CN111144829A - Weak-standardization cloud collaborative manufacturing method - Google Patents
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Abstract
The invention discloses a weak-standardization cloud collaborative manufacturing method which weakens qualified standards through a detection and evaluation technology, identifies or grades parts based on detection and evaluation results, stores the detection and evaluation results in a cloud server, identifies when in use, optimizes a matching set based on the detection and evaluation results for assembly, and finally realizes the production of parts with the best quality. The cloud collaborative manufacturing method can be integrated with technologies such as a cloud detection technology, big data, cloud computing, automatic sorting and intelligent vertical warehouse, so that the qualified standard can be weakened at lower cost, the requirements on part manufacturing equipment, personnel, processes and the like are greatly reduced, the rejection rate of parts is greatly reduced, and the quality and the stability of parts are greatly improved; and moreover, a tracing system in the monitoring and circulation processes of the product manufacturing process can be strengthened, and the viscosity between the upstream and the downstream of a product production supply chain is improved.
Description
Technical Field
The invention relates to a weak standardized cloud collaborative manufacturing method of workpieces with assembly relations.
Background
Standardized manufacturing is a necessary condition for modern mass production, and standardization promotes mutual coordination and coordination in the production process of related products. Particularly the production of complex products, often involves many enterprises or departments, with collaboration points being spread around the world. Standardization allows the manufacture of complex products to be performed in a systematic manner. The standardized manufacturing greatly reduces the cost of mass production and improves the production efficiency.
With the improvement of the quality requirements of people, the requirements of manufacturing standards for manufacturing parts in batches are higher and higher, and enterprises mainly achieve the improvement of the quality of products by strengthening (i.e. strongly standardizing) the manufacturing standards of the parts. The strong standardized manufacturing models result in ever increasing demands on manufacturing equipment, personnel, processes, etc., and increasing relative costs. The strongly standardized manufacturing model is embodied in the field of mechanical manufacturing as the manufacturing tolerances of the components are getting smaller and smaller.
In the mechanical manufacturing process, the error of product manufacture is related to the service life and efficiency of the product, and is directly related to the difficulty and cost of product production. With the development of high-end manufacturing industry, the product matching is tighter and tighter, the size tolerance band is narrower and narrower, in order to meet the requirements of consistency and interchangeability of products, manufacturers are forced to adopt production and processing equipment with higher precision, and the requirements on skills of processing personnel are also higher and higher.
Disclosure of Invention
The invention aims to solve the technical problems that in the prior art, the precision requirement on workpieces with an assembly relation is higher and higher, the size tolerance band is narrower and narrower, and the manufacturing cost and the manufacturing difficulty are greatly increased in order to meet the requirements on the consistency and the interchangeability of products, and provide a weak-standardization cloud collaborative manufacturing method for the workpieces with the assembly relation.
In order to solve the technical problems, the invention provides the following technical scheme:
a weak-standardization cloud collaborative manufacturing method weakens qualified standards of parts through detection technology, marks or grades the parts based on detection results, identifies and preferentially assembles matching parts during use, and finally achieves production of parts with optimal quality.
The method specifically comprises the following steps:
1) identifying workpieces produced according to the standard, measuring the matched size of the workpieces, uploading the measurement result to a cloud platform, and classifying products according to the measurement result;
2) matching information of a workpiece matched with the manufacturing error of the cloud platform from the cloud platform by scanning the product identification;
3) and selecting and assembling matched products based on manufacturing errors.
Further, the identification is a code of a two-dimensional code or other accessible cloud server database for inquiring product information.
Further, the products are classified and packaged according to the manufacturing error of the matched size. When in packaging, products with similar errors are packaged together or obvious identification symbols (such as colors, grades, numbers and the like) are arranged on the package according to manufacturing errors, so that the user can conveniently select and assemble the products.
