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联轴器设计及相关技术研究【说明书+CAD】,联轴器,设计,相关,技术研究,说明书,CAD
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Research and application of the custom-oriented rapid product design platformWANG Zong-yan，CHEN Ying-jie，WU Shu-fang，QIN Hui-bin, LU Chun-yue(College of Mechanical Engineering and Automation，North University of China，Taiyuan 030051)Abstract：In order to achieve rapid product design, under the thinking of the parameter customization and product holographic model sharing driven, we planned the reusable design resources, studied the “products - components - parts features” four levels of resource reuse design methodology, generalized modular product family model and the design of the product variant design technology and rule-based and case-based reasoning matching techniques, achieved the rapid product design of a model-driven, established the platform for adaptive system based on the co-design of client / server / workstation (referred to as C / S / W), built a rapid design platform of the bridge crane for custom, substantially improved the design efficiency and product quality and enhanced the ability of enterprises to respond quickly to market significantly.Key words：mass custom; rapid design; reusable design; co-design; variant design; client / server / workstationCLC: TP391 Document code: A0 IntroductionFoundation item：Project supported by theNational High-Tech.R&D Program，China（No.2005AA415240） and Sci-Tech development Program，Shanxi（No.20090321024）.2Rapid design technology is an integrated product design technology. The current study of the rapid design focuses on product family modeling and planning techniques, modular design, intelligent design, custom network design, configuration design, variant design 1. The strategic priorities of the product rapid custom design are business process reengineering, information resources restructuring and product restructuring. Design reuse through the use of existing design knowledge and experience, making custom officers based on the existing designs to modify the component shape and change the attribute parameter, letting relational product models achieved product structure and information restructuring, finished the product rapid variant design. Meanwhile, within the enterprise or union, using the network-based computer virtual environment established an efficient and stable collaborative model and management model, can improve data sharing and information exchange capabilities. So that designers in different places can around the same design task, completing the subtasks of the design of the corresponding part, do rapid design parallel, interactively, collaboratively and complete the design task together 2. Design reuse and collaboration design emphasize on the way of the designer groups work, play their respective expertise and subjective initiative, make full use of and management of existing design resources, reaching the purpose of reducing product costs, improving product quality, increasing product diversity, and shortening the developing cycle 3. At present, domestic and foreign scholars have done a large number of studies on design reuse and collaborative design 4-6. However, majority of the previous product information is not high enough to be reused in new products, just have some of the more successful applications at parts and components level and the conceptual design stage, not having combined parameterized, modular and systematic design ideas together.The custom-oriented rapid product design process is based on product family reusable design resources, through the configuration and variant of the main structure based on the product, making the products, modules, parts, features, customized and reused. The custom-oriented rapid product design platform established in this paper, through the rational planning of the reusable design resources and the establishment of the generalized modular product family model, designs the rule definition, reasoning and the architecture of the product design workflow, providing custom-oriented product design a good reuse and collaborative environment.2121 Reusable design resource planning1.1 Product family planning and design processThe product family planning is important to build the rapid design of custom-oriented products. Rationalization and reuse of resource planning directly related to the degree of the impact of the new products on the existing manufacturing process, the greater the impact, the higher the cost. Reasonable planning, efficiently combine the functional structure module of the product, thereby reducing the multiple variant design of the product in the subsequent customization process, improving the efficiency of product design. Custom-oriented product family planning process shown in Figure 1.Figure1 Custom-oriented product family planning process(1) Custom-oriented product family design is a parallel design process. From the access to diverse needs of customers to the product market demand segmentation, the segmentation process is the standardization of customer needs process, and a segmentation of the result is a class of customer needs. Customer needs include original information such as user requirements, design conditions etc. Different types of customer needs build up diverse needs products collection, each parallel products collection program design builds up the product design program(2) Since the establishment of the product set, according to the customer needs to determine the total function of each type of product, make the product family modular planned, and then determine the place that design targeted products in the series products, and then on the basis that constitutes a product function hierarchy, based on the degree of the effect that the sub-function on customer demands, finish the division of the total product function and the establishment of the functional model of the product. According to product family “feature - principle - structure” three-view mapping relationship to determine the form of structural units of the sub-function model and divide the product structure and function module, achieving the transformation form the product family functional model to the