CN103149844B - Method for controlling pull-in voltage consistency of batch products of relay - Google Patents

Abstract

The invention relates to a method for controlling the pull-in voltage consistency of batch products of a relay and aims to solve the problem of low consistency of the batch products in a manufacturing process caused by lack of a consistency control method for guiding a developer to allocate reasonable tolerances to controllable parameters in a relay product development process. The method for controlling the pull-in voltage consistency of the batch products of the relay provided by the invention comprises the following steps of: 1, performing orthogonal experimental design; 2, analyzing test data contribution ratio; 3, establishing a tolerance allocation target function; 4, determining key parameters and tolerances thereof; and 5, controlling a relay manufacturing process. The method is applied to the field of consistency control in a relay development phase.

Description

Relay batch products pick-up voltage consistance control method

Technical field

The present invention relates to relay batch products pick-up voltage consistance control method.

Background technology

The subject matter of current existing relay product quality is not poor performance, and the dispersiveness of batch products is too large, this is due in the domestic and international research and development at relay product and manufacture process, focus on the output performance of product, the output valve of the characteristics such as such as pick-up voltage, release voltage, pickup time, release time, and lack clear and definite consistance control method and instruct research staff to carry out the conforming correlation analysis of batch products and control.

For relay batch products consistance control and correlative study prior art in, be mainly the reliability degree calculation method based on probability statistical analysis.The method is according to the Tolerance Allocation scheme of controllable parameter (comprising the machined parameters of parts and the assembly parameter of assembly), the tolerance band of usual employing Monte Carlo method split-phase relay static attractive torque characteristic and static spring load characteristic, thus fiduciary level or the accepted product percentage of batch relay product is calculated according to suction counter-force matching relationship, the consistance of Indirect evaluation batch products is carried out with this.If the fiduciary level calculated does not meet the demands, then research staff is needed to adjust the tolerance of each parameter by rule of thumb and recalculate fiduciary level, until meet the demands.

The consistance of pick-up voltage is the important indicator of examination relay batch products mass property, existing method only accurately can calculate relay controllable parameter tolerance under appointment manufactures grade, the fiduciary level that the static attractive force and spring force characteristics of batch products coordinates, and each parameter cannot be determined directly, quantitatively under current tolerance grade to the consistent sex significance degree of batch products pick-up voltage, cause research staff to lack objectivity when given parameters tolerance, the optimization of quality and cost can not be reached.In addition, the method is carried out the consistance of Indirect evaluation batch products, directly can not assess with relay dynamic output characteristic and pick-up voltage.

Owing to manufacturing dispersed outwardness, relay can not carry out processing and assembling according to the central value of parameter of specifying in process of production completely, causes the mass property of product and theoretical value produce deviation and present random fluctuation.Therefore, need for controllable parameter distributes tolerance to retrain the fluctuation of product quality characteristics.If all distribute very high-precision tolerance for all parameters, the output characteristics of product is inevitable very excellent, but can cause that the production cost of product is too high even exceeds working ability scope, and this is obviously worthless.Therefore, need to find to the significant controllable parameter of the influence of fluctuations of output of products characteristic and distribute rational tolerance for it, and still adopt lower tolerance grade to inapparent factor, thus ensure under existing manufacturing capacity, make the consistance of batch products reach target call.But, owing to still lacking relevant consistance control method at present, research staff cannot determine that the key factor in numerous controllable parameter also distributes rational tolerance grade for it, causes the consistance of relay batch products poor, and becomes the main cause affecting relay product quality level.

Summary of the invention

The present invention will solve in relay product R&D process the control method that is lack of consistency to instruct research staff to distribute rational tolerance to controllable parameter, and then cause the problem of batch products consistance difference in manufacture process, and propose relay batch products pick-up voltage consistance control method.

Relay batch products pick-up voltage consistance control method realizes according to the following steps:

One, Orthogonal Experiment and Design

Relay is set and has n controllable parameter X ₁, X ₂..., X _n, adopt orthogonal experiment design experiment scheme:

Each controllable parameter is got three levels according to formula (1) and is carried out gauge outfit design, and three levels are respectively central value m _iand according to tolerance Δ _ithe higher limit of fluctuation and lower limit;

Two, test figure Contribution Rate

Calculate the relay pick-up voltage y that each testing program is corresponding ₁, y ₂..., y _nafter, statistical study is carried out to n test figure, obtains each controllable parameter X _icontribution rate ρ _i/ %, is divided into once item contribution rate ρ _xil/ % and quadratic term contribution rate ρ _xiq/ %;

