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附錄一
英文文獻(xiàn)
橋式起重機模塊化綜述
隨著經(jīng)濟發(fā)展的全球化、市場競爭的日益激烈，許多國的制造業(yè)面臨著巨大的挑戰(zhàn)，制造企業(yè)必須提高復(fù)雜產(chǎn)品及設(shè)備的創(chuàng)新能力和快速響應(yīng)市場的能力，才能在全球競爭的范圍內(nèi)立于不敗之地。本文將以功能分析為基礎(chǔ)，綜述模塊化設(shè)計理論的方法.
1模塊化設(shè)計研究現(xiàn)狀
1.1模塊化設(shè)計的概念 模塊化設(shè)計的設(shè)計理念是在生產(chǎn)部門希望快速響應(yīng)市場，同時降低產(chǎn)品開發(fā)成本，縮短設(shè)計周期的要求下提出的。其基本思想是以有限的模塊組成多樣的產(chǎn)品，達(dá)到既要滿足用戶對產(chǎn)品的個性需求，又保證批量生產(chǎn)從而降低成本的目的。模塊化是一種思想，也是產(chǎn)品設(shè)計和制造的技術(shù)。目前，對模塊化還沒有一個統(tǒng)一的定義，許多學(xué)者根據(jù)各自的研究，從不同的角度對其進(jìn)行了表述: 有人認(rèn)為:模塊化設(shè)計是綜合考慮系統(tǒng)對象，把系統(tǒng)按功能分解成不同用途和性能的模塊，并使之接口標(biāo)準(zhǔn)化，選擇不同的模塊(必要時設(shè)計部分專用模塊)以迅速組成各種要求的系統(tǒng)的一種方法。有人認(rèn)為:模塊化設(shè)計是在對一定范圍內(nèi)的不同功能或相同功能不同性能、不同規(guī)格的產(chǎn)品進(jìn)行功能分析的基礎(chǔ)上，劃分并設(shè)計出一系列功能模塊，通過模塊的選擇和組合可以構(gòu)成不同的產(chǎn)品，以滿足市場不同需求的設(shè)計方法. 有人認(rèn)為，模塊是一組同時具有相同功能和相同結(jié)合要素，而具有不同性能或用途甚至不同結(jié)構(gòu)特征，但能互換的單元，模塊化設(shè)計是基于模塊的思想，將一般產(chǎn)品設(shè)計任務(wù)設(shè)計成模塊化產(chǎn)品方案的設(shè)計方法。它包括兩方面內(nèi)容:一是根據(jù)新設(shè)計要求
進(jìn)行功能分析，合理創(chuàng)建出一組模塊— 即模塊創(chuàng)建;二是根據(jù)設(shè)計要求將一組存在的特定模塊合理組合成模塊化產(chǎn)品方案— 即模塊綜合。它有兩種設(shè)計形式:一是基型設(shè)計，另一是變型設(shè)計。基型設(shè)計明顯包含上述兩方面內(nèi)容，而變型設(shè)計一般只包含第二方面內(nèi)容，但當(dāng)互換模塊不存在時，也須包含第一方面的內(nèi)容。70 年代末，日本學(xué)者提出機床模塊化就是“把具有一定用途和功能的部件結(jié)構(gòu)標(biāo)準(zhǔn)化，使其互相便于組合和拆開。選擇所需要的部件進(jìn)行組裝，即可構(gòu)成一臺能發(fā)揮全部功能的機床或系統(tǒng)?！敝袊粰C部機床設(shè)計工作研究班把機床模塊化設(shè)計定義為:將機
床上同一功能的單元，設(shè)計成具有不同用途或性能的、可以互換選用的模塊，用以更好的滿足用戶需要的一種設(shè)計方法。認(rèn)為模塊化是標(biāo)準(zhǔn)化的高級形式，是一種思維的工具。一般認(rèn)為，截止目前為止，對模塊化這個概念還沒有形成統(tǒng)一的定義隨著研究的進(jìn)一步發(fā)展，人們對其本質(zhì)的認(rèn)識還將進(jìn)一步深化。
2模塊化設(shè)計的研究內(nèi)容
2.1 模塊化設(shè)計實施方法的研究要搞好模塊化設(shè)計，應(yīng)開展五個方面的工作;市場調(diào)查、技術(shù)預(yù)測、品種規(guī)劃、科研先行、功能分析，并探討了模塊化設(shè)計的具體實施中需要注意的一些問題。模塊化設(shè)計要依次按三個層次進(jìn)行，即模塊化產(chǎn)品系統(tǒng)的設(shè)計(系統(tǒng)分析階段);模塊系統(tǒng)設(shè)計(詳細(xì)設(shè)計階段);模塊化產(chǎn)品設(shè)計(系統(tǒng)應(yīng)用階段):模塊選擇、模塊綜合。隨著計算機技術(shù)的發(fā)展，越來越多的人開始研究計算機輔助下的模塊化設(shè)計。
2.2 模 塊 劃分方法的研究 模塊劃分是模塊化設(shè)計的前提和基礎(chǔ)。模塊劃分是否合理，直接影響模塊化系統(tǒng)的功能、性能和成本。綜合當(dāng)前模塊劃分的研究，大致有以下途徑。(1) 系統(tǒng)化的途徑。(2) 綜合考慮全生命周期中模塊化影響的模塊劃分。首先確定全生命周期中模塊化的影響因素，建立模塊識別矩陣在該矩陣中，確定各功能載體對各因素的影響程度，據(jù)此對各功能載體進(jìn)行聚類。(3) 基 于 相關(guān)程度的劃分。通過分析組成產(chǎn)品的各零部件(功能)之間在材料、能量、信息、空間等各方面的相互作用程度，確定模塊的劃分.(4) 技 術(shù)與 經(jīng)濟因素相結(jié)合的模塊劃分。(5) 其它用于模塊劃分的工具。
