CN107016141B - Electromagnetic relay step tolerance optimization method based on change contribution rate - Google Patents

Electromagnetic relay step tolerance optimization method based on change contribution rate Download PDF

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CN107016141B
CN107016141B CN201610153200.XA CN201610153200A CN107016141B CN 107016141 B CN107016141 B CN 107016141B CN 201610153200 A CN201610153200 A CN 201610153200A CN 107016141 B CN107016141 B CN 107016141B
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邓杰
叶雪荣
林义刚
付饶
董宝旭
翟国富
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Harbin Institute of Technology
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Abstract

The invention discloses a step tolerance optimization method of an electromagnetic relay based on change contribution rate, which comprises the following steps: s1: determining a standard for tolerance optimization; determining the tolerance range of the key factors according to the relationship between the key factors and the output characteristics and the actual processing capacity; s2: determining the level number of the key factor; designing orthogonal tests, and calculating the output result of each group of orthogonal tests; calculating the contribution rate of each key factor; s3: reducing the tolerance of the contribution rate according to a certain tolerance step length to obtain a new tolerance range of the key factors; calculating the contribution rate of each key factor again; s4: finding an output characteristic fluctuation range of a corresponding new tolerance range within the new tolerance range determined in step S3; s5: and repeating the operation of the steps S3-S4 until the fluctuation range of the output characteristic meets the tolerance optimization standard or the new tolerance range reaches the lower limit of the machining precision, wherein the new tolerance range is the final result of the step tolerance optimization.

Description

Electromagnetic relay step tolerance optimization method based on change contribution rate
Technical Field
The invention relates to the technical field of relay product design, in particular to a step tolerance optimization method of an electromagnetic relay based on change contribution rate.
Background
Electromagnetic relay product designs include overall designs, parametric designs, and tolerance designs. The overall design is realized by completing system functions, the parameter design improves the anti-interference performance of the product by changing the central value, and the tolerance design improves the anti-interference performance of the product by controlling the design tolerance. The change of the central value not only affects the anti-interference performance, but also changes the product performance, and the analysis is complex; the tolerance design can not change the central value, and the application range is wider. Therefore, the significance of improving the quality consistency of batch products of the electromagnetic relays by adopting a tolerance design method is great.
And the tolerance optimization is to determine the contribution rate of each factor to an output result based on an orthogonal test method, and then perform inverse distribution on the tolerance according to the contribution rate to obtain a tolerance scheme meeting the requirement. The traditional tolerance optimization method determines the variation range of the tolerance of each factor according to the first and second contribution rates of each factor and the variation quantity of the output characteristic, and the directly determined new tolerance scheme has three disadvantages: the distribution scheme is not unique, and the tolerance range of each factor needs to be manually adjusted to meet the requirement of output characteristics; the distribution mode is only based on the contribution rate of the original tolerance, and the condition that the original non-significant factors possibly become significant after the tolerance is shortened is not considered, so that the distributed scheme is not optimal; the allocated scheme is not verified, and it cannot be guaranteed that the new tolerance scheme can meet the requirements.
Disclosure of Invention
The invention aims to solve the problems that the tolerance range of each factor needs to be manually adjusted in the traditional tolerance optimization method at present, and provides a step tolerance optimization method of an electromagnetic relay based on a variation contribution rate.
In order to achieve the purpose, the invention provides an electromagnetic relay step tolerance optimization method based on a variation contribution rate, which comprises the following steps of:
s1: determining a tolerance optimization standard according to the quality consistency requirement of the electromagnetic relay product; determining the tolerance range of the key factors according to the relationship between the key factors and the output characteristics and the actual processing capacity;
s2: determining the number of levels of the key factor from the tolerance range determined in step S1; designing orthogonal tests according to the number of the key factors and the horizontal number, and calculating the output result of each group of orthogonal tests by using a rapid calculation model; calculating the contribution rate of each key factor according to the output result;
s3: reducing the tolerance of the contribution rate according to a certain tolerance step length to obtain a new tolerance range of the key factors; performing an orthogonal test according to the new tolerance range, and calculating the contribution rate of each key factor again;
s4: based on the monte carlo method, generating a virtual sample in the new tolerance range determined in the step S3, calculating the output characteristic distribution of the virtual sample by using a fast calculation model, and calculating the output characteristic fluctuation range of the corresponding new tolerance range;
s5: and (4) checking whether the output characteristic fluctuation range obtained in the step (S4) meets the tolerance optimization standard, if not, repeating the steps (S3) -S4 until the output characteristic fluctuation range meets the tolerance optimization standard or the new tolerance range of each key factor reaches the lower limit of the machining precision of the equipment in the actual production process, wherein the new tolerance range of each key factor is the final result of the step-by-step tolerance optimization.
According to the optimization method proposed by the present invention, in step S3, the tolerance step size set in the initial stage of tolerance optimization is larger than the tolerance step size set in the final stage of tolerance optimization.
The optimization method proposed by the present invention, wherein the step S3 further includes introducing an acceleration coefficient meeting the setting of the tolerance step into the tolerance step calculation, and then obtaining a calculation formula of the tolerance step by combining the contribution ratio:
Ii+1＝αρiMi
in the formula Ii+1The step length of the step (i + 1); rhoiThe contribution rate calculated for the ith step; miThe tolerance limit value of the step i, α is an acceleration coefficient, and the calculation is carried out according to the following formula
Figure BDA0000943871470000021
Formula (III) ηiRepresenting the ratio of the output characteristic fluctuation range calculated in the ith step to the tolerance optimization standard;
tolerance limit M of step i +1i+1Comprises the following steps:
Figure BDA0000943871470000022
wherein the lower limit value of the actual processing capacity is shown in the formula; [ -Mi+1,Mi+1]I.e. the new tolerance range.
Compared with the prior art, the invention has the following beneficial effects:
the electromagnetic relay step tolerance optimization method based on the change contribution rate enables the situation that the original inconspicuous factors possibly become remarkable after the tolerance is shortened in the traditional tolerance distribution method to be considered, and ensures that the tolerance distribution scheme is optimal; in addition, the invention has high tolerance optimization speed, and can automatically adjust the tolerance range of each factor to meet the requirement of output characteristic quality consistency.
The method is used for calculating the changed contribution rate after tolerance distribution by utilizing orthogonal test design according to the quality consistency requirement and the actual processing capacity of the product in the design stage of the electromagnetic relay product, introducing the tolerance step length, and obtaining the optimal tolerance distribution scheme capable of meeting the quality consistency requirement and the processing capacity requirement of the product through multiple iterations.
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FIG. 1 is a flow chart of a step tolerance optimization method of an electromagnetic relay based on a variation contribution rate according to the present invention.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be obtained by a person skilled in the art without inventive effort based on the embodiments of the present invention, are within the scope of the present invention.
The first embodiment is as follows:
the present embodiment is described below with reference to fig. 1, and the electromagnetic relay step tolerance optimization method based on the variation contribution rate in the present embodiment includes the following steps:
s1: determining a tolerance optimization standard according to the quality consistency requirement of the electromagnetic relay product; determining the tolerance range of the key factors according to the relationship between the key factors and the output characteristics and the actual processing capacity;
s2: determining the level number of the key factors according to the newly determined tolerance range; designing an orthogonal test according to the number of key factors and the horizontal number, and calculating the output result of each group of