Three, Tolerance Allocation objective function is set up

By controllable parameter X each in step 2 _icontribution rate bring formula (2) into, obtain characterising parameter tolerance from Δ _ichange into Δ ' _itime the corresponding output characteristics degree of consistency funtcional relationship that changes, i.e. Tolerance Allocation objective function:

$\mathrm{\δ}=\underset{i=1}{\overset{n}{\mathrm{\Σ}}}({\mathrm{\ρ}}_{\mathrm{Xil}}{\left(\frac{{\mathrm{\Δ}}_i^{\′}}{{\mathrm{\Δ}}_i}\right)}^2+{\mathrm{\ρ}}_{\mathrm{Xip}}{\left(\frac{{\mathrm{\Δ}}_i^{\′}}{{\mathrm{\Δ}}_i}\right)}^4)+{\mathrm{\ρ}}_e...\left(2\right)$

Wherein, Δ _irepresent the tolerance before changing, Δ ' _irepresent the tolerance after changing, ρ _xilexpression factor X _ionce item contribution rate, ρ _xiqexpression factor X _iquadratic term contribution rate, ρ _erepresent error term contribution rate;

Four, key parameter and tolerance thereof is determined

According to the size determination relay key parameter of each controllable parameter contribution rate value, and the manufacture grade that should reach after determining the tolerance improvement of each parameter in the mode of formula (3);

Δ′ _i＝(1-k×ρ _i)Δ _i＝[1-k×(ρ _Xil+ρ _Xiq)]Δ _i(3)

Wherein, k is the Tolerance Allocation factor, ρ _ifor controllable parameter X _icontribution rate, by k × ρ _ias the weight coefficient of Tolerance Allocation; For the coincident indicator determined, by changing the value of k, the consistance of batch products is made to be increased to target call;

Five, relay manufacture process control

According to each controllable parameter tolerance that step 4 is determined, specify the precision that each controllable parameter in relay manufacture process should meet, ensure that the consistance of batch products pick-up voltage meets target call.

Invention effect:

The present invention is directed to the crucial output characteristics parameter of batch relay product---the coincident indicator of pick-up voltage, propose relay batch products pick-up voltage consistance control method, in R & D of complex, instruct research staff complete the analysis of controllable parameter tolerance and determine.Test figure Contribution Rate is taken into account by orthogonal experiment plan, according to controllable parameter fluctuation to the consistent sex conspicuousness of batch products pick-up voltage, it is sorted, and set up describe each parameter tolerances change and pick-up voltage consistance change between the Tolerance Allocation objective function of corresponding relation; By setting up weight coefficient, according to coincident indicator have according to be controllable parameter distribution tolerance grade, thus in the manufacture process of batch relay product, reasonable request is carried out to each controllable parameter, ensure that the consistance of batch products pick-up voltage meets target call.

Accompanying drawing explanation

Fig. 1 is process flow diagram of the present invention.

Embodiment

Embodiment one: the relay batch products pick-up voltage consistance control method of present embodiment realizes according to the following steps:

One, Orthogonal Experiment and Design

Relay is set and has n controllable parameter X ₁, X ₂..., X _n, adopt orthogonal experiment design experiment scheme:

Each controllable parameter is got three levels according to formula (1) and is carried out gauge outfit design, and three levels are respectively central value m _iand according to tolerance Δ _ithe higher limit of fluctuation and lower limit;

Two, test figure Contribution Rate

Calculate the relay pick-up voltage y that each testing program is corresponding ₁, y ₂..., y _nafter, statistical study is carried out to n test figure, obtains each controllable parameter X _icontribution rate ρ _i/ %, is divided into once item contribution rate ρ _xil/ % and quadratic term contribution rate ρ _xiq/ %;

Three, Tolerance Allocation objective function is set up

By controllable parameter X each in step 2 _icontribution rate bring formula (2) into, obtain characterising parameter tolerance from Δ _ichange into Δ ' _itime the corresponding output characteristics degree of consistency funtcional relationship that changes, i.e. Tolerance Allocation objective function:

$\mathrm{\δ}=\underset{i=1}{\overset{n}{\mathrm{\Σ}}}({\mathrm{\ρ}}_{\mathrm{Xil}}{\left(\frac{{\mathrm{\Δ}}_i^{\′}}{{\mathrm{\Δ}}_i}\right)}^2+{\mathrm{\ρ}}_{\mathrm{Xip}}{\left(\frac{{\mathrm{\Δ}}_i^{\′}}{{\mathrm{\Δ}}_i}\right)}^4)+{\mathrm{\ρ}}_e...\left(2\right)$

