仓储设备及作业流程监控虚拟化技术研究

现代仓储具有订单量庞大、批次多、异构设备多等特点,导致作业过程复杂、仓储设备难以实现统一的分布式监控.以密集仓储的设备及作业过程为研究对象,基于OPC统一设备通信技术、Web服务化技术、可视化技术、数据库技术等,提出了设备及作业流程虚拟化模型并给出实现途径.建立仓储资源及作业流程与监控服务对象之间的虚拟映射以及双向反馈...     

快拆轴生产流程改造

在分析快拆轴制造特点的基础上,提出了一种面向客户需求快速反应的精益生产制造体系.重点研究了基于甲骨文数据库的ERP系统流程技术、基于平衡工序的制造流程技术、生产节拍、生产机台摆放等关键生产技术,通过实际生产线的改造应用,验证了所提出的精益生产制造体系在企业中的可行性和实用性.     

生产物流跟踪的钢铁企业作业成本计算方法研究

针对目前钢铁企业多品种、小批量生产模式下成本归集和分配难以反映实际作业过程不足的问题,提出以炉号、生产批次为依据且面向作业资源管理的物料跟踪模型,并在此基础上研究生产跟踪数据向成本数据的转化方法,总结出多重资源分配方法,进而研究基于生产物流跟踪的钢铁企业作业成本计算方法.通过在某钢铁企业的应用,验证了该成本计算方法的有效件.     

基于Flexsim的飞机客舱安装作业仿真研究

为提高B747飞机大修作业效率,基于现行的作业流程、工时和操作人员等信息,设计了客舱安装作业数据库,在Flexsim软件环境下,建立了客舱安装件作业仿真模型.通过仿真模型测试发现现行的客舱安装作业人员平均闲置率为27.6%.通过调整作业步骤和作业流程,使人员的平均闲置率降到17.3%.该结论通过仿真模型的测试得到了证实.     

车间作业排序的遗传算法解码方法研究

应用遗传算法进行车间作业排序时,编码操作和遗传操作会得到不同的的染色体,这些染色体必须利用解码技术才能被转化成各个机器上工件的实际加工顺序.文中以数据库的数据交互为基础,采用了一种活动化解码算法进行作业排序,同时对模拟遗传算法编码技术、解码算法原理、算法流程设计等几个方法进行了分析研究,最后给出了应用实例,进一步验证了文中研究的解码算法及技术是可行的,可以在工程实际中进行推广应用.     

某高压开关曲杆销轴应力试验及影响分析

某型号高压开关曲杆销轴在机械传动过程中,承受着双向交变载荷,要求其有足够的疲劳强度,为了解在传动过程中销轴所受应力情况,选择同批次销轴进行光谱分析、力学性能试验及金相检验,并对拉杆进行应变试验,间接计算销轴所受应力,然后使用有限元分析曲杆衬套和拉杆衬套内径尺寸变化对销轴应力的影响,最后从实际应用方面对销轴进行应用讨论.结果 表明:销轴应力小于力学性能试验测得的屈服强度,拉杆衬套内径尺寸变大会使销轴所受应力增加较多.使用过程中应注意确认相关零部件的状态,以及严格执行装配工艺等可预防销轴过早疲劳.     

过程数据的应用层次和数据获取研究

基于实时数据库和关系数据库,将过程数据的应用层次分成集成、整合和校正3个层次。用ODBC数据库绑定技术研究3个层次数据应用的建立方法和数据获取技术。用SQL、ASP等技术建立数据查询器、修正器和浏览器。提出基于实时数据库和关系数据库的数据集成实时数据库／数据整合批次关系数据库／数据校正有效数据库的过程数据应用层次模型。该研究对于企业信息化、装备信息管理、指挥与决策等系统的开发具有重要意义。     

并行工艺过程设计的研究与实现

为解决传统串行工艺过程设计效率不高的问题,结合并行工程思想,建立了并行工艺过程设计模型.为搭建并行工艺过程设计实现环境,构建了封装组件式CAPP/PDM集成系统.在此基础上,研究了并行工艺过程设计实现技术:并行工艺过程设计总流程定制、工序对象流程管理、中间数据库工艺信息共享.介绍了并行工艺过程设计在某国防制造企业的应用情况.     