structural model. (3) On the basis of the structure and function module that having been divided, according to the universal extent of the unit that constitutes the product modules to determine the generic degree and the mutation degree of each structural module, and then divide into generic module and mutation module correspondingly. After the module division, we need to design the module structure in detail. The detailed design of the module is a parallel process. Designers according to the generic properties and mutation properties of the module features in the design process extract and analysis the characteristic parameter, doing the series design and interface design of the product family module. Finally, on the basis of product configuration, according to the selection and combination of different modules, do the product family design and achieve the products of diverse needs as result. The detailed design defines the products and the detailed characteristics of the constituent element from the perspective of the product and its composition and lays the foundation for the reuse of resources.1.2 Multi-level design resource reuse modelProducts rapid custom design pursues the multi-level reuse that includes product layer, component layer, part layer and characteristic layer, helps to reduce the element type of the various levels, improves the speed of product development, and responds quickly to market demand. In order to improve the reuse of design resources, need to record the design knowledge including various design results, decision-making reasoning process and supporting knowledge, and link with the underlying products, components, parts, features. From the resource organization and management and modeling process, the product structure data can be divided into a hierarchy that can dynamically adjusted in accordance with the principle of dynamic granularity, the highest level is the product level, the lowest level is the manufacturing feature level, high-level task containing low-level task, hierarchy form of organization shown in Figure 2. Figure 2 Multi-level design resources reused modelProduct layer: The product family is located in the surface of the product layers, describing the overall information, constitutes information, management information, customized according to customer requirements and inherent design constraints as a condition. It is the final product model that constituted by lower parts module through certain assembly relations. Under the premise of the design principles, when the customer needs and product design constraints there is no conflict, customized products can be used as reusable product.Component layer: The product family also applies to the component layer, belonging to the module family of the product family to describe the overall information, constitutes information and management information of the components, and parts layer is divided according to the structural and functional decomposition. It can be customized through the structure, function, requirements, and design principles. It is an important component module of the product configuration design.Parts layer: Parts family belongs to products family. Parts layer is similar to the component layer, describing characteristics of parts, relationship between the characteristics and the characteristics method etc. It is sub-parts of the component layer and can be achieved through the structure and function decomposition as well. The specific structure of the parts is determined by the SML, constraints, eigenvalue. At the same condition, the structure, function, requirements, and design principles for customization.Characteristic layer: Characteristic layer is located in the bottom of the design resources organizational structure, describing the relationship between the topology information such as points, lines, surfaces etc and sub-features, determined by its structural features and the manufacturing process, and take these as a custom condition.According to the product family design resource structure diagram, through the standardization and serialization in the modular design, establishing the modular product knowledge base, database and management system, you can build the modular system of the product family. So the system established is conducive to product modules improve the product reuse level (Priority in order as follows: product reuse, component reuse, parts reuse, features reuse) in the configuration process. Reuse the product family instances at all levels to a maximum and improve the design and production flexibility and agility greatly, reduce the complexity of the design and manufacturing.2 Relational model of the generalized modular product family Custom-oriented rapid product design is to use the minimum internal diversification to meet the maximum diversification of customer needs and directly expressed as the parts type and quantity of the smallest. Product family design is an effective way to achieve product internal diversification of the smallest, is the optimization program of the product internal complexity and external diversity, and also is the basis of the product configuration design and product variant design. Since the structure and function of the product is a one-to-one mapping relationship, therefore, the structure of the product structure is the process of solving the functional structure. The establishment of generalized modular product family structure model is through the functional analysis of the products, combined with its design, manufacturing, maintenance features, divide and build a more adaptive generalized module and a generalized product platform. On the basis of the products common module and available module through a combination of generalized module or the derivative of the generalized product platform to spread out the design, rely on the parts topology standardization and size parameter to form a new module, build the system of modular product family, so that different modules can be combined configuration and achieve rapid product design. Generalized modular product family design not only can achieve the standard, fixed rigid modular design, but also achieve the flexible module design according