Wherein, Δ _irepresent the tolerance before changing, Δ ' _irepresent the tolerance after changing, ρ _xilexpression factor X _ionce item contribution rate, ρ _xiqexpression factor X _iquadratic term contribution rate, ρ _erepresent error term contribution rate;

Four, key parameter and tolerance thereof is determined

According to the size determination relay key parameter of each controllable parameter contribution rate value, and the manufacture grade that should reach after determining the tolerance improvement of each parameter in the mode of formula (3);

Δ′ _i＝(1-k×ρ _i)Δ _i＝[1-k×(ρ _Xil+ρ _Xiq)]Δ _i(3)

Wherein, k is the Tolerance Allocation factor, ρ _ifor controllable parameter X _icontribution rate, by k × ρ _ias the weight coefficient of Tolerance Allocation; For the coincident indicator determined, by changing the value of k, the consistance of batch products is made to be increased to target call;

Five, relay manufacture process control

According to each controllable parameter tolerance that step 4 is determined, specify the precision that each controllable parameter in relay manufacture process should meet, ensure that the consistance of batch products pick-up voltage meets target call.

In present embodiment step 4, for the coincident indicator determined, by changing the value of k, the consistance of batch products is made to be increased to target call.

Present embodiment effect:

Present embodiment is for the crucial output characteristics parameter of batch relay product---the coincident indicator of pick-up voltage, propose relay batch products pick-up voltage consistance control method, in R & D of complex, instruct research staff complete the analysis of controllable parameter tolerance and determine.Test figure Contribution Rate is taken into account by orthogonal experiment plan, according to controllable parameter fluctuation to the consistent sex conspicuousness of batch products pick-up voltage, it is sorted, and set up describe each parameter tolerances change and pick-up voltage consistance change between the Tolerance Allocation objective function of corresponding relation; By setting up weight coefficient, according to coincident indicator have according to be controllable parameter distribution tolerance grade, thus in the manufacture process of batch relay product, reasonable request is carried out to each controllable parameter, ensure that the consistance of batch products pick-up voltage meets target call.

Embodiment:

For certain model balanced armature-type electromagnetic relay, the relay batch products pick-up voltage consistance control method that application the present invention proposes, instructs research staff to carry out analysis and control to the consistance of batch products pick-up voltage:

One, the main controllable parameter of relay is determined

Relay is made up of electromagnetic system and contact spring system, altogether comprise twenties parts and numerous controllable parameter, need to filter out wherein main parameter and carry out test design, for the balanced armature-type electromagnetic relay studied in this example, its electromagnetic system controllable parameter is all parts machining parameter, and prove through relative theory analysis, when there is fluctuation in electromagnetic system controllable parameter in current tolerance grade, very little on the conforming impact of batch products, contact spring system controllable parameter comprises the machined parameters of parts and the assembly parameter of assembly, its parameter fluctuation is very large on the conforming impact of batch products, the main controllable parameter determined through theoretical analysis is five assembly parameters: quiet resultant pressure, contactor gap, magnetic gap, no-load voltage and over travel, and four machined parameters: reed width, movable contact spring thickness, dynamic circuit connector quiet spring thickness and the quiet spring thickness of quiet conjunction, each controllable parameter is got three levels according to formula (1) and is carried out gauge outfit design, three levels are respectively central value m _iand according to tolerance Δ _ithe higher limit of fluctuation and lower limit,

Controllable parameter and water-glass as shown in table 1:

The main controllable parameter of table 1 and water-glass thereof

Two, orthogonal test scheme is determined

According to the number of controllable parameter and the horizontal number of parameter, choose L ₂₇(3 ¹³) orthogonal arrage, adopt simulating analysis, set up the realistic model of relay physical construction and calculate its dynamic perfromance, thus obtaining the output characteristics value of relay pick-up voltage, testing program and test findings are in table 2:

Table 2 testing program and test findings

Three, Contribution Rate is carried out to test figure

Calculate the relay output characteristics that each testing program is corresponding---pick-up voltage y, and obtain test figure y ₁y ₂..., y _nafter, statistical study is carried out to n test figure.Level value due to controllable parameter is equally spaced, therefore can utilize orthogonal polynomial regression theory that the fluctuation that each parameter causes is decomposed into once item fluctuation quadratic sum and quadratic term fluctuation quadratic sum, and obtain corresponding contribution rate.