When the product A and the product B have an assembly relation, after the product A and the product B are manufactured by the same manufacturer or different manufacturers, the assembly sizes of all the produced products A and B are measured, unique identifiers are set on all the products, measured assembly size data are uploaded to a data cloud platform, a recognition classification system accesses the data cloud platform through accessing the unique identifiers to obtain the manufacturing error of the assembly size of a specific product, the data cloud platform provides a suggestion of the product category which is best matched with the user based on the product manufacturing error, and the user can conveniently select the product B which is best matched with the product A after adopting the product A.
The "weak-Standardization manufacturing" (also called "limited-Standardization manufacturing") refers to an innovative manufacturing mode for "weakening" the requirement on manufacturing qualified standards in the manufacturing process by technical means, thereby reducing the manufacturing cost, reducing the waste and improving the product quality. The narrow "weak standardization" concept refers to its application in the machine manufacturing industry.
As is well known in the mechanical manufacturing industry, the manufacturing of parts (such as shafts and sleeves) with matching relationship is based on the production principle of interchangeability to control the manufacturing dimensional deviation of the parts within a certain range (i.e. the dimensional tolerance of the parts), so as to control the formed matching error of the parts after assembly to be always within a reasonable range (i.e. the matching tolerance of the assembly body) meeting the use requirement of the assembly body. Under the form of mass production organization, a standardized production mode is widely adopted at present, namely, standardized means are used for unifying the processing requirements, the process, the operation method and the like of product production and implementing effective control. This prior standardized manufacturing model utilizes standardized means to control the machining dimensional deviation of the parts to achieve that the fitting error of the assembly is always within the allowable fitting tolerance range, i.e. in short, the process elements are controlled to obtain acceptable results. The 'weak standardization' idea provided by the invention is to realize substantial reduction of the standard tolerance grade of part processing by means of 'partition control + optimization matching' based on result guidance on the standard tolerance of process elements, thereby effectively reducing the manufacturing cost of part processing on the premise of not reducing the matching precision of an assembly body and greatly reducing the rejection rate of part processing.
Weak normalization is different from personalized or non-nominal. In non-standard manufacturing situations, each product may be different, such as personalized manufacturing of garments. The weakly standardized manufacturing weakens the mandatory requirements for acceptable standards (the tolerance level is enlarged) on the premise of complying with the standards, so that the parts which are not qualified under the strict standards and are processed in an out-of-tolerance way can be assembled into acceptable parts.
The main techniques involved in weakly standardized manufacturing include: (1) industrial identification technology; (2) a detection technique; (3) automatic matching and sorting technology (cloud measurement, industrial big data, intelligent vertical warehouse and the like). The basis of weak standardization is that in the standardized manufacturing process, each workpiece is identified, the matched size of each workpiece is measured, the measurement result is uploaded to a cloud platform, and products are classified (stored or packaged) according to the measurement result; before the workpiece is used, the matching size of the workpiece is obtained from the cloud platform through scanning the product identification, the optimal matched product is found through calculation, and information such as the type and subclass of the matched product is suggested. And the optimally matched products are automatically and accurately provided to an assembly station according to requirements through information sharing, in-plant logistics, intelligent vertical warehouse and the like, so that the assembly of perfectly matched workpieces is completed.
The industrial identification technology such as laser marking is used for marking a two-dimensional code on a metal workpiece, and the two-dimensional code comprises an internet address for accessing a cloud platform and a unique code of the workpiece. By scanning the two-dimensional code, a user can log in the cloud platform to obtain relevant information of the workpiece, including but not limited to part numbers, manufacturers, workshops, batches, production managers, matching sizes (or shape detection data), belonging categories, suggested matching models and categories and the like. The workpieces (products) needing to be packaged can be additionally provided with color marks and the like, so that the different categories of the workpieces can be conveniently and visually identified by a user.
The detection technology is the core of weak standardization, and the classification of the error grade of the fit size of the part is completed through detection. Since the tolerances of high standards are usually relatively small, the requirements for the detection accuracy must be at least one third to one fifth of the tolerances. For example, to achieve weakly standardized manufacture, the shaft machining tolerance is scaled up to (+/-0.05mm) or (0 to 0.10mm) and the tolerance band is divided into 5 equal parts, each 0.02mm, and to accurately measure the 0.02mm tolerance band, the measurement accuracy needs to be 0.006mm or 0.004 mm!
