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拖拉机
变速箱
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全部
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拖拉机变速箱的设计(全部结清）,拖拉机,变速箱,设计,全部,结清
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先进制造技术在拖拉机变速箱制造中的应用 北京航空工艺研究所刘新亚 陆广 译摘要介绍了并行工程、敏捷制造及精良生产等先进制造技术的特点及在拖拉机变速箱研制中的应用,提出了如何深化和推广这一应用的具体措施。关键词：拖拉机变速箱、并行工程、敏捷制造、精良生产在机床工业中,随着社会对产品要求的不断提高,随着市场竞争的不断加剧,满足用户要求,包括提高产品质量、缩短生产周期、降低成本、改进售后服务已成为赢得市场的突破口。为了达到赢得市场这一目的,应当引入现代先进制造技术:并行工程、敏捷制造及精良生产,以促进拖拉机变速箱的发展。1并行工程并行工程又称为同步工程,是集成、并行地优化设计产品及其各种相关过程(包括制造及支持)的系统方法,这种方法引导产品开发人员一开始就考虑到产品从概念设计到消亡的整个生命周期中的所有因素,包括质量、成本、进度计划和用户需求等。并行工程最早是作为缩短产品开发周期的一种手段而发展起来的。其特征是将产品的开发、生产中涉及的各种工程行为分解成一系列子任务,如市场分析、设计、工艺设计、生产计划和器材外购、加工、质量保证、检测及售后服务等。这些子任务尽可能并行同步统筹考虑,以达到改进设计、缩短周期、提高质量、降低成本、优化设计的目的。它强调集成、协调和并行,即:(1)将管理、设计、生产、服务等所有与项目有关的人员及产品信息集成为一个整体,强调各相关部门总体目标及利益的一致;(2)采取设置一个称职的项目负责人和有合理人才结构的协同工作小组的管理模式,由工作组负责项目中各部分子任务的协调及推进;(3)并行处理各阶段的工作。根据项目中不同任务之间关联性的不同,各部分子任务的工作过程可以部分重叠或完全重叠。根据这些原则,制定一个合理、优化的工作计划,并在其中必要的位置设置考核点,由项目工作组具体落实,使各子任务并行、有序地向前推进,以保证整个项目的顺利实施。11并行工程与传统工作方式的比较按传统的工作方式,各阶段的工作是连续串行的。在这种产品开发方式中,各阶段相互脱节,互不关联,导致设计错误增多,且难及时发现,这样造成设计返工多,使开发周期拉长,成本增加。采用并行工作方式后,将各项工作过程集成起来并行考虑,各项工作可重叠进行。有问题时可以及时协调更改,以免因遗留到后续阶段而增加改正的难度及费用。因此,采用并行工程可明显缩短产品开发周期,降低成本,很适合拖拉机变速箱专业的发展。12应用实例将并行工程的方法应用于产品开发中,效果非常显著。1997年3月,北京航空工艺研究所与某摩托车厂签定了设计制造6台曲柄加工机床的合同项目,要求年 底交货,且机床的要求与以往有较大差别。在该项目中采用了并行工程的方法,平行、交叉作业,大大缩短了设计、制造工期,圆满地完成了任务。拖拉机变速箱并行开发的具体做法是:(1)设立一个由多专业人员组成的开发研制工作组。由工作组具体实施项目的各部分工作，工作组成员分工协作,各负其责,及时协调,从而实现优化的设计。如机床的一种夹具要求在夹紧过程中零件能够浮动,如果单独从机械结构方面考虑,满足这一要求比较困难,夹具的结构也复杂。后来通过与电器控制及液压设计人员协调,提出了修正控制程序、改变夹紧动作次序、调整液压压力的解决方案,满足了夹紧的要求。(2)在制定工艺方案、签定合同阶段,就初步确定了一些标准部件。(3)多次多级方案评审。在确定机床总体工艺方案、关键部件总体设计过程中,由技术委员会多次对设计方案进行评审,并且在投入生产前还要经过用户对设计方案会审。这样,就达到从设计一开始就考虑到工艺设计、工装设计、加工制造、装配调试等下游各阶段可能出现的问题,从而大大减少了设计额定更改次数,满足了用户要求,使设计方案达到最佳。(4)采用设计预发布的方法。在正式机床总体图出图以前,分阶段公布已确定的各部件主要结构及主要数据,使工艺设计、工装设计能提前进行。在机床总体设计的同时,确定出一些部件如夹具、刀具等的协调尺寸,并同时开始设计夹具和刀具,另外,还同时确定滑台、移动工作台等部件,这些部件尽可能选择已有的标准部件,在总体设计未完成时就将其投产。在设计中总体与各部件如夹具、刀具之间及时协调,有关联的尺寸改动时互相及时协调,使其他相关图纸的尺寸得到及时改正。(5)部件设计中可以将加工周期长的零件如夹具体等铸件尽早定型,提前进行工艺设计,投入生产。(6)各部件一完成设计,就随时进入工艺设计及生产阶段。所以各部件中的零件也是在车间并行加工的。采用这一方式,工作组4人只用了4周的时间就在将部分通用部件如滑台、移动工作台和动力头等投产的同时,完成了机床的机械设计及外购件订货。机床的生产过程中,各个部件在北京航空工艺研究所和几个外协厂家同时进行。在机床的安装和调试时,也是几台机床同时进行,通过这些工作,为机床的按时交付争取了宝贵的时间。2 敏捷制造敏捷制造是美国里海大学在“21世纪制造业战略”的报告中提出的一种全新的制造模式。经过发展,美国lacocca研究所将其定义为:“敏捷是指一个公司在连续的不可预测市场变化的竞争环境中发展和繁荣起来的一种能力,即对迅速变化的全球市场的快速响应能力,是公司用计算机网络与全球生产系统、市场、竞争者连接起来,在高质量、高性能、低成本、顾客设定产品配置等用户需求驱动的市场形势下所表现出的一种能力”。其特征是把柔性生产技术、灵活的组织管理和掌握专业技能的人员集成为一个协调、互相关联的系统,同时为了实现统一的战略目标,把同一行业的不同企业通过共同的基础结构连结起来,将过去你死我活的竞争变为友好合作的竞争,从而对瞬息万变的市场作出快捷的响应。因此,这种技术很适合拖拉机变速箱专业的发展。(1)敏捷首先是推进产品的模块化,反映在拖拉机变速箱中就是推行机床功能部件的标准化和系列化。在曲轴加工机床的开发与设计中,能大大缩短设计周期,并行工程的应用是一个因素,大量标准部件、通用部件的应用也是一个关键因素。(2)在敏捷制造中,必须体现人和组织都是最宝贵的财富。在大批量的生产中,人们总是把技术当作解决制造和销售问题的关键,而在敏捷制造中,以最佳方式利用人则是解决问题的关键,技术仅是方法或手段。因此,需要推行项目工作组的组织模式,提倡爱岗敬业精神,充分发挥员工的主观能动性。3精良生产精良生产是90年代美国在总结日本丰田汽车公司生产管理方式的基础上总结出来的生产方式。它强调通过改进企业在生产中的包括管理等各项活动的效率,并对各种活动进行成本核算,以达到以最快的市场响应速度、最低的生产成本、最优的产品设计来设计和制造市场所需要的产品。其特征是以用户为上帝,以人为中心,以精简为手段,以零缺陷为目标。4 深化及推广先进制造技术的应用从以上分析可看出,先进制造技术在北京航空工艺研究所的拖拉机变速箱的研制中已得到了一些应用,但仍需进一步深化和推广这一应用。在以后的工作中,应注意以下几个方面:(1)进一步推行项目工作组的模式,实行责任到人,由该小组用并行工程的方式负责完成机床从技术方案到设计、制造、调试和交付的工作;同时加强员工的知识与技能培训,随时跟踪国内外拖拉机变速箱行业的最新进展。(2)研究市场的变化,制定预研计划;同时保持与用户的密切联系,对用户定期回访,为用户提供优质的售后服务,并了解设备运行情况及用户需求,以便改进设计。(3)以优质的产品赢得用户。在拖拉机变速箱的开发中,除了增强质量意识外,新技术、新工艺的应用也是占领市场的一个重要手段。现在用户普遍要求机床提高效率、增加柔性,并适应小批量、多品种的加工。要提高拖拉机变速箱的生产效率,在设计中应从提高切削速度、采用先进刀具、集中加工工序3个方面进行考虑。(4)重视开发产品的可重构性,实现机床结构的模块化。在设计中,可采用成组技术,推进拖拉机变速箱通用功能模块的开发应用,也可采用数控柔性坐标单元的模式。(5)推行敏捷制造技术的应用,建立有效的虚拟联盟的动态合作形式。进一步加强与外购件生产厂及外协厂的合作。充分利用社会上已有的技术、信息及人员设备等资源,实行强强联合,优势互补,利用虚拟公司的模式扩大我们的生产能力。(6)在拖拉机变速箱的设计与生产中进一步推广计算机及信息、网络技术的应用。推进CAD技术的应用,实现无图设计,进而建立CAD/CAM/CAPP集成工程设计的环境。(7)进一步加强技术合作与交流,提高我所拖拉机变速箱在行业内的地位及知名度,同时积极发掘新的市场及用户。应努力开拓国际市场,如向日本丰田汽车制造公司出口用于汽车发动机机体的深孔加工的立式数控双轴深孔钻床,为我所的拖拉机变速箱进入国际市场开了一个好头。