Suppose there are A, B, C tri-controllable parameters, each parameter gets three levels, then total mass property fluctuation, the output characteristics parameter fluctuation that namely total Test factor causes is

$S_T^{\′}=\underset{i=1}{\overset{n}{\mathrm{\Σ}}}{\left(y_i\right)}^2=S_m+S_{\mathrm{Al}}+S_{\mathrm{Aq}}+S_{\mathrm{Bq}}+S_{\mathrm{Cl}}+S_{\mathrm{Cq}}+S_e$

Wherein, S _mfor exporting the sum of square of deviations of average, when carrying out tolerance analysis, this usual value is 0;

S _al, S _aqfor once item fluctuation quadratic sum and the quadratic term fluctuation quadratic sum of factor A, S _bl, S _bqfor once item fluctuation quadratic sum and the quadratic term fluctuation quadratic sum of factor B, S _cl, S _cqfor factor C once item fluctuation quadratic sum and quadratic term fluctuation quadratic sum, its computing formula in table 3, T in formula _1A, T _2A, T _3Abe respectively test figure y ₁, y ₂..., y _nr the test figure sum (the horizontal number of each experimental factor of r=n/) of middle corresponding factor A the 1st level, the 2nd level and the 3rd level, T _1B, T _2B, T _3Bbe respectively test figure y ₁, y ₂..., y _nr test figure sum of middle corresponding factor B the 1st level, the 2nd level and the 3rd level, T _1C, T _2C, T _3Cbe respectively test figure y ₁, y ₂..., y _nr test figure sum of middle corresponding factor C the 1st level, the 2nd level and the 3rd level;

S _efor error sum of squares, its computing formula is;

S _e＝S′ _T-S _m-S _Al-S _Aq-S _Bl-S _Bq-S _Cl-S _Cq

Based on above calculating, and finally determine that the tolerance of each controllable parameter is to the consistent sex contribution rate of relay batch products, is divided into once item contribution rate and quadratic term contribution rate by table 3:

Table 3 Contribution Rate table

Note: when carrying out error analysis, need S _m, S _al, S _aq, S _bl, S _bq, S _cl, S _cqin compare V _elittle item is merged into error sum of squares S _ein, obtain new error sum of squares (S _e) and degree of freedom, suppose S in table 3 _m, S _bqand S _cqfor merging item;

According to the Contribution Rate method that table 3 proposes, carry out statistical study to test findings, data results is in table 4:

Table 4 test figure Contribution Rate result statistical form

Four, the Tolerance Allocation objective function of pick-up voltage is set up

According to Contribution Rate result, obtain describing controllable parameter tolerance from Δ _ichange into Δ ' _itime the corresponding output characteristics degree of consistency funtcional relationship that changes, i.e. Tolerance Allocation objective function:

$\mathrm{\δ}=\underset{i=1}{\overset{n}{\mathrm{\Σ}}}({\mathrm{\ρ}}_{\mathrm{Xil}}{\left(\frac{{\mathrm{\Δ}}_i^{\′}}{{\mathrm{\Δ}}_i}\right)}^2+{\mathrm{\ρ}}_{\mathrm{Xip}}{\left(\frac{{\mathrm{\Δ}}_i^{\′}}{{\mathrm{\Δ}}_i}\right)}^4)+{\mathrm{\ρ}}_e...\left(2\right)$

Wherein, Δ _irepresent the tolerance before changing, Δ ' _irepresent the tolerance after changing, ρ _xilexpression factor X _ionce item contribution rate, ρ _xiqexpression factor X _iquadratic term contribution rate, ρ _erepresent error term contribution rate;

By each controllable parameter X _icorresponding contribution rate coefficient ρ _i/ % brings formula (2) into, obtains the objective function of Tolerance Allocation:

$\mathrm{\δ}=1.864{\left(\frac{{\mathrm{\Δ}}_A^{\′}}{{\mathrm{\Δ}}_A}\right)}^4+2.039{\left(\frac{{\mathrm{\Δ}}_B^{\′}}{{\mathrm{\Δ}}_B}\right)}^4+0.910{\left(\frac{{\mathrm{\Δ}}_B^{\′}}{{\mathrm{\Δ}}_B}\right)}^4+2.807{\left(\frac{{\mathrm{\Δ}}_C^{\′}}{{\mathrm{\Δ}}_C}\right)}^4+$

$2.301{\left(\frac{{\mathrm{\Δ}}_D^{\′}}{{\mathrm{\Δ}}_D}\right)}^2+1.987{\left(\frac{{\mathrm{\Δ}}_E^{\′}}{{\mathrm{\Δ}}_E}\right)}^2{+1.229\left(\frac{{\mathrm{\Δ}}_G^{\′}}{{\mathrm{\Δ}}_G}\right)}^2+3.139{\left(\frac{{\mathrm{\Δ}}_G^{\′}}{{\mathrm{\Δ}}_G}\right)}^4+$

$46.91{\left(\frac{{\mathrm{\Δ}}_H^{\′}}{{\mathrm{\Δ}}_H}\right)}^2+1.419{\left(\frac{{\mathrm{\Δ}}_H^{\′}}{{\mathrm{\Δ}}_H}\right)}^4+35.395$

Five, key parameter and tolerance thereof is determined

By contrasting the contribution rate coefficient ρ of each controllable parameter _i, can determine that the key parameter in relay manufacture process is: no-load voltage (controllable parameter H) simply, intuitively; Other controllable parameters are very little on the conforming impact of batch products pick-up voltage.