In addition, the automatic matching and sorting technology of the workpieces comprises related technologies such as cloud measurement, industrial big data, an intelligent vertical library and the like. Cloud measurement is helpful for data evaluation of products manufactured in different places, as in the previous example, the shaft and the sleeve are manufactured in different factories and workshops respectively, measurement result evaluation, matching and the like are completed at the cloud end after local measurement, collaborative manufacturing is achieved, and waste is reduced. The industrial big data can be used for knowing the production or circulation condition of the product based on the measurement data and other production history data of the cloud database, and providing support for enterprise production, process improvement, logistics and the like. The intelligent vertical warehouse can automatically and timely and accurately deliver the sorted parts to the designated positions, and automatic assembly is realized.
The weak standardization can be embodied in different industries, and the weak standardization of mechanical part manufacturing is realized through automatic identification, size detection, cloud platform, automatic sorting and the like. And weak standardized manufacturing, namely weakening qualified standards (such as widening of dimensional tolerance of mechanical manufacturing) through detection technology, identifying or classifying (grading) parts based on detection results, identifying and preferably assembling matched parts when in use, and finally realizing the production of parts with optimal quality. The weak standardization manufacturing mode solves the problem of assembly optimization between workpieces with simple matching sizes, and the main application field of the method is cloud collaborative manufacturing of mechanical parts with single or less matching sizes, such as bearings and bearing seats, turbine shafts and turbine discs, hydraulic transmission parts, precision guide rails and sliding blocks and the like. For the case of many matching parameters, best-fit (best-fit) matching can be performed based on the weights of the matching parameters to obtain a preferred matching object.
The generalized weak standardization concept can be extended to a wider field. Such as: the final inspection of tire production determines whether the tire is qualified, the standard of the judgment is a quantitative index, for example, the comprehensive score is 0 to 100, more than 70 is qualified products, less than 70 is unqualified products, the unqualified products need to be repaired or scrapped, and the qualified products are sold according to a uniform price. That is, in the (strong) standardized mode, the product is only "unqualified" or "qualified", the unqualified product can be only discarded or repaired, and the qualified product can be only sold on the market at a uniform price, such as 500 yuan. Under the weak standardization concept, the product detection is comprehensively graded from 0 to 100, the product grade below 50 is listed as a rejected product which must be discarded, the product grade of 50 to 60 is 'standard-2', the product grade of 60 to 70 is 'standard-1', the product grade of 70 to 80 is 'standard', the product grade of 80 to 90 is 'standard + 1', and the product grade above 90 is 'standard + 2'. Products of "standard" grade, sold at the original price of good, such as 500 dollars per strip (50000 kilometers warranted); the original unqualified variety can sell each 400 yuan (guarantee 40000 km) in a better standard-1 grade and each 300 yuan (guarantee 30000 km) in a standard-2 grade; products of "standard" grade can still sell 500 yuan each (50000 km warranted); and a rating above "Standard" such as a rating of "Standard + 1" can sell each 600 Yuan (guarantee 60000 km), and a rating of "Standard + 2" can sell each 700 Yuan (guarantee 70000 km). Therefore, finished products of the products are graded and sold through quality detection, a single standard type product is divided into a plurality of subclasses (grades), guaranteed mileage, graded pricing and selling and the like are provided according to actual product quality grading, products which are slightly worse than standard qualified products are reasonably utilized to generate benefits, resource waste is reduced, and enterprise benefits are improved.
Another "generalized weakly normalized" case (for the purposes of illustrating the "weakly normalized" concept, the data was not rigorously quantified): the design standard of a certain highway bridge is '80 km/h per hour and 50 years of service life'; if the traffic speed per hour is increased to 100 km/h, the service life is reduced to about 40 years. After the bridge is opened and operated, because speed measuring radars are arranged at a plurality of positions on the bridge, drivers need to decelerate from 100 kilometers per hour to 80 kilometers per hour before passing the bridge every time, so that the bridge is seriously congested, the bridge is full of large cars which stop and go, and the actual passing speed is far less than 80 kilometers per hour (the dynamic and static loads borne by the bridge are much higher than expected). After relevant departments adjust the traffic speed to 100 kilometers per hour, the bridge basically does not block the traffic, the traffic quality is improved, the actual dynamic and static loads of the bridge are greatly reduced, and the traffic effect and the service life are better than those of the original design standard. By weakening the original standard in use, unexpected effects are achieved.
