虚拟仿真智慧船厂的建设与研究

为对接船舶与海洋工程装备制造业转型发展,必须针对新的船舶建造过程中技术工艺、人员培训、生产管理的难推广、难落实、难改革问题,通过在船舶与海洋工程装备类企业中运用基于虚拟仿真技术的智慧船厂,开展新装备、新技术的人员培训,实现智能化生产管理,提高建造工艺效率,推动造船企业高质量发展。     

基于诊断分析的生产线虚拟设计及其应用研究

利用离散事件仿真工具QUSET ,提出了基于诊断分析的生产线虚拟设计的体系结构、设计流程及其设计内容。详细研究了生产线的虚拟设备建模、虚拟工艺建模、虚拟控制建模等建模方法 ,并通过某生产线的实际工艺内容进行了生产验证 ,快速地诊断了其瓶颈工序 ,为生产线的设计、分析和调整提供了新的途径 ,为产品制造规划提供了有力的虚拟仿真工具 ,从而可以快速地响应市场变化和客户个性化生产需求     

Production engineering-oriented virtual factory: a planning cell-based approach to manufacturing systems design

In the traditional process of designing a manufacturing system, a sequential approach treats each of the design steps individually, without considering the requirements of concurrent design activities. The lack of systematic and concurrent consideration of the interactive impact of design decisions leads to repeated and excessive changes in the design and process. To resolve this problem, this research develops a production engineering-oriented virtual factory — a planning cell-based manufacturing systems design approach. The manufacturing systems design process based on a planning cell is reengineered according to the concept of concurrent engineering. The process modeling of a production engineering-oriented virtual factory is proposed at generic and particular levels. An illustrative example of an engine assembly plant demonstrates the effectiveness of the new approach.     

Production engineering-oriented virtual factory: a planning cell-based approach to manufacturing systems design

In the traditional process of designing a manufacturing system, a sequential approach treats each of the design steps individually, without considering the requirements of concurrent design activities. The lack of systematic and concurrent consideration of the interactive impact of design decisions leads to repeated and excessive changes in the design and process. To resolve this problem, this research develops a production engineering-oriented virtual factory – a planning cell-based manufacturing systems design approach. The manufacturing systems design process based on a planning cell is reengineered according to the concept of concurrent engineering. The process modeling of a production engineering-oriented virtual factory is proposed at generic and particular levels. An illustrative example of an engine assembly plant demonstrates the effectiveness of the new approach.     

Evaluation of Tools for Modeling Manufacturing Systems Design with Multiple Levels of Detail

This paper presents an investigation of simulation packages regarding their ability to model business processes related to manufacturing systems. Three simulation packages are investigated: VS7, SIMAN/CINEMA IV, and SIMFACTORY II.5. These packages are evaluated with regard to their capabily of modeling problems related to the manufacturing systems design (MSD) framework, which involves different levels of detail: the conceptual modeling level and the detailed design level. The investigation is based on a case study related to manufacturing systems. The main objective of this investigation is to examine the manufacturing simulation packages and their ability to offer variable detail modeling. Research findings suggest that no simulation environment offers sufficiently flexible facilities for the variable detailed modeling of manufacturing systems design. The paper proposes a method for systems entity classification to increase the levels of detail in an effective manner without duplication of data collection and model building efforts.     

数字化制造中的建模和仿真技术

论述了面向数字化制造的三类建模和仿真技术,即产品建模和仿真技术、工艺过程建模和仿真技术以及制造系统建模和仿真技术,并结合具体研究项目,重点介绍了面向制造的产品数字化建模、导管数控弯曲过程建模与仿真、虚拟装配与装配过程仿真、生产线建模与仿真技术的应用和发展。指出为提高制造系统的快速响应特性、运行效率及可靠性,应在产品数字化建模研究的基础上,重视对工艺过程,即产品加工过程、装配过程及生产系统规划、重组和仿真等技术的研究,以实现生产资源和加工过程的优化以及从传统制造向可预测制造模式的转变。最后指出了推动数字化建模和仿真技术朝实用化方向发展的几项关键技术。     

A functional approach to feature recognition in production planning

One of the key elements for improving manufacturing productivity is the integration of CAD/CAM systems. An essential intermediate step is planning for production. This requires the automatic conversion of design data to an understandable format for computer-aided process planning (CAPP) systems in the preparation of process plans. The paper examines the functions of planning for production from the integration viewpoint and proposes a methodology for one of the functions — feature recognition.     