According to the contribution rate coefficient of each controllable parameter, the manufacture grade that the present embodiment should reach after proposing to determine the improvement of its tolerance in the mode of formula (3); Wherein, k is the Tolerance Allocation factor, ρ _ifor controllable parameter X _icontribution rate, by k × ρ _ias the weight coefficient of Tolerance Allocation; For the coincident indicator determined, by changing the value of k, the consistance of batch products is made to be increased to target call;

Δ′ _i＝(1-k×ρ _i)Δ _i＝[1-k×(ρ _Xil+ρ _Xiq)]Δ _i(3)

In this example, using the target that 50% promotes as consistance, Tolerance Allocation is carried out to relay.By changing the value of k, utilizing formula (3) to change the tolerance of each experimental factor, and the Tolerance Allocation objective function utilizing step 4 to determine, verifying whether coincident indicator corresponding to this Tolerance Allocation scheme meets target call.Thus when determining k=1.72, after improving, the consistance of batch relay product pick-up voltage can be promoted to original 50.67%, and Tolerance Allocation process terminates.After improving, the Tolerance Allocation scheme of each controllable parameter is in table 5.

The Tolerance Allocation table that table 5 is target with pick-up voltage consistance

Claims (1)

1. relay batch products pick-up voltage consistance control method, is characterized in that relay batch products pick-up voltage consistance control method realizes according to the following steps:

One, Orthogonal Experiment and Design

Relay is set and has n controllable parameter X ₁, X ₂..., X _n, adopt orthogonal experiment design experiment scheme:

Each controllable parameter is got three levels according to formula (1) and is carried out gauge outfit design, and three levels are respectively central value m _iand according to the tolerance Δ before change _ithe higher limit of fluctuation and lower limit;

Two, test figure Contribution Rate

Calculate the relay pick-up voltage y that each testing program is corresponding ₁, y ₂..., y _nafter, statistical study is carried out to n test figure, obtains each controllable parameter X _icontribution rate ρ _i/ %, is divided into once item contribution rate ρ _xil/ % and quadratic term contribution rate ρ _xiq/ %;

Three, Tolerance Allocation objective function is set up

By controllable parameter X each in step 2 _icontribution rate bring formula (2) into, obtain characterising parameter tolerance from Δ _ichange into Δ ' _itime the corresponding output characteristics degree of consistency funtcional relationship that changes, i.e. Tolerance Allocation objective function:

$\mathrm{\δ}=\underset{i=1}{\overset{n}{\mathrm{\Σ}}}({\mathrm{\ρ}}_{\mathrm{Xil}}{\left(\frac{{\mathrm{\Δ}}_i^{\′}}{{\mathrm{\Δ}}_i}\right)}^2+{\mathrm{\ρ}}_{\mathrm{Xiq}}{\left(\frac{{\mathrm{\Δ}}_i^{\′}}{{\mathrm{\Δ}}_i}\right)}^4)+{\mathrm{\ρ}}_e---\left(2\right)$

Wherein, Δ _irepresent the tolerance before changing, Δ ' _irepresent the tolerance after changing, ρ _xilexpression factor X _ionce item contribution rate, ρ _xiqexpression factor X _iquadratic term contribution rate, ρ _erepresent error term contribution rate;

Four, key parameter and tolerance thereof is determined

According to the size determination relay key parameter of each controllable parameter contribution rate value, and determine the tolerance after the change of each parameter in the mode of formula (3);

△′ _i＝(1-k×ρ _i)△ _i＝[1-k×(ρ _Xil+ρ _Xiq)]△ _i(3)

Wherein, k is the Tolerance Allocation factor, ρ _ifor controllable parameter X _icontribution rate, by k × ρ _ias the weight coefficient of Tolerance Allocation; For the coincident indicator determined, by changing the value of k, the consistance of batch products is made to be increased to target call;

Five, relay manufacture process control

According to each controllable parameter tolerance that step 4 is determined, specify the precision that each controllable parameter in relay manufacture process should meet, ensure that the consistance of batch products pick-up voltage meets target call.