基于信息溯源与多场耦合分析的机械装备再制造可靠性问题研究

Reliability is the key factor for the remanufactures to gain a competitive advantage and improve customer acceptance. From the whole life cycles of service, remanufacture and re-service, the reliability problem of machinery equipment remanufacturing is analyzed in this project. Firstly, combined with the failure features of the mechanical parts, the service process of the machinery equipment reappears based on information tracing and computer simulation to analyze the evolution rule of the failure information. Secondly, the mapping influence of each factor of remanufacturing process on reliability features of remanufactured equipment is analyzed. Thirdly, the reliability analysis platform of remanufactured equipment in multi-physics coupling environment is built, the failure mode and effect of the remanufactured equipment in the process of re-service is analyzed and the reliability dynamic model of remanufactured equipment based on Markov chain Monte Carlo simulation is established. Fourthly, the reliability growth theory of remanufactured equipment based on structure redesign and optimization is proposed. Finally, the proposed reliability analysis method is validated with the engineering practices of machine tool remanufacturing and construction machinery remanufacturing. The reliability analysis method of machinery equipment remanufacturing based on information tracing and multi-physics coupling analysis will be proposed which is conducive to the efficient implementation of China's pilot work of mechanical and electrical products remanufacturing, with a broad development prospect.

可靠性是再制造机械装备取得竞争优势并获取用户认可的关键因素。本项目从机械装备服役、再制造、再服役的全生命周期过程出发，针对机械装备再制造的可靠性问题展开研究：基于信息溯源与计算仿真还原机械装备服役过程，全面分析机械零部件服役过程失效信息演变机理；对再制造工艺过程各因素对再制造装备可靠性特征的影响规律进行映射分析；搭建多物理场耦合环境下再制造装备可靠性分析平台，在对再制造装备服役过程故障模式及危害影响分析的基础上，建立基于马尔科夫链与Monte Carlo仿真的再制造装备可靠性动态模型；提出基于结构再设计与优化的装备再制造可靠性增长方法及理论；最后，以机床装备、工程机械再制造为工程背景，验证所建立的可靠性分析模型。本项目将形成一套基于信息溯源与多场耦合分析的机械装备再制造可靠性分析方法，有利于支撑我国机电产品再制造试点工作的高效开展，应用前景广阔。

高可靠性是再制造机械装备获取用户认可的关键因素。本项目从机械装备服役、再制造、再服役的全生命周期过程出发，针对机械装备再制造的可靠性问题展开了研究：① 调研分析机械零部件失效模式及损伤机理，提出了一种基于改进ICP算法的损伤零部件精确配准方法用于确定废旧零部件的损伤量，并用可再制造度来量化描述其失效特征与再制造过程之间关系，运用信息溯源与计算仿真集成的方法对机床导轨磨损失效过程及规律进行了分析；② 提出了再制造工艺过程可靠性的概念，对再制造工艺过程各因素对再制造装备可靠性特征的影响规律进行了映射分析，并提出了一种基于GO法的再制造工艺过程可靠性分析方法以及基于改进模糊神经网络的废旧零部件再制造工艺方案决策方法；③ 提出了再制造机械装备可靠性的定义及内涵，并以ANSYS、COMSOL Multiphysics等软件平台为基础，完成了再制造装备服役多物理场耦合分析环境平台的搭建，提出了再制造装备服役过程故障模式及危害影响分析（FMECA）的方法及步骤，构建了基于马尔科夫链与Monte Carlo 仿真的再制造机械装备可靠性动态模型；④ 在获取再制造机械装备服役过程故障原因、故障模式以及可靠性相关数据的基础上，提出了一种基于装备结构再设计与优化的再制造装备可靠性增长方法；⑤ 以上模型、理论及方法已在机床再制造过程中展开了应用，并将逐步扩展到工程机械、模具再制造。围绕上述研究内容，共发表或录用学术论文11篇，其中SCI/EI论文9篇；项目前期研究成果获重庆市科技进步三等奖1项；合作培养绿色制造与再制造等方向硕士研究生2名。本项目属于应用基础研究，形成了一套基于信息溯源与多场耦合分析的机械装备再制造可靠性分析方法，有助于提升再制造机械装备质量及可靠性，并可为我国机械装备再制造战略性新兴产业发展提供理论支撑。