中国特色的再制造零件质量保证技术体系现状及展望

再制造在实现资源能源节约的条件下生产出经济发展所需要的产品,是建设资源节约型、环境友好型社会的有效途径针对中国特色的再制造模式,结合再制造产品及其生产环节,分析影响再制造零件质量的主要因素,指出为保证再制造零件质量应把控的几个环节,即再制造毛坯质量评价、再制造生产过程监测、再制造零件/涂层质量检验,并提出再制造零件质量保证技术体系,介绍我国近几年在再制造标准方面的主要成绩,并指出为适应我国再制造产业快速发展需要,急需加强再制造成形技术方法和再制造质量检测评价方法等方法标准的研究。阐述再制造毛坯和再制造涂层质量无损监/检测评价方法,并结合车辆发动机典型零件再制造实践,介绍无损检测评价技术在再制造质量保证中的应用。展望中国特色再制造零件质量保证技术的未来发展。     

汽车备件管理指标研究

针对汽车生产企业售后服务备件管理工作,指出建立汽车备件管理指标的意义,并就备件供应满足率、备件及时到达率、备件索赔率、备件抱怨率等汽车备件管理指标的范围与具体内容进行阐述,为系统地建立客观而准确的备件管理评价模型提供参考。     

REPAIRABLE SYSTEM AVAILABILITY MODEL WITH RESPECT TO LIFE DISTRIBUTION OF SPARE PARTS

The failed components of repairable systems are replaced with spare parts that may have different failure distributions from those of the components that have failed. The spare parts may be either the same as new, better than new, or worse than new. This is the reality in maintenance engineering. Repair with better spare parts is defined as ＂super repair＂. The failure distributions of the spare parts affect the availability of the components and their systems. A novel model is proposed to describe the availability of repairable systems across their operating time, at the level of their components, on the assumption that the failed components are immediately replaced. The model functions with arbitrary failure distributions of spare parts. It can be used to compute the availability of components and systems not only under perfect and imperfect repair but also under super repair.     

报废汽车零部件回收再利用的价值潜力

汽车产业的发展离不开对资源的索取和利用,然而大部分的车用材料都是有限且不可再生的,因而资源的回收再利用是汽车产品闭环设计必须坚持执行的准则.该研究以乘用汽车的寿命分布函数为依据建立了汽车报废量和零部件回收价值之间的关系.通过对报废汽车零部件的三种主要回收利用方式(零部件再使用、再制造和升级再制造)理论价值模型的建立,形...     

中国出台汽车产业振兴规划

China's State Council recently passed in principle the auto industry rejuvenation plan. Major contents of the plan are:to foster auto consum ption market, including a 50 percent cut in the vehicle purchase tax on passenger vehicles with a displacement of 1.6 liters and below; to promote reorganization of the auto industry and support large auto enterprise groups to carry out mergers and acquisitions, and key auto spare enterprises to expand production; to support independent innovation and technical upgrading by enterprises: the central government wiU appropriate RMB 10 billion in a special fund to support technical innovation and renovation and development of new energy automobiles and spare parts by enterprises in the next three years;to implement a new energy auto strategy :subsidy from the central budget will be appropriated to support the spread of energy saving and new energy automobiles in large-and medium-sized cities; and to promote development of independent brands of automobiles, speed up construction of auto and spare parts exportbases, develop a modern auto service industry and improve auto credit.     

New approach for robust multi-objective optimization of turning parameters using probabilistic genetic algorithm

Limited by techniques, the process of remanufacturing exists masses of uncertainties which have a great impact on the remanufactured parts quality, how to achieve a higher quality of mechanical products by using limited remanufactured parts precision, has become one of the key issues of remanufacturing industry. Firstly, with a target to reduce uncertainties and improve the quality of automatic products, a method of tolerance grading allocation for remanufactured parts is proposed based on the uncertainty analysis of the remanufacturing assembly. The dimensional tolerances of the mechanical parts are divided into positive and negative two groups. We use selective assembly method to reduce assembling deviation. Then, the method is proven by mathematical formulas that the remanufactured parts variance can be expanded to two times, and the tolerances can be liberalized 40 % through tolerance grading allocation method. It is also the theoretical basis for improving the reuse radio and quantitatively describing the tolerance liberalization in this paper. Finally, feasibility research on this method is studied from the angle of cost–benefit. Furthermore, a tolerance grading allocation example of remanufactured engine piston assembly in a power corporation shows the validity and practicality of the proposed method.     

