周期性手工装配作业肌肉疲劳预测建模与其装配质量改善

Manual assembly operations are still prevalent in industry due to the dexterity and flexibility of human labor. However, physical hazards, such as repetitive operations, high physical load, and awkward postures, often lead to musculoskeletal disorders and injuries, and further result in productivity reduction and even quality defects. Cumulative muscle fatigue is one of major reasons leading to those problems, and there are great discrepancies in fatigue progression among different workers. Therefore, this research puts focus on the local muscle fatigue in intermittent manual assembly operations and quality issues caused by the fatigue. A muscle fatigue model integrating subject-specific fatigue attributes is going to be proposed for intermittent manual assembly operations and experimentally validated. The cause-effect mechanism between muscle fatigue and quality deviation will be verified via experimental studies through an intermediate variable: manual ability. Field study will be conducted by integrating the muscle fatigue model and the fatigue-quality mechanism to develop an effective method to manage muscle fatigue. The potential contribution of this research would be reducing work-related musculoskeletal disorders and improving assembly quality simultaneously.

手工装配在复杂装配任务中仍大量存在。由于作业姿势笨拙、重复度高、负荷强度大，往往导致作业人员出现肌肉骨骼疾患，作业效率下降及装配质量缺陷增加。肌肉疲劳累积是导致肌肉骨骼系统损伤的重要原因之一，且不同类别作业人员的疲劳过程亦存在较大差异。本研究聚焦于周期性手工装配作业的肌肉疲劳，拟通过结合个体肌肉疲劳属性和周期性作业任务参数，构建适用于周期性作业的肌肉疲劳预测模型并加以实验验证；以手工作业能力为中间变量，通过实验手段深入研究肌肉疲劳对装配质量的影响机理；最后，将以上研究结果结合生产实际中的手工装配任务，提出有效可行的现场肌肉疲劳管控办法。该研究可以在一定程度上实现面向个体作业人员的肌肉疲劳管理，降低肌肉骨骼损伤的风险，在保障作业人员健康和安全的前提下，稳定作业效率，改善手工装配质量。

手工装配在现代工业系统中仍大量存在，由于作业重复度高、持续时间长、姿势笨拙，导致作业人员肌肉疲劳累积，进而引发肌肉骨骼失调。为了减少疲劳对操作人员带来的肌骨损伤和避免工作效率受损，本项目完成了如下四个部分的研究：（1）建立并验证了周期性施力条件的肌肉最大可持续周期数模型，该模型可以预测周期性载荷下肌肉的坚持极限；（2）提出并验证了基于肌肉疲劳模型的个体最大耐受时间模型，该模型可以预测持续性载荷下个体肌肉的坚持极限；（3）通过实验，探究了腕部肌肉疲劳前后手工作业能力的变化，特别是稳定能力、敏捷性的变化；（4）在实验室利用表面肌电信号刻画肌肉疲劳，并以此基础预测生产效率。在生产现场则采用可穿戴设备测量肌电信号，评估工人肌肉疲劳程度，进而用机器学习算法预测装配效率。本研究可以在一定程度上实现面向个体作业人员的肌肉疲劳管理，降低肌肉骨骼损伤的风险，在保障作业人员健康和安全的前提下，稳定作业效率，改善手工装配质量。