基于ABAQUS/fe-safe的服役后轴类零件疲劳分析方法

以CAD、CAE以及疲劳分析软件fe-safe联合仿真技术为基础,结合残余应力检测设备,建立了服役后零件疲劳耐久性分析流程.以某服役后待再制造的汽车变速箱输入轴为研究对象,应用有限元分析软件ABAQUS,建立轴的有限元模型,得到轴的应力结果;使用疲劳分析软件fe-safe读取应力结果,对轴进行疲劳分析得到其整体寿命分布云图及危险区域分布状况.分析结果对轴的再制造过程具有指导意义.     

基于n维仿射空间的批次跟踪模型

为满足离散制造企业生产过程中批次可追溯性的需求,提出基于n维仿射空间的批次跟踪模型.模型中将批次视为一个仿射空间中的点,并通过规范使得每一批次处于唯一的仿射空间,将零部件批次加工组装至最终产品批次的过程映射为批次在仿射空间中对应向径的线性组合过程,通过批次在仿射空间中的向径坐标更清楚地表达批次构成和批次关系.批次的前向和后向跟踪在特定的仿射空间中进行,避免了传统方式跟踪过程中大量的数据检索.通过应用实例说明该模型在批次跟踪搜索性能等方面得到了提高.     

Plant information at the desktop-exploiting corporate IT infrastructure

A generic solution to the problem of collecting and analysing batch plant data from different control systems has been developed using Microsoft's front and back office product set. It offers low-cost exploitation due to world-wide company standardisation on the MS Office product set. A standard set of event message types have been defined which are now generated automatically by different control systems used in ZENECA. All events are collected in real time and the batch data server configures itself automatically by analysing the data collected to determine product names, batch identities, unit names, operation names, phase names, etc. Plant data is loaded into normalised SQL server data tables whose structure is independent of the original batch control systems. A standard client application has been developed in MS Access which allows users to analyse single and multiple batches and relate process measurements to batch events. It is tightly integrated with other components of MS Office and data can easily be exported into spreadsheets or documents. Validation effort required for specific applications of the validated product set is minimised as it configures itself from the underlying data. The batch data server acts as an interface between the proprietary world of batch control systems and corporate standards for information technology.     

改进MKPCA方法及其在发酵过程监控中的应用

针对间歇发酵过程缓慢时变和非线性等特点,提出一种基于滑动窗技术的多向核主元分析(MWMKPCA)方法.该方法结合了核主元分析(KPCA)和滑动窗口技术的优点,其中KPCA能有效解决过程数据的非线性问题,保证数据信息抽取的完整性;而滑动窗口技术能有效避免MKPCA在线应用时预报未来测量值所引入的误差,提高监控性能.对于已判断正常的新批次过程数据,将其加入模型参考数据库进行更新,从而提高间歇过程性能检测的准确性.将该方法应用到工业青霉素发酵过程的监控中,并与MPCA、MKPCA方法的监测性能进行了比较.结果表明:该方法能有效提取过程变量间的非线性关系,降低运行过程的误报率,对缓慢时变的间歇过程具有更可靠的检测性能.     

Online batch recipe adjustments for product quality control using empirical models: application to a nylon-6,6 process

The application of batch profile characterization tools to enhance process understanding by uncovering the signature of the primary disturbances on the profiles and its effect on the product quality is illustrated on a nylon-6,6 process. The historical profile data for the fixed recipe operation are systematically studied to understand the primary disturbances affecting the process, and it is shown that good online predictions of the final product quality are possible much before the completion of the batch from the available measurement profiles. A simple online recipe adjustment strategy based on the predicted quality deviation from the target is proposed. Results show that the recipe adjustments significantly reduce the variation in the final product quality. Issues in the use of empirical prediction models from recipe-based data are discussed.     