Taguchi method for analyzing the tactical planning model in a closed-loop supply chain considering remanufacturing option

Recent years, there has been a growing interest in reverse logistics, recycling, remanufacturing, and reusing due to the environmental concerns, economical issues, and legal obligations. Companies should take into account the recovery options such as recycling, remanufacturing, etc. while preparing their tactical plans. In this paper, a mixed integer linear programming model is proposed for tactical planning in a conceptual closed-loop supply chain with remanufacturing option. In the model, both forward and reverse flows are involved and two production alternatives are considered: either production of new products directly in manufacturing plants or bringing the returned products back to “as new condition” in the remanufacturing facilities. The proposed model attempts to optimize all of the consecutive stages in the closed-loop supply chain. Hence, the purpose of this research is to formulate a mathematical programming model to focus primarily on integrating remanufacturing as a recovery option into tactical planning process. The proposed model is applied to an illustrative case and solved by LINGO 9.0 optimization solver. In order to obtain the best objective function value that is targeted, the effects of the major factors regarding reverse flows and remanufacturing system are examined with the help of Taguchi experimental design technique at the end of the study. Analysis of variance, Taguchi's signal/noise ratios, analysis of means graphs and interaction graphs are provided by MINITAB 14 software and interpreted for the evaluation of experimental results and effects of related factors.     

详解发动机关键零部件质量追溯方案

介绍了发动机关键零件在生产过程中的追溯过程,结合生产实际,详细分析了发动机关键零部件的追溯方案,不同方案应用及对质量控制的影响,针对出现质量问题的零件,如何对其进行判别、隔离、锁定,如何防止不合格零件装入发动机流入客户端,造成质量事故。质量门追溯体系能够在最大限度节约成本的前提下,更好的实现关键零部件的质量追溯。     

基于剩余寿命的备件管理研究

备件管理的好坏直接影响着设备维修时间、维修质量、设备的可开动率以及设备的正常运行,而且进一步影响到企业产品的产量、质量、成本、交货期、安全和环保等诸多方面。由于备件管理系统涉及因素多,在有些情况下,现有的解析方法目前还不能解决这些问题。因此,我们运用剩余寿命预测法对维修管理系统进行研究,以便更全面地解决备件管理中遇到的主要问题。本文以齿轮为例说明了基于剩余寿命备件管理的基本思路和方法。     

我国再制造政策法规分析与思考

再制造工程是废旧机电产品高技术修复改造的产业化,是实现节能减排和促进循环经济发展的有效途径。我国的再制造发展经历了产业萌生、科学论证和政府推进三个阶段。我国再制造产业的持续稳定发展,离不开国家政策的支撑与法律法规的有效规范。通过对我国再制造发展历程、政策法规梳理和实施效果的分析以及发达国家再制造政策法规特点的总结,有利于进一步完善我国再制造政策法规,更好地推动我国再制造产业的发展。梳理了2005年至2014年我国再制造的政策法规及其特点,在此基础上,分析我国目前再制造产业发展面临的挑战。借鉴发达国家再制造产业经验,我国再制造产业的发展不仅要完善法律体系和产品标准体系,同时要引入生产者责任制度,实现我国再制造产业的集聚化、跨越式发展。     

再制造系统大规模定制特性及其三维优化策略

未来再制造产业的发展不仅要求再制造产品在功能、性能上能够达到甚至超越新品,还要求其像新产品一样能适应多样化个性化的客户需求和快速多变的竞争市场。引入大规模定制理论,揭示再制造系统源于废旧零部件回收重用率极大化定制需求和面向客户多样化个性化定制需求的双向大规模定制特性。基于再制造系统的定制特性分析,建立再制造系统大规模定制过程框图模型。集成产品再制造与制造过程,提出再制造系统大批量定制化过程三维定制优化策略,三个优化维度包括产品结构维、再制造过程维、零部件重用维。结合某企业车床及滚齿机床再制造实践,分析并验证大规模定制化优化策略应用效果。     

基于寿命匹配函数的主动再制造设计方法

针对产品主动再制造时其关键零件往往存在“提前再制造”或“滞后再制造”的问题,提出了寿命匹配函数的概念。通过研究不同特征结构参数组合下关键零件主动再制造时机的变化,建立了关键零件主动再制造时机与特征结构参数的映射关系,并引入寿命匹配因子作为寿命匹配完成的标志。提出了基于寿命匹配函数的主动再制造设计方法,根据寿命匹配函数,优化特征结构参数,实现关键零件与产品主动再制造时机的匹配。最后,以某型号柴油机为例进行寿命匹配,验证了该方法的有效性和可行性。     

基于网络的回转体轴类零件参数化设计的应用研究

基于网络应用程序进行二次开发,用形体分析法将轴类零件分解为若干基本形体,零件图是基本形体图素的组合。用java语言对操作界面和基本形体图素等进行编程,并将软件与interne链接。对快速完成的参数化设计图形文件进行格式转化,实现网络图形并进行图形浏览和平台无关的零件特征识别,为异地设计和制造提供技术基础。     