to the needs of the users personalized needs. In the generalized modular product family, the module is divided into basic module and optional module, basic module is the basic unit whichconstitutes the product structure, is the module that recurring and must be included, that is mandatory module. Optional module is a module that very special, complementary and must be customized according to customer special requirements. Customers can choose or do not choose this module according to the functional needs. Relational model of the generalized modular product family shown in Figure 3.Figure 3 Relational model of the generalized modular product familyThe generalized modular product family design uses three adjustment methods, namely horizontal adjustment, vertical adjustment and mixed adjustment, shown in Figure 4. Horizontal adjustment is applicable to the modular product design, based on the same interface, through modules add, replace or remove to make up different products. Vertical adjustment is applicable to parametric product design, by changing the range of the manipulated variable to achieve varying degrees of performance and structure instances products in the case of constant parameters unchanged. Mixed adjustment is applicable to adaptive product design, the integrated use of horizontal adjustment and vertical adjustment methods have greater potential economic benefits. Generalized modular product family is to fully exploit these units, under the condition that the product constant parameter unchanged, by the horizontal adjustment and vertical adjustment which can adjust variable, transform the custom product design problem into batch design problem through product restructuring and process restructuring, achieve a variety of products meet customer needs and respond quickly to the changing market demand.Figure 4 Generalized modular product family design3 Key technologies for custom-oriented rapid product design3.1 Rule-based and case-based reasoning matching techniquesTo support the configuration management of a series of products, usually used product standardization and variant design to create a variable structure model, in fact, it contains optional and replacement parts for the main structure of the product family (family master model, PMS) model. PMS describes the composition of a configurable, modular product family, according to customer demand, derived the customized product structure 7, 8. We need to take full account of all the constituent features of the product modules in order to create a configurable product family main structure. Rule-based and case-based level two matching, through the ECA (Event Condition, Action) rules (in the product configuration process to select the set of rules) and the parameters of the instances stored in the SML, choose optional modules in the main structure of the product family, organic combine with other modules to complete the configuration options of the main structure of the product family. Establish an appropriate configuration design rule is the premise that improves the reuse of the configuration design knowledge, maintainability of the knowledge base and search efficiency. ECA rule mainly refers to the constraint relationship of the various constraints compositions of product modules, including the association, generic, alternative mix. Product customization uses the configurable properties of the modular structure, parameters, material properties and other modules to obtain different properties of the product. Case-based reasoning do matching operations through the feature set of customer demand and the variables set of the corresponding main structure of the product family , customers required instance retrieved from the case library, and then it modify the design to complete product configuration. Rule-based reasoning can quickly get the instance of the model, so adopt this method at first, if the level of inference rules are complex, using case-based reasoning, thus borrow the closest instance in the case library. Figure 5 shows the configuration design process for customized products. Configuration and solving process is an iterative process. Products according to the customized depth achieve the configuration design which is full automation or manual interfere semi-automatic, completing the product customization design that meets customer needs.Figure 5 Configuration design process for customized products3.2 Product variant technology based on the hierarchical tabularThe custom-oriented three-dimensional variational design is completed on the basis of Parts master model, using top-down and bottom-up combination of design approach, build product assembly sketch, using the organic combination of the shape characteristics, interactive modeling of parts of the master model and product configuration. Modeling of the parts master model adopts the method of products holographic modeling and hierarchical Tabular combined. Holographic modeling packages the model in the way of geometric models and unstructured information model, fully expresses the product information, controls the assembling sketch using the establish methods, parameter setting, size , relationship constraints and other detail information of each characteristic included, and then control the master model of the flexible module, complete product-level parametric model-driven. Modular variant design is based on modular product instance, according to the user needs to find, match a similar instance. Achieving the modular variant design by replace, modify and create some modules of the similar instance. This is conducive to the sharing and reuse of design resources. In the extraction of design variables, first extract size parameters, characteristics, constraints, and model parameters which are available to drive from a well-defined model as design variables, and then grade the design variables which reflect the main characteristics of the parts, such as into one, two, three, etc, so as to facilitate data query. When store the extracted design variables, deposit them in the appropriate level of SML according to the classification of the design variables. Adopting Hierarchy Tabular method to establish the main model, not only