The invention has the following beneficial effects: the invention realizes perfect matching between the product A with the manufacturing error D and the product B with the reverse error (-D) by measuring the matching size error of each product and then classifying and matching, realizes cloud-based cooperative manufacturing, greatly reduces the requirement of matched products on the manufacturing precision of the matching size, reduces the qualified standard of the product size by the processes of hundred percent product measurement, cloud storage, identification and matching, and greatly reduces the manufacturing cost and difficulty without influencing the use. Through measurement, strict consistency and interchangeability in machining are changed into matching completion in a data cloud platform, so that weak standardization is realized, and the requirement on workpiece manufacturing precision is greatly reduced.
The direct benefits of a weakly standardized manufacturing model are: (1) the requirements on the manufacturing equipment, personnel, process and the like of the parts are greatly reduced; (2) the rejection rate of parts is greatly reduced; (3) the quality and the stability of the parts are greatly improved; (4) a tracing system in the monitoring and circulation process of the product manufacturing process is strengthened; (5) the viscosity between the upstream and downstream of the product production supply chain is improved.
Detailed Description
The following description of the preferred embodiments of the present invention is provided for the purpose of illustration and description, and is in no way intended to limit the invention.
Examples
The bearing seat belongs to typical traditional mechanical products, and the bearing seat needs to be produced according to the fit tolerance provided by a bearing manufacturer in the production process, so that the sleeve for mounting the bearing on the bearing seat is ensured to be well matched with the outer ring size of the bearing. Along with the improvement of the requirements of users on transmission efficiency and product service life, the manufacturing tolerance band of the matching size of the bearing sleeve becomes smaller and smaller, and the requirements of production and processing equipment and workers are greatly improved. The cloud coordination method of the workpieces with the assembly relation is adopted to guide the production and assembly of the bearing seat and the bearing. A bearing seat manufacturer measures, classifies and identifies the fit size of a bearing seat (the fit size of the bearing seat and a bearing) by adopting an automatic measuring system, so that each bearing seat has a unique identification code (such as a two-dimensional code), and the actual measurement data of the fit size of the bearing seat and the fit size or category information of a suggested matched bearing are stored in a data cloud platform. Similarly, bearing manufacturing enterprises measure the sizes of the bearings matched with the bearing seats completely and upload the sizes to a data cloud platform, and matched suppliers can share the cloud platform and complete the optimal matching of the bearing seats and the bearings on the cloud platform. In addition, the bearing seat can be packaged according to the manufacturing error value, such as the color, the sub-number, the measured value and the like of the packaging box to distinguish the manufacturing error. By scanning the unique identification code, a user can access the data cloud platform to obtain the measured value of the matching size of the bearing seat sleeve and the bearing matching outer diameter size which is optimally matched with the bearing seat, and automatic product identification and matching are achieved.
According to the invention, by a cloud cooperation method, the internal viscosity of the supply chain is enhanced by measuring the processing size of the product by hundreds, the production cost of the matched product is reduced, and the enterprise competitiveness is improved. For example, after the original requirement of manufacturing accuracy is +/-0.05mm, after the cloud cooperation method is adopted, when the error of the inner diameter (assembly size) of the bearing seat is 0.5 mm, a matched product with the error of the outer diameter (assembly size) of the bearing being-0.5 mm can be selected and assembled with the bearing seat, the requirement of manufacturing tolerance is greatly relaxed, and the matching accuracy of the bearing seat and the bearing is improved, and only a matched workpiece with a corresponding error needs to be selected and assembled on a data cloud platform.