3.模塊化設(shè)計的技術(shù)經(jīng)濟意義模塊 化 設(shè) 計在技術(shù)上和經(jīng)濟上都具有明顯的優(yōu)點，經(jīng)理論分析和實踐證明，其意義1.節(jié)約設(shè)計時間，縮短供貨周期:采用模塊化設(shè)計方法，企業(yè)產(chǎn)品系列中己有很多通用模塊，在用戶提出要求后，可用已有模塊或設(shè)計制造少量專用模塊便可組成用戶所要求的產(chǎn)品。如德國SCHIESS公司，其機床產(chǎn)品采用模塊化設(shè)計后，從訂貨到供貨一般只需四個月時間。2.便于產(chǎn)品更新?lián)Q代，發(fā)展變型產(chǎn)品:根據(jù)用戶需要，設(shè)計新的功能模塊，組合成具有新功能的模塊系統(tǒng).用新技術(shù)設(shè)計性能好的模塊，取代原有功能模塊，發(fā)展性能好的變型產(chǎn)品。3,提高產(chǎn)品質(zhì)量，降低生產(chǎn)成本:模塊精心設(shè)計，批量加工，有利于組織專業(yè)化生產(chǎn)，既提高質(zhì)量又降低成本。模塊化不僅是設(shè)計方法的改革，而且是推動整個工廠技術(shù)、生產(chǎn)、管理及組織體制的改革。4便于維修:由于產(chǎn)品由相對獨立的模塊組成，因此，很便于維修，必要時可更換模塊，而不致影響生產(chǎn)。5便于實現(xiàn)標(biāo)準(zhǔn)化功能模塊:傳統(tǒng)的標(biāo)準(zhǔn)化建立在零件級基礎(chǔ)上，而模塊化則是根據(jù)產(chǎn)品的不同建立在模塊級上的標(biāo)準(zhǔn)化，是一種趨向于宏觀的標(biāo)準(zhǔn)化。
4模塊化設(shè)計理論在起重機行業(yè)中的應(yīng)用 模塊化設(shè)計是起重機設(shè)計的發(fā)展方向之一。它根據(jù)模塊化原則，設(shè)計一些基本模塊單元，通過不同的組合形成不同的產(chǎn)品，以滿足用戶的多種需求。起重機模塊化設(shè)計以功能分析為基礎(chǔ)，將起重機上同功能的基本單元、復(fù)合單元設(shè)計成不同用途、不同功能
的模塊。選用不同模塊進(jìn)行組合可形成各種不同類型和規(guī)格的通用和專用起重機。起重機采用模塊化設(shè)計，不僅是一種設(shè)計方法的改革，同時會影響到整個起重機行業(yè)的技術(shù)、生產(chǎn)和管理。目前 .德 國、英國、法國、美國和日本的著名起重機公司都己采用模塊化設(shè)計技術(shù)，并取得了顯著的效益。據(jù)資料介紹26]，德國的德馬格(DEMAG)公司所設(shè)計和制造的單梁吊車改為模塊化設(shè)計后，其設(shè)計費用僅為單件設(shè)計時的12%，生產(chǎn)成本降為45%>顯著提高了經(jīng)濟效益和產(chǎn)品的競爭力。芬蘭的拷尼(KONE)公司采用模塊化技術(shù)開發(fā)了SM600-SM110。系列橋式起重機，并編制了相應(yīng)的管理軟件。通過該軟件的應(yīng)用，設(shè)計人員可以在很短的時間內(nèi)設(shè)計出滿足客戶需求的產(chǎn)品。同時，該系列的開發(fā)也大大降低了生產(chǎn)制造和售后服務(wù)成本。如該公司在上海的子公司僅用30人就完成了年產(chǎn)了的臺系列起重機的生產(chǎn)制造任務(wù)。
Summary modular bridge crane
With the economic development of globalization, the increasingly fierce market competition, Many of the country's manufacturing industry is facing significant challenges, manufacturers must increase the complexity of product and equipment innovation and the ability to respond quickly to market to global competition in the framework of an invincible position. In this paper, functional analysis will be based on overview of the theory of modular design method.
1 Modular Design Research
1.1 The concept of modular design Modular design is the design philosophy hope in the production sector to respond quickly to market while lowering product development costs. Shorten the design cycle of the request made. The basic idea of the modules is based on a limited variety of products, To reach users not only to meet the demand for the product's personality, but also to ensure that production and thus reduce costs. Modular is an ideological as well as product design and manufacturing technology.At present, there is not a modular definition of uniform, and many scholars according to their research, from different angles of their statements: Some people think that: a modular system design is considered