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某企业齿轮制造过程的生产工艺瓶颈分析数字化仿真与优化

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摘    要
齿轮是各种机械产品中不可或缺的零件,其制造过程效率的高低对企业影响巨大。但是由于齿轮生产制造过程的复杂性,以及生产线所处环境的不确定性,要找出影响齿轮制造过程效率的瓶颈环节并加以改进是非常困难的。经验表明,计算机仿真方法是辅助改进和优化生产工艺的有效工具。本文选择某企业齿轮制造过程的生产工艺为仿真为研究背景,探讨了齿轮制造过程仿真建模方法。并以某齿轮轴车间为例进行了仿真建模,通过仿真软件的运行及其仿真结果的分析,提出了可行的优化措施,为企业齿轮生产工艺最终优化方案的确定提供决策参考。
论文首先,回顾了齿轮生产工艺仿真的研究动态,在此基础上阐述了齿轮制造发展的趋势。同时对系统仿真的基础知识进行了深入分析,说明了系统仿真技术在齿轮制造过程中的重要作用;
其次,介绍了生产瓶颈的理论基础,并结合仿真软件的特点,归纳总结出了齿轮生产工艺建模仿真的总体思路,提出了仿真建模的步骤,并以仿真软件eM-plant为工具做了具体的研究和阐述;
最后,以某齿轮制造企业齿轮轴生产车间为为研究对象,利用仿真软件eM-plant对现实的生产工艺进行了仿真建模、参数设定、模型验证、仿真运行与结果处理。在设定优化目标的要求下,通过改变工艺路线,增加设备台数,对比分析优化前后的仿真结果,为企业提高生产效率、降低生产成本提供决策参考。


关键词:齿轮制造,eM-plant,仿真,优化

ABSTRACT
Gear is all an integral part of the machinery parts, the level of the manufacturing process efficiency tremendous impact on enterprises. However, due to gear production of the complexity of the manufacturing process and production line environment in which the uncertainty, to find out the impact on the efficiency of the gear manufacturing process bottlenecks and to improve it is very difficult. Experience has shown that computer simulation is assisted to improve and optimize the production process of effective tools. In this paper, choose an enterprise gear manufacturing process for the production process simulation to study the background on the gear manufacturing process simulation modeling methods. And a gear shaft workshop as an example the simulation modeling, simulation software and the operating results of the simulation analysis, a viable optimization measures for enterprises gear production process ultimately determine the optimal scheme to provide decision-making.
First of all papers, reviewed the gear production process simulation of dynamic, on the basis of this gear manufacturers on the development trend. At the same time on the basis of knowledge of system simulation conducted in-depth analysis shows that simulation technology in the manufacturing process gear to the important role;
Secondly, on the basis of the theory of production bottlenecks, combined with the characteristics of simulation software, summarized a gear production process modeling and simulation of the general idea, put forward the steps of the simulation modeling and simulation software to eM-plant as a tool to do the And sets out specific research;
Finally, a gear to gear shaft manufacturers for production workshop for the study, use of simulation software eM-plant on the reality of the production process for the Modeling and Simulation, parameter settings, model verification, simulation results of operation and handling. In setting the goal of optimizing the request of the line by changing technology, equipment Taiwan increased the number of comparative analysis before and after the optimization of the simulation results, for enterprises to improve production efficiency, reduce production costs to provide decision-making.

Key words:Gear manufacturers, eM-plant, simulation, optimization

目    录     26000字
中文摘要    I
英文摘要    II
1 绪  论    1
1.1    本论文研究背景及意义    1
1.2    国内外相关研究现状及发展趋势    2
1.2.1    国内研究现状    2
1.2.2    国外研究现状    3
1.3    本文研究的内容    4
2 数字化仿真理论基础    5
2.1    数字化仿真    5
2.1.1    系统仿真的分类    6
2.1.2    数字化仿真的相关概念    6
2.2    离散事件系统仿真    7
2.2.1    离散事件系统的概述    7
2.2.2    离散事件系统仿真的原理及策略    8
2.2.3    离散事件系统仿真模型的组成    10
2.3    面向对象仿真建模及仿真软件介绍    11
2.3.1    面向对象仿真建模概述    11
2.3.2    面向对象仿真模型的构建    11
2.3.3    eM-plant仿真软件    13
3 瓶颈分析方法研究    15
3.1    瓶颈的概念    15
3.2    确定生产工艺的方法    15
3.3    本论文所用的生产工艺瓶颈分析方法    17
4 某企业齿轮制造过程的生产工艺瓶颈分析与优化    18
4.1    某企业齿轮的生产描述    18
4.1.1    生产设备及加工流程    18
4.1.2    车间问题分析    18
4.2    仿真模型的建立    19
4.2.1    仿真建模的目标    19
4.2.2    仿真建模的数据搜集方法    19
4.2.3    仿真模型的思路    20
4.2.4    仿真模型的数学模型    20
4.2.5仿真建模的构建    21
5仿真结果的输出    25
5.1优化前生产工艺瓶颈分析    25
5.1.1基于关键工序能力的分析    25
5.1.2    基于Bottleneck的瓶颈分析    30
5.2优化后生产工艺瓶颈分析    35
5.2.1基于关键工序能力的分析    36
5.2.2基于Bottleneck的瓶颈分析……………………………………………………….38
    5.3方案评价…………………………………………………………………………………..42
5.4    两种瓶颈分析结果的对比及应用    48
6 总  结    50
致    谢    52

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