Information requirements analysis for holonic manufacturing systems in a virtual environment

The design and development of holonic manufacturing systems requires careful, and sometimes risky, decision making to ensure that they will successfully satisfy the demands of an ever-changing market. In this paper, the authors propose a methodology for a holonic manufacturing systems requirement analysis that is based on a virtual reality approach and aimed at assisting designers of such systems along the entire systems design and development process. Exploiting virtual reality helps the user collect valid information quickly and in a correct form by putting the user and the information support elements in direct relation with the operation of the system in a more realistic environment. A prototype software system tool is designed to realise the features outlined in each phase of the methodology. A virtual manufacturing environment for matching the physical and the information model domains is utilised to delineate the information system requirements of holonic manufacturing systems implementation. A set of rules and a knowledge base is appended to the virtual environment to remove any inconsistency that could arise between the material and the information flows during the requirement analysis.     

Disassembly sequence planning approach for product virtual maintenance based on improved max–min ant system

In order to realize automation and intelligence of product disassembly process in a virtual maintenance environment, an improved max–min ant system based methodology for product disassembly sequence planning was proposed. The feasibility graph for product disassembly process was defined and the mathematic model of product disassembly sequence planning problem was set up. Thus, the problem of product disassembly sequence planning was transformed into the problem of searching optimal path on a feasibility graph. Moreover, an improved max–min ant system based on the strategy of sorting elite ants was presented and the flowchart of the improved algorithm was designed. Finally, by simulation examples, the robustness and outperforming others of the improved algorithm were verified.     

Virtual plastic injection molding based on virtual reality technique

Virtual reality (VR), as a new technology, is integrated with software systems for engineering, design, and manufacturing. The integration has given a new impetus to the field of computer-aided engineering. This paper presents a research effort aimed at creating a virtual plastic injection molding (VPIM) environment, which is designed and implemented based on techniques such as VR, multidiscipline simulation, and scientific visualization. The VPIM system includes two parts: designing in VPIM and evaluation in VPIM. It is the first system to scrutinize virtual prototype mock-ups of new products, machines and production processes in interactive graphic simulation. During the evaluating phase, coupled to appropriate computer-based reasoning and decision-support tools and driven by data from the real manufacturing environment, a realistic impression of the process of plastic injection molding and manufacture can be achieved and can be changed interactively, and it is possible to thoroughly examine the planned system and eventually detect and remove any defects and inadequacies. The construction approach and key techniques (FEA, virtual assembly, stereoscopic display, a triangulated boundary-representation of an approximating polyhedron, collision detection, etc.) of the system are described in detail. The overall system is a powerful new approach for highly relevant industrial application of VPIM which focuses on the construction and assessment of alternate manufacturing sequences and mold design in an early design stage. Improvement of the design and manufacturing process will lead to better design and reduced development time and cost.     

可重构制造系统集成设计框架研究

提出了基于可重构制造单元的可重构制造系统集成设计框架.在该框架中,从规划和运行方面阐述了可重构制造系统的设计目标、设计流程及采用的关键技术,建立了支持可重构制造系统实施的计算机辅助设计系统的功能模型和体系结构,并讨论了系统的内部集成和外部集成问题.根据该设计框架,开发了集重构、布局规划、生产调度和仿真优化为一体的软件系统,该系统现已应用于航天、船舶和兵器部门.     

生产线虚拟设计及其应用仿真研究

针对传统生产线设计方式的缺点,提出一种基于虚拟制造技术的新型生产线设计方法--生产线虚拟设计,详细研究了其设计原理、基本特征、体系结构、设计内容和设计流程.生产线虚拟设计可有效地集成生产线的设计、仿真、分析、诊断、优化和重组等功能.结合应用实例,建立了生产线的虚拟模型,可视化地仿真其运行状态,迅速地诊断了其瓶颈工序,诊断结果与现实状况较为吻合.     