the object, according to the functions of the system broken down into different uses and performance of the module, and interface standardization, choose a different module (if necessary, the design of part of a dedicated module) to the requirements of the rapid component a method of the system. Some people think that: the modular design is in a range of different functions or different functions the same as the performance of the products with different specifications based on functional analysis, and design into a series of functional modules, through the choice and combination of modules can constitute different products to meet market demand for the design of different methods. Some people think that is a set of modules at the same time with the same combination of features and the same elements, but with different performance or use of different structural characteristics or even, but an exchange of units, modular design is based on the idea of modules, will provide product design tasks designed modular product design method. It includes two aspects: First, under the new design requirements
Functional analysis, and reasonable to create a set of modules - that is, the creation module; two design requirements are based on the existence of a group of rational combination of specific modules into a modular product program - that is, an integrated module. There are two forms of its design: First, design-based, and the other is a variant design. Based design clearly contains the above-mentioned two aspects, and the variant design contains only the second general aspects, but there is no exchange of modules, it must be included in the first dimension. The end of the 70s, the Japanese scholars modular machine is "the purpose and function of a certain structure standardized components to facilitate the combination and open with each other. Select the components required for assembly, can constitute a play all function machine or system. " Ministry of China machine tool design course modular design of the machine tool is defined as: the machine The same function in bed unit, designed with different uses or properties, selection of interchangeable modules to better meet the needs of a design method. That modularity is the advanced form of standardization is a tool for thinking. Is generally believed that, as of now, the concept of modularity has not yet form a unified definition of the study along with further development, it is of its nature will further deepen the understanding.