热交换器生产中CAPP的应用

调查了热交换器制造企业工艺设计的现状,对热交换器生产中应用Word／Excel／AutoCAD及其他图形系统填表型cAPP系统和数据库的参数式CAPP系统2种开发方式所引起的问题作了讨论,论述了热交换器CAPP系统总体设计、数据处理应达到的目标,指出实施的关键就是如何有效地利用典型工艺知识这一宝贵的知识财富,并能实现人机交互,从而有效制订出焊ki-zr-艺卡以及进行焊接工艺的管理,为热交换器生产中G心P技术的开发提供一些参考。     

基于iMAN的CAPP系统的设计与实现

设计了基于 PDM(i MAN)的 CAPP系统的构架 ,着重研究了 CAPP与 i MAN的集成、工艺数据的数据库存储与 JAVA本地动态连接库调用等关键技术。在此基础上开发了基于 i MAN的 CAPP系统—— i MAN CAPP,通过 PDM(i MAN)这一 CAD/CAPP/CAM的集成平台 ,不仅可以实现对工艺设计过程的管理 ,还可以与同样构造在PDM(i MAN)平台上的其它应用系统紧密集成。该系统已在企业运行 ,取得了满意的效果。     

石油炼制企业生产过程监控与管理系统研究

这里针对石油炼制企业生产过程监控、工艺信息管理等方面存在的问题,进行了分析和研究,提出了相应的解决方案.介绍了具有生产过程实时数据采集,基于网络和实时数据库的工艺数据分析与管理等的生产过程监控与管理系统.同时,还给出了系统所采用的关键技术和实施实例.系统应用JSP、Servlet、JavaBean、XML、OWC和Oracle数据库实现.系统可以在集成环境下运行,满足了石油炼制企业生产过程监控与管理的需求.     

Shared and service-oriented CNC machining system for intelligent manufacturing process

To improve efficiency, reduce cost, ensure quality effectively, researchers on CNC machining have focused on virtual machine tool, cloud manufacturing, wireless manufacturing. However, low level of information shared among different systems is a common disadvantage. In this paper, a machining database with data evaluation module is set up to ensure integrity and update. An online monitoring system based on internet of things and multi-sensors "feel" a variety of signal features to "percept" the state in CNC machining process. A high efficiency and green machining parameters optimization system "execute" service-oriented manufacturing, intelligent manufacturing and green manufacturing. The intelligent CNC machining system is applied in production. CNC machining database effectively shares and manages process data among different systems. The prediction accuracy of online monitoring system is up to 98.8% by acquiring acceleration and noise in real time. High efficiency and green machining parameters optimization system optimizes the original processing parameters, and the calculation indicates that optimized processing parameters not only improve production efficiency, but also reduce carbon emissions. The application proves that the shared and service-oriented CNC machining system is reliable and effective. This research presents a shared and service-oriented CNC machining system for intelligent manufacturing process.     

Automatic validation of vibration signals in wind farm distributed monitoring systems

A rapid growth of wind farms as a leading renewable energy sector has compelled a number of companies to develop dedicated distributed systems of monitoring and diagnosis (SM&D). Such systems are capable of early mechanical faults detection, which prevents from costly critical repairs. Fault detection of wind turbines is based on vibration and process signals analysis. Modern SM&D are usually advanced hardware and software technological products, which on the basis of collected data are capable of continuous execution of enormous number of analyses. However, the expansion of distributed systems has disclosed new challenges accompanying the transition from a singular signal analysis to automatic interpretation of large data sets. The paper deals with the assessment of data acquisition final products, namely the correctness of vibration signals recording process. The proposed validation, which is to be implemented a priori to data analysis, is required for significant calculation of any signal features as well as for legitimate storage of raw waveforms in the system database. The latter aspect is especially important in terms of gigabytes of disk space frequently wasted for corrupted data. The paper presents a step-by-step method for automatic signal validation, which can be implemented on a personal computer. Finally, the algorithm is evaluated on a real wind turbine database.     

基于计算机技术的铸造工艺数据库分析

计算机技术是信息技术的先进代表,凭借其强大的数据处理功能得到了广泛地运用。建立铸造工艺数据库能够为企业提供多方面的实用信息,引导铸造生产人员严格按照工艺标准完成加工,提升金属构件的品质水平。现分析基于计算机技术的铸造工艺数据库的相关问题,提出自然语言通信及可编程控制器的实际应用。