can describe the composition of the assembly components, but also can describe the relationship between the various components. The platform only needs to enter a small amount of data based on customer needs, by changing the relationship of the characteristic parameters between parts in the Hierarchical Tabular, the transmission of information form a module to the next module can be achieved. When the product variants, each layer tabular data is passed to the API functions of the parametric CAD software. The software will automatically derive variant products that customers required. Hierarchical Tabular shown in Figure 6.Figure 6 Hierarchical Tabular4 Implementation and Application of the platform The bridge crane is a product that structure is relatively stable and series parts common parts and similar parts account for a certain percentage. In the actual design process, a variety of structures is not entirely new development, mostly by reference to existing similar design, using knowledge and experience to complete, so adopting parametric variant design based on the master model and the main document. On the basis of the module division, then do the subsequent detailed design, at the same time, in the design process, not only need to consider the needs of the structure, function of the machine and parts, but also consider the performance requirements to ensure the needs of its strength and stiffness. For the project design process, personnel, products, documents, data and other information need effective management, so we need the module management to manage. Based on the above analysis, developed a model bridge crane rapid design platform. The platform on the basis of the integration of 3D graphics software SolidWorks, database management software SQL and intelligent interface development languages Visual Basic and the intelligent CAD system of Solid Works API and the basis of Knowledge Base Management System which consider access and management of the production design knowledge (including the design manual, standard, specification, and expertise, etc) as the core content forms the formation of intelligent CAD system platform. When the user for the detailed design though the interface, it redesign the data stored in the database (but the data structure remains unchanged) in fact. After the user conform these data, and then create a new instance by taking effect on the module within the rules of the model one package.4.1 Architecture of the custom-oriented bridge cranes rapid design platform Architecture of the custom-oriented bridge cranes rapid design platform is shown in Figure 7, including the interface layer, function layer, connector layer and support layer four levels. Figure 7 Architecture of the custom-oriented bridge cranes rapid design platform shown(1) Interface layer: The interface layer is the interface of the user and platform, including user login interface and parameters to customize interface, achieving the function of the user, product informations input and output. Login interface achieves the purpose of user identification and the parameters to customize interface achieves the purpose of the product design. The interface should have nice visibility, integrity, ease of operation and fault tolerance, and other functions.(2) Function layer: The functional layer is the core layer of the platform capabilities, showing the contents of functions, including platform management, knowledge base management and reasoning modules. Platform management includes management of user permissions and registration information. Knowledge management includes the management of the contents of the product case library, design knowledge, product configuration, and design rules. Reasoning module is a reasoning process based on rule and examples. These processes can expand the human-computer interaction between platforms and designers and complete the specific operation of product customization.(3) Connector layer: The connector layer is an effective channel for the various functions of the functional layer, including three-dimensional software API function connector, management software function connector and connection to the database connector. The connector layer can be divided into internal connector and external connector. Module uses an internal connector for parameter passing, function call, and transmits information by returning value. The external connector is the connector that user interacts with menu through the input connector.(4) Support layer: The support layer as the base layer of the platform, other layers must consider support layer as the basis for proper operation to achieve various functions. The support layer is the core of the design resources. It is related to the contents of the product case library, databases, knowledge base, as well as other resources library, its data call is very strictly, and only the personnel who enjoy the privileges can view and take advantage.4.2 Platform workflowCo-design can take people located in different locations to work together for a design task, parallel develop, and complete the task. Parametric model-driven and drawings adjustment need a certain amount of running time, if the number of users is very large, it will make users wait a long time, this will reduce the efficiency, setting several workstations based on this, so that the workstation work in parallel state. The platform on the basis of the traditional C / S (client / workstation), adopts C / S / W (multi-client / single server / workstation) architecture and integrates with the PDM system. The appropriate application includes client programs, server-side programs and workstation programs. They communicate through database as a medium, shown in Figure 8. The client program is used by the general user, it is responsible for the parameter settings and submit. Server-side programs are data management procedures for data processing and maintenance. Workstation runs the model driver programs for model-driven, engineering drawings adjustment and document generation. Different clients take workstation IP to a different setting in the platform initialization login screen, when the client stores the data to the server, the workstation will