机械产品全生命周期再制造性评估

再制造性评估是机械产品再制造过程中的关键技术之一,该评估应贯穿于产品的整个生命周期中。主要体现在设计阶段的再制造性评估,废旧零件的可再制造性评估,以及再制造后零件的性能评估。首先建立了基于产品全寿命周期的再制造性综合评价模型,然后分别构建了设计阶段对零件进行的再制造特性评估模型,和对服役后废旧零件的可再制造性(进行)评估模型。最终通过某型号装载机的废旧销轴为实例,验证了其再制造性评估模型的有效性。     

阀芯零件激光再制造工艺方法及试验研究

为了实现损伤阀芯零件的高质量修复,提出了一种基于几何重构与路径位姿规划的阀芯再制造工艺方法。引入再制造边界预制原则对阀芯损伤部位进行预处理设计并制定其实施步骤,基于NURBS理论实现了再制造边界曲面及待修复阀芯模型的高精度重构;采用等距截平面法生成再制造工艺路径,根据直线逼近和误差控制原理计算了各插补点坐标,并将光斑面积与插补点姿态相结合确定激光喷头动态位姿;运用ABB机器人系统进行路径与位姿校验并导出代码进行了阀芯再制造实践。结果表明：所提方法中规划路径及位姿能够有效跟随阀芯再制造边界曲面进行熔覆,形成了无气孔、无裂纹的致密涂层,涂层晶粒尺寸和平均硬度分别为14～54μm和573.6HV_0.5±51.8HV_0.5,耐冲蚀腐蚀性能提高了30.8%,满足阀芯再制造要求。     

再制造机床可修复零部件精度分配研究

研究可修复零部件精度参数的分配是关系到再制造机床性能和再制造成本的重要问题。本文提出了用BP+GA的混合算法优化分配可修复零部件精度参数的方法。首先利用BP神经网络建立零部件精度参数与再制造机床空间几何误差之间的正向映射模型,然后用正交设计法得到训练样本数据并训练网络,最后再用BP+GA的混合算法逆向确定零部件的精度参数。仿真结果表明了混合算法是解决复杂精度分配问题的一种理想方法,优化结果可用于指导零部件精度的修复。     

自动变速器的再制造工艺及特点

自动变速器是汽车上具有重要再制造价值的部件之一.结合自动变速器再制造公司生产、管理的事例和经验,论述了自动变速器再制造的工艺流程及工艺过程,总结了自动变速器再制造质量保证的主要内容,指出自动变速器再制造需要绿色生产方式.     

分体式多轴组合钻

利用多轴组合钻解决瓶颈结构中螺孔的钻削问题,以提高劳动生产率,满足零件大批量生产的需要。     

Joint optimization of spare parts inventory and maintenance policies using genetic algorithms

In general, the maintenance and spare parts inventory policies are treated either separately or sequentially in industry. However, since the stock level of spare parts is often dependent on the maintenance policies, it is a better practice to deal with these problems simultaneously. In this study, a simulation optimization approach using genetic algorithms (GAs) has been proposed for the joint optimization of preventive maintenance (PM) and spare provisioning policies of a manufacturing system operating in the automotive sector. A factorial experiment was carried out to identify the best values for the GA parameters, including the probabilities of crossover and mutation, the population size, and the number of generations. The computational experiments showed that the parameter settings given by the proposed approach achieves a significant cost reduction while increasing the throughput of the manufacturing system.     

Optimal pro-rata warranty decision with consideration of the marketing strategy under insufficient historical reliability data

Warranties play an important role in the market, not only safeguarding the rights and interests of consumers, but also promoting the sales and reputation of manufacturers. Due to their impacts on the market, manufacturers should take their warranty policies into consideration in developing an integrated marketing strategy which can promote a product by simultaneously considering pricing, production, and related post-sale services. Most of the studies regarding the issue of pro-rata warranties (PRW) only focus on cost analysis with the reliability estimation, and few consider how marketing strategies can be integrated in the warranty decision. Moreover, the manufacturer may not have sufficient historical data to estimate the deterioration of a newly developed product, and therefore, the results obtained from analytical models may not be reliable. A Bayesian analysis should be a reasonable approach in order to deal with such a problem for the situation of insufficient historical data because it can effectively assess the deterioration based on experts’ opinions and possibly few relevant data. Accordingly, this paper proposes a Bayesian decision-making model which considers the PRW policy with the pricing and the production strategy. Moreover, in order to deal with the complexity of computation of the proposed model, a heuristic algorithm is also provided, and finally, a practical application case is used to demonstrate its usefulness.