Application of Advanced Manufacturing Technology in Modular Machine Tool Beijing Institute of Aviation Technology Liu xin YaAbstract introduced a concurrent engineering, agile manufacturing and sophisticated production, and other advanced manufacturing technology and the characteristics of the development of machine tools in the portfolio of applications, how to deepen and extend the application of specific measures.Keywords：Modular machine tool、Concurrent Engineering、Agile Manufacturing、Sophisticated productionIn the machine tool industry, with the social demands of the continuous improvement of products, along with the growing competition in the market to meet user requirements, including the improvement of product quality, shorten production cycles, reduce costs, improve service and win market has become a breakthrough. In order to achieve this goal and win market, it should be the introduction of modern and advanced manufacturing technology: concurrent engineering, agile manufacturing and sophisticated production, in order to promote the development of combination machine.1 Concurrent EngineeringConcurrent Engineering is also known as concurrent engineering, integrated, parallel to optimize product design and its related processes (including manufacturing and support) system approach, which guide the product development staff began to consider a product from concept to design to the demise of throughout the life cycle of all the factors, including quality, cost, programming and user needs.Concurrent Engineering is the first to shorten product development cycles as a means to develop. Products will be characterized by the development, production engineering involved in the acts broken down into a series of tasks, such as market analysis, design, process design, production plans and equipment purchases, processing, quality assurance, testing and after sales service. These sub-tasks as far as possible and consider synchronous parallel to achieve improved design to shorten the cycle and improve quality, reduce costs, optimize the design purpose. It stressed that integrated, coordinated and parallel, namely: (1) management, design, production, and service of all project-related personnel and product information integration as a whole, and stressed that all relevant departments and the interests of the overall goal line (2) to the establishment of a competent and reasonable charge of the project personnel structure of the working group coordinated management model, by the Working Group in the ministries responsible for project elements, and the promotion of the coordination of tasks, (3) parallel processing stages of the work. According to the project in the different tasks of the linkages between the different ministries mandate of the elements of the work process can be completely overlap or duplication. In accordance with these principles, formulate a reasonable, and optimize the work plan, and the location in which the necessary settings assessment, the Working Group by the project implementation so that all sub-tasks in parallel, to move forward in an orderly manner, so as to ensure the smooth implementation of the whole project .1.1 concurrent engineering work with the traditional way of comparisonAccording to the traditional methods of work, the work of the various stages in a row serial. In such a product development approach, divorced from each other at various stages, are not related, resulting in increased design error, and difficult to discover such a design rework, to lengthen the development cycle, adding to the costs.Parallel working methods used, the process will be integrated with parallel consideration, the work can be carried out duplication. Problems can be promptly coordinate the changes so that the follow-up stage left to increase the difficulty of correction And costs. Thus, the application of concurrent engineering can significantly shorten the product development cycle, reduce costs, it is suitable for the development of professional portfolio machine.1.2 ApplicationsConcurrent engineering methods will be applied to product development, the effect was very significant. March 1997, Beijing Institute of Aviation