虚拟环境中卸箱机的运动建模

对灌装线主机运动建模是灌装线虚拟制造系统的重要任务，如何在虚拟环境中提高主机运动建模的效率，对于整个灌装线动态仿真的实时性有重要作用。提出利用对等模型和辅助节点来建立卸箱机运动模型。其优点是紧密结合卸箱机的机构运动特点，充分利用WTK的场景构造元素和树状层次结构，显著提高了运动建模的效率，又简单直观，易于理解和实现。详细说明了卸箱机的运动建模过程，并给出相应的运动图线。     

制造系统人因仿真参考模型及若干关键技术

人因仿真是对制造系统进行人因分析的重要手段。针对制造系统设计中人因的评价问题,提出了指导人因仿真实施的通用参考模型与系统方法,并给出了各个层次人因仿真的特点和应用领域。其次,给出了面向任务的人因仿真步骤和方法集,研究了建立任务网络模型、工作失误仿真以及工作任职需求仿真等关键技术。最后结合一个三维激光焊接生产单元的实例说明了人因仿真技术在自治生产单元设计中的应用。     

Development and evaluation of feature-focused dynamic routing policy

This paper reports on a development of feature-focused dynamic routing policy and its evaluation in a flexible manufacturing systems (FMS) simulation framework. The dynamic policy is based on an integrative methodology in which process planning system IMPlanner is integrated with FMS simulation module. IMPlanner’s rule-based system process selection system performs knowledge-intensive task of generating alternative processing options for each feature for parts in production plan. Generated alternative routings (process plan network) for each part are utilized in the FMS simulation module such that routing decision in FMS are made on periodic intervals by considering alternative processes for each feature and making decision based on the current system status and performance. The proposed framework has been evaluated in an experimental FMS simulation module, implemented in Arena, in which two performance criteria, machine utilization and WIP, were used to make routing decisions. The feature-focused approach is compared with traditional static decision-making, and its improved performance is demonstrated.     

圆柱铣刀铣削力过程的物理建模

密切结合先进制造技术的需要,以虚拟制造技术作为研究课题,运用金属切削理论等,对铣削力建模进行了系统深入的研究.该模型中考虑了前刀面上作用的正压力和摩擦力,给出了适用于圆柱螺旋刃铣刀的三维单元铣削力模型.论文为丰富虚拟制造建模理论体系、开发实用的铣削加工过程物理仿真系统奠定了坚实的基础.     

A pragmatic system to support interactive assembly planning and training in an immersive virtual environment (I-VAPTS)

Assembly planning for complex products is a difficult task requiring both intensive knowledge and experience. Computer aided assembly planning (CAAP) systems have been the subject of considerable research in recent years without achieving a wide application in manufacturing industry. In this paper an alternative approach to the generation of an optimal assembly planning scheme is presented based on the adoption of immersive virtual reality. A product is assembled from CAD models by providing a CAD interface to transfer assembly constraint information from the CAD system to a virtual environment. In the virtual environment an efficient dynamic recognition and management method based on surface geometry is employed, and a process-oriented assembly task model is established to support interactive assembly planning and evaluation. The system is implemented using an object oriented methodology, and has been successfully applied to train and guide the assembly workers in a pump assembly process.     

制造系统虚拟环境的多Agent建模方法

建模与仿真是虚拟制造系统的核心，具体的制造系统虚拟环境建模必然会遇到许多新的问题，提出了制造系统虚拟环境的多Agent建模方法，以具体生产线为对象，对系统进行了划分，描述了各Agent的特征，并给出了Agent的定义与实现方法。     

面向生产现场的虚拟装配工艺规划技术

针对生产现场的需求和虚拟装配技术的发展,阐述了虚拟装配技术在装配工艺规划、装配精度预分析、管路与线缆装配及装配现场管理等方面的应用和发展.提出了半沉浸式虚拟装配工艺规划系统的整体思路及实现方法;虚拟环境下的线缆和管路的离散控制点建模及动态布局技术;虚拟环境下的带公差的产品建模方法和装配精度预分析技术.指出虚拟装配工艺规划技术能充分利用人的经验和感知,通过模拟真实装配过程,不仅可实现产品的装配顺序和路径规划,而且也是提高装配精度和装配可靠性问题的有效手段,为提高装配现场现代化管理水平提供了有效途径.     

制造系统虚拟环境计算模型研究

制造系统虚拟环境仿真是虚拟制造研究的重要内容,建模虚拟制造环境会遇到很多复杂的问题,采用适当的方法至关重要。通过对制造系统虚拟环境的特点和各种描述方法的分析比较,提出了制造系统虚拟环境的多Agent建模方法,将虚拟生产线系统转化为一个多Agent系统的设计与开发,给出了制造系统虚拟环境的计算模型,对Agent数据结构中的各个组元进行了详细定义与分析,采用消息传递驱机制作为虚拟系统运行控制方式,在仿真循环中实现了制造系统虚拟环境模型的运行控制。