drive model and adjust engineering drawings correspondingly based on the user-configured IP, this will ensure that multiple workstations to work simultaneously without any interference and improve work efficiency. Meanwhile, the participation of the integration with PDM systems is conducive to the client collaborative design, project and document management. The client design can do the parallel design to the corresponding parts based on the appropriate permissions. The platform is a network design and calculation software, highly automated data exchange between the data processing of the various design aspects and data exchange of design aspects. Individual designer is fragmented, but the design information is a high degree of sharing. The design results can feedback simulation results to the design platform to design changes timely. Product project information, model call information, design parameter information, interface information can achieve different levels of sharing and reuse and designers can be anywhere for product design.As to the new custom contract, administrators first need to create a project to determine the chief designer and designer, and then create the products by the director of designers. Designers set corresponding parts according to the allocation of authority to operate. Client designers under the arrangements of the chief designer to customize the design of the product and they are mainly responsible for the calculation and optimization of design parameters. Designers customize parameters of the product of existing permission. After the server receives the clients service request, the related data should be inquired, added or deleted, modified, calculated, and then the calculate result is passed to the workstation, the workstation is responsible for product model, drawings and documentations generation, and finally turn the running result back to the server. Users download customized products and documents from the server. C / S / W structure model greatly simplifies the work of the client, allowing designers to work on the same project and multi-user collaborative design can be achieved.Figure 8 Client / workstation / server work flow chart4.3 Platform development module(1) Design and calculation moduleDesign and calculation module is the design module mainly based on knowledge and examples. In crane design, customized parameters of a large part is mathematics calculated according to the crane industry standards, and therefore need to design calculation module for data intensive computing. The object of the design calculation module is the main beam, end beams, deputy main beams and other parts in bridge crane. The platform stores design knowledge in the database combining database, and in accordance with order requirements and design knowledge to establish a sound calculation module, completing the design and calculation of the typical components of the bridge crane.(2) Database support moduleBecause product design involves a lot of the design manual, structural specifications, design criteria, empirical data, and inference rules knowledge, we need to build a knowledge base in form of database in order to facilitate access and retrieval. The same time, parameters of the custom need the help of a database to store, so that it is subsequent to call parametric variations and analysis at any time. The database can continue to expand in the process of using to facilitate follow-up design.(3) Management moduleManagement module includes a user management module, a database management module and a project management module. The user management module includes deleting users, creating a new user, modifying user permissions (read, write, delete) three modules. The database management module includes the creation of new data, data maintenance and inquiry. The project management module includes product version management, lifecycle management, personnel management three modules.(4) Checking moduleChecking module is parameterized finite element analysis module, using the finite element analysis tools to complete the analysis and evaluation of the structure of the bridge crane parts. After the product parametric variant design, in order to ensure product safety, its stiffness and strength need to be checked. If the check result does not meet the design requirements, we need to combine the design calculation module, correct the main model parameters to determine again, and then drive, check again, until the design products meet safety and customer demand. In checking process, on the basis of design objects and custom parameters, using Parametric Design Language APDL (Ansys Parametric Design Language) in the ANSYS analysis environment, establish a simplified finite element model of the structure and do the solving and post-processing to achieve the parameters finite element analysis of the whole process.(5) Model and document generation moduleModel generation module is a driver module of the Product three-dimensional parametric variant. The documentation includes a variety of documents which record parameter information of customized products, users personal information and platform information. The product information is the qualitative response to product structure and quality, is essential to the user, including the report of the various parameters, finite element analysis. Users personal information and platform usage information are used to ensure platform security required, including a variety of historical records and log reports. These documents use the document generation module to generate.(6) Drawings adjustment moduleBridge crane-related drawings with their corresponding model are a one-to-one mapping. Platform models and drawings are in a two-way drive. After variant of model parameters, the proportion, view, comment of the newly generated drawing sheet is unreasonable and can not be used to product. Therefore, drawings adjustment module is needed to adjust.Product customization includes customization of bridge cranes performance parameters (span, weight, working-level, etc.), custom product attribute information (color, number, etc.), detailed customization of the pr
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