2 modular design of the study
2.1 the implementation of modular design method
Modular design to do a good job should be done in five areas of work; market research, technology forecasting, planning varieties, research first, functional analysis and modular design of the specific implementation of a number of issues requiring attention. Modular design to be followed by three levels , That is, modular product design (analysis phase); modular system design (detailed design stage); modular product design (application phase): module selection, module integrated. With the development of computer technology, more and more people began to study computer-assisted modular design.
2.2 Method of module division Modular design module is divided into the premise and foundation. Module into the reasonableness of a direct impact on the function of modular systems, performance and cost. Module integrated into the current study, the following way. (1) a systematic way. (2) considering the entire life-cycle impact of the module in the modular division. First of all, the entire life cycle to determine the impact of modular factors, the establishment of the matrix to identify modules in the matrix to determine the vector of the function of the impact of various factors, which function on the cluster vector. (3) based on the relevance of the division. Products by analyzing the composition of the components (function) between the materials, energy, information, space and other aspects of the degree of interaction to determine the division of modules. (4) technical and economic factors into the combination of modules. (5) the division of other tools for the module.
3. The modular design of the techno-economic significance Modular design of the technical and economic advantages are obvious, the theoretical analysis and practice has proved that the significance of 1. Saving design time and shorten the delivery cycle: the use of modular design methodology, enterprise product series has been a lot of common modules , upon request in the user can have a small number of modules or design and manufacture of specialized modules can be composed of the products required by users. SCHIESS companies such as Germany, the modular design of machine tool products from order to delivery only four months in general. 2. To facilitate product replacement, the development of variant products: According to user needs, the design of new functional modules, combined into a new modular system function. With a good performance of the new technical design modules to replace the function modules, the development of the performance of good change products. 3, improve product quality, reduce production costs: carefully designed modules, batch processing, and conducive to the organization of specialized production, both to improve quality and reduce costs. Modular design method is not only reform, but also promote the technology throughout the plant, production, management and organizational structure reform. 4 to facilitate maintenance: As the product by the relatively independent modules, it becomes very easy to repair, if necessary, replace the module, without affecting production. 5 to facilitate the standardization of functional modules: the standardization of traditional class based on the basis of parts, and modular products are based on the different modules based on the level of standardization, is a trend in the standardization of the macro.
4 modular design theory in the crane industry Modular design is the crane, one of the design direction of development. In accordance with the principles of its modular design and include some basic modules, through different combinations to form different products to meet the diverse needs of users. Crane modular design based on functional analysis, the crane on the basic unit of the same functional compound unit designed for different purposes, different functions Module. Selection of different modules can be combined to form different types and specifications of the general and special cranes. Modular design of crane, the design is not only a method of reform, at the same time will affect the entire crane industry, technology, production and management. Present. Germany, Britain, France, the United States and Japan are already well-known crane modular design techniques, and achieved remarkable results. According to information on 26], Demag, Germany (DEMAG) the design and manufacture of the company's single-girder cranes replaced by modular design, its design cost only one-piece design, 12% of the cost of production dropped to 45%> significant Improve the economic efficiency and competitiveness of their products. Nigeria beat Finland (KONE) technology company has developed a modular SM600-SM110. Series of bridge crane, and the preparation of the corresponding management software. Through the application of the software, designers can be in a very short period of time to design products to meet customer needs. At the same time, the development of the series is also greatly reduced the cost of manufacturing and after-sales service. If the company's subsidiary in Shanghai, only 30 completed the annual output of Taiwan's series of crane manufacturing tasks.