Assuming that the fit tolerance phi 50H7/k6 of the gear hole and the shaft can meet the use requirement after the gear and the shaft are assembled, the fit tolerance is the theoretical design fit tolerance of the gear hole and the shaft as shown in the following table:
| theoretical design | Ultimate deviation of hole | Extreme deviation of the shaft | Hole to shaft fit tolerance |
| H7 | K6 | φ50H7/k6 | |
| Upper deviation of | 0.025 | 0.018 | 0.023 |
| Lower deviation | 0 | 0.002 | -0.018 |
In this fit tolerance, φ 50 represents the nominal diameter of the gear bore and shaft; h7 shows the tolerance band of the gear hole is H, and the tolerance level is IT7 level; k6 indicates that the tolerance band of the shaft is k and the tolerance class is IT 6; phi 50H7 represents that the diameter size tolerance of the gear hole is 0-0.025 mm, namely the diameter size processing allowable range of the gear hole is 50-50.025 mm; similarly, for the shaft, phi 50k6 represents that the diameter dimension tolerance of the shaft is 0.002-0.018 mm, namely the diameter dimension processing allowable range of the shaft is 50.002-50.018 mm; phi 50H7/k6 represents the fit tolerance of the two parts of the gear hole and the shaft after assembly, and the allowed fit clearance (or interference) is in the range of-0.018-0.023 mm (note: the fit is a transition fit). In the existing standardized production, the assembly precision between the gear hole and the shaft is ensured by controlling the machining precision of the gear hole and the shaft, namely, as long as the machining precision of the two parts is ensured to be within the allowable dimensional tolerance range, the assembly precision of the two parts is ensured to be within the allowable fit tolerance range. In the standardized control mode, more redundancy tolerance exists in the diameter size tolerance zone of both the gear hole and the shaft and cannot be fully utilized, so that the traditional standardized production organization form is not the most economical and optimized production mode, the production efficiency can be greatly improved through mode reconstruction and innovation optimization, and the reconstructed and innovative production organization mode is a weakly standardized production mode. The specific method is shown in the following table:
the standard tolerance grade of a gear hole is reduced from the grade IT7 to the grade IT8 (the lower the tolerance grade is, the lower the manufacturing cost is), the standard tolerance grade of a shaft is reduced from the grade IT6 to the grade IT8, meanwhile, the actual machining tolerances of two groups of parts, namely the gear and the shaft, are measured and are respectively divided into 5 grades, the size deviation range of each grade is one fifth of the standard tolerance zone and is gradually increased, and the parts of the same grade can be assembled in a matched mode only when the parts are assembled.
As shown in the table above, by adopting the fit tolerance phi 50H8/k8 after the tolerance is substantially reduced, not only can the assembly precision requirement in phi 50H7/k6 designed by theory still be met, but also the fit tolerance of the assembly body is greatly reduced from the range of minus 0.018-0.023 mm to the range of minus 0.008-0.008 mm, namely, the fit precision is improved by more than two times. The improvement of the production efficiency does not increase any processing conditions or improve the production control process, and on the contrary, the processing and production cost of the part can be greatly reduced due to the reduction of the processing tolerance grade.
In summary, in the conventional standardized manufacturing mode, the allowable tolerance of the low-requirement fit dimension is large (the qualified standard is reduced), and the allowable tolerance of the high-requirement fit dimension is small (the qualified standard is increased). Generally, products with small tolerances require more precise equipment, more skilled personnel, more manufacturing procedures and more rigorous processing, which results in rapid increases in the manufacturing costs of precision products. Whereas weakly standardized manufacturing allows production to be carried out with greater tolerances without changing the nominal value. The shaft processing method comprises the steps of identifying each shaft, carrying out actual measurement on the matching parameters (the shape and the diameter of the shaft) of each shaft by adopting a precise measurement means, recording and uploading the measured values to a cloud platform for storage and use by a user; the sleeve processing method adopts similar technical means to mark and actually measure and record the inner diameter of each sleeve; during the assembly of the shaft sleeve assembly, the identification on the workpiece is recognized through the automatic sorting system, the actual measurement diameter of the shaft and the sleeve is obtained from the cloud database, the shaft and the sleeve are automatically optimized and matched and selected, the intelligent warehouse is combined, the optimal matching is realized, and the optimal gap assembly is realized for each shaft sleeve assembly, so that the quality of the shaft sleeve assembly as a product is improved.