Technology with a motorcycle design and manufacturing plants to sign the 6-crank machine project contract for delivery end of the year, and the requirements of machine tools in the past quite different. In the project using a concurrent engineering approach, in parallel, cross-operation , greatly reducing the design, manufacture period, the successful completion of the tasks.Parallel development of the combination of machine specific methods are:(1) the establishment of a multi-composed of professionals to develop working groups. By the Working Group of the specific part of the implementation of the project, members of the Working Group in collaboration division of duties, timely and coordinated in order to achieve optimization of the design. Such as a machine tool demand in the clamping fixture parts to the process of floating, if separate consideration from the mechanical structure to meet this requirement more difficult, complex structure of the fixture. Later, with the hydraulic design of electrical control and coordinate, control procedures proposed amendments to change the order clamping action, adjusting the hydraulic pressure of solutions to meet the requirements of the clamping.(2) in the formulation of programmes, the signing of the contract stage, on the preliminary identified a number of standard components.(3) Multiple Multi-accreditation programme. Machine Tool Technology in determining the overall programme, key components in the overall design process, many times by the technical committee to review the design plan, and put into production before the user in the design plan joint trials. Thus, from the design to take into account the beginning of a process design, tooling design, manufacturing, assembly and other downstream various stages of debugging problems that may arise, thus greatly reducing the number of design changes Rated meet user requirements, to achieve design best.(4) a design pre-release method. Machine overall plans in a formal drawing ago, has been released in stages set by the main structure and the major components of data, process design, tooling design can be carried out ahead of schedule. In the design of the machine tool to determine some components such as fixtures, tools such as the coordination of size, and at the same time began to design and tool fixture, and, also identified slider, mobile workstations and other components, these components have the choice as far as possible Standard components, in the design of its operation will be completed. And the overall design of the various components such as fixtures, and timely coordination between the tool, linked to changes in the size of each other timely coordination so that the size of other relevant drawings are promptly corrected.(5) components in the design of the processing cycle can be long specific parts such as folders, such as casting stereotypes as soon as possible to advancing the process design, production.(6) completion of the various components of a design, process design and ready to enter the production stage. Therefore, the various components of the parts is in the workshop, parallel processing.Adopt this approach, the Working Group 4 were used only four weeks time on the part of generic components such as the slider, mobile platforms and power first went into operation at the same time, the completion of the mechanical design of the machine and outsourcing of orders. Machine tool production process, the various components in the Beijing Institute of Aviation Technology Association, and several manufacturers at the same time. In the machine, installation and debugging, but also several machine at the same time, through these work, and machine tools for the timely delivery of valuable time.2 Agile ManufacturingAgile manufacturing in the United States of the Caspian Sea, the 21st century manufacturing strategy in the report of a new manufacturing paradigm. After development, the United States lacocca Institute will be defined as: a company that is agile in the market for the unpredictable changes in the competitive environment in the development and prosperity of a capability, that is rapidly changing global market a rapid response capability, with the company computer network and the global production system, the market, competitors to link up in the high-quality, high-performance, low-cost, customer product configuration settings, such as user demand-driven market situation demonstrated a capability. Characterized by the flexible production technology, flexible organization management and professional skills of the staff have integrated into a coordinated, interconnected systems, in order to achieve the strategic goal of reunification, the same industry in different enterprises through joint infrastructure links, past life-and-death competition will become friendly and cooperative competition, thereby changing market faster response. Therefore, this technology is suitable for the development of professional portfolio machine.(1) promote the Agile first modular products, reflected in the composition of the machine is in the machine tool components and the standardization of serialization. Crankshaft Machine Tool in the development and design, can greatly shorten the design cycle, the application of concurrent engineering is a factor, large number of standard components, the application of common components is a key element.(2) In the Agile Manufacturing, must reflect the people and organizations is the most valuable asset. In the production of large quantities, people are always technical solution as manufacture and sale of the crux of the problem, and in Agile Manufacturing, the best use of people is the key to solve the problem, technology is only a method or means. Therefore, the need for the Project Working Group organizational model advocated hard working, give full play to their initiative.3 Sophisticated productionSophisticated production is the United States in the 1990s, Japans Toyota Motor Corporation summed up production management methods on the basis of summing up by the production. It stressed that by improving the production of enterprises in the management of the activities, including the efficiency of various activities and cost accounting, to achieve the fastest speed of response to the market, the lowest cost of production, the optimal product design to design and Manufacturing of products needed by the market. Its features are user-God, a people-centred, as a means to streamline, to zero defect goal.4 deepen and promote the application of advanced manufacturing technologyCan be seen from the above analysis, and advanced manufacturing technology in the Beijing Institute of Aviation Technology Portfolio machine has been developed in a number of applications, but still need to further deepen and extend the application. In later work, Should pay attention to the following aspects:(1) Working Group on the further implementation of the project model, a responsibility to the people, by the use of concurrent engineering group responsible for the completion of the way from the machine tool technology programme to design, manufacture, testing and delivery of the work of the staff at the same time strengthen the knowledge and skills training, keep track machine tool industry at home and abroad combination of the latest developments.(2) market changes and the development of pre-study plan at the same time maintain close ties with users, users who regularly visit provides its users with quality after-sales service, and equipment operation and understanding of user needs, in order to improve the design.(3) high-quality products to win customers. Machine Tool in the development portfolio, in addition to enhancing the sense of quality, the new technology, the application of new technology in the market is also an important means. Now users generally require machine efficiency, flexibility, and adapt to
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