环境对工艺设计和资源配置提出的快速性与柔性要求，研究工艺规划与机床重构协同优化的理论和方法。通过分析加工特征和机床运动的耦合关系，建立底层工艺元素与机床重构的内在信息传递机制；采用多色集合与模糊逻辑集成理论，进行工艺元素及设计约束中不确定性关系的建模，将传统工艺知识向底层信息集成；根据零件特征成型方式进行工艺方法的析取和优化，生成用于协同优化的备选工艺方案；通过机床重构模块聚类分析，建立单元模块的运动耦合关系，形成与工艺规划同源约束的双向耦合机理；构建工艺规划与机床重构协同优化模型，确定优化目标和策略；设计二维基因遗传求解算法，从优化结果中解析工艺路线和机床重构方案，完成基于机床重构方案的工艺路线二次优化合并；实现理论模型向数据库二维关系模型的转化，搭建系统仿真平台进行理论方法验证。从而揭示可重构制造模式下资源间信息及关系的传递机制，通过协同优化降低制造系统运营成本。

针对可重构制造系统中资源优化配置问题，本项目研究了工艺的可重构设计方法及可重构机床结构配置方法。(1)分析了基础特征单元加工过程中机床、工具及工件的耦合运动关系，建立了基于多色集合理论的特征成型方式的描述模型，构建了传统工艺信息模型的新的表述方式；(2)以加工精度、表面粗糙度为主要工艺质量约束，建立了特征成型方式与质量约束的关系模型，并结合模糊集理论将人工工艺设计经验进行量化的关系处理，确定了隶属度函数实现工艺方法的评定和选择；(3)在特征成型方式与工艺约束模型的基础上，研究了零件加工工艺的设计方法，根据零件的特征构成和加工质量要求，对表述约束关系的围道布尔矩阵进行搜索，析取了有效的特征加工工艺方法集，结合工艺设计原则，确定零件的加工工艺路线集；(4)以工艺设计原则为工艺路线优化准则，以换刀次数、机床变更次数及成型方式变更频次为优化目标，设计了基于约束模型的遗传算法，实现了工艺路线的工步级优化；(5)进行了可重构机床的结构及模块聚类分析，定义了机床系统功能模块及关联关系，利用多色集合理论完成了功能部件的刀具侧创成和工件侧创成关系的映射，为可重构机床的创成提供了信息基础模型；(6)采用实例研究的方法，以单个工序为例，根据其特征成型方式搜索机床功能结构关系矩阵，获得了机床的多种结构配置方案，并从模块数、重构成本、功能冗余度等多个优化目标实现了配置方案的评定；(7)研究了基于工艺路线的可重构机群的配置方案优化问题，针对该问题建立了多目标优化模型，采用了理想点法和遗传算法相结合的方法进行目标寻优，通过实例研究，验证了模型和算法的有效性。本项目研究的工艺规划与机床重构的协同设计与优化方法，有利于降低制造系统重构成本，缩短制造周期，提高企业对客户化需求的快速响应能力，同时可以促进传统工艺设计方法向新型制造系统的融合，增强传统CAPP的适应性。