Statistically, the manufacturing error exhibits a normal distribution. In the standardized manufacturing model, the improvement in product quality is manifested by smaller and smaller manufacturing tolerances (deviations from the ideal values). Narrower tolerance bands require less deviation of acceptable products from ideal values. In the conventional standardized manufacturing mode, the reduction of the allowable error is the improvement of the qualified standard or precision level. In order to achieve this, the demands on processing equipment, personnel, processes, etc. are increased, and the relative costs are naturally increased.
And in the weak standardized manufacturing mode, the tolerance band is divided into a plurality of sections according to the high-requirement standard. Equally dividing the shaft into 5 equal parts according to the tolerance value difference, classifying the products according to the measured diameter value through high-precision measuring equipment, and adding an identifier A, B, C, D, E; similarly, the "holes" associated with the "axis" are also treated in the same manner, and the "holes" are also classified A, B, C, D, E according to the measured inner diameter value. During assembly, products are sorted and paired through the marks, the shaft of the A type is assembled with the hole of the A type, the shaft of the B type is assembled with the hole of the B type, and by analogy, the matching tolerance of the components (shaft and gear) assembled by the shaft and the hole finally meets the requirement of (-0.018-0.023 mm), so that the shaft and gear products meeting the new requirement of higher quality standard are produced by weakening the qualified standard (instead of having no standard) under the condition of not changing the machine mode of the existing products.
With the improvement of quality requirements of people, the qualification standard or tolerance grade is continuously improved, and further enterprises are forced to continuously upgrade elements such as equipment, personnel and technology. The weak standardized manufacturing mode is provided, so that the investment pressure of enterprises on equipment, personnel, technology and the like is relieved, and the production of low-cost and high-quality products is realized. Thanks to the rapid development and the widespread application of technologies such as detection technology, big data, cloud computing, automatic sorting, intelligent vertical warehouse, etc., the weak standardized manufacturing mode can be realized at a lower cost, and the weak standardized manufacturing will gradually become a very competitive choice for high-quality production.
Finally, it should be noted that: although the present invention has been described in detail with reference to the foregoing embodiments, it will be apparent to those skilled in the art that changes may be made in the embodiments and/or equivalents thereof without departing from the spirit and scope of the invention. Any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (6)
1. A weakly standardized cloud collaborative manufacturing method is characterized in that product parts are identified or graded through parameter detection, best matching accessories are selected for assembly through identification marks or grading during use and detection results, and therefore weakly standardized high-quality component production is achieved.
2. The weakly standardized cloud collaborative manufacturing method according to claim 1, comprising the steps of:
1) performing parameter measurement and identification on workpieces produced according to the standard, uploading measurement results to a cloud platform, and classifying products according to the measurement results;
2) matching information of an accessory which is best matched with the cloud platform by scanning the product identification;
3) and selecting and assembling matched products based on manufacturing errors.
3. The cloud collaboration method for artifacts in assembly relationship as claimed in claim 2, wherein the identifier is a two-dimensional code or other code that can access a cloud server database to inquire product information.
4. The cloud collaboration method for workpieces in assembly relationship as claimed in claim 3, wherein the scan mark user can log on the cloud platform to obtain the relevant information of the workpiece, the relevant information including but not limited to part number, manufacturer, workshop, batch, production responsible person, fitting size, belonging category, model and category of suggested matching.
5. The cloud coordination method for workpieces in assembled relationship as claimed in claim 2 wherein said products are packaged in sorted order by manufacturing tolerance of fit size.
6. The cloud coordination method for workpieces having assembly relations as claimed in claim 5, wherein the packaging of the product is marked by adding color, grade or number, which is convenient for users to visually identify different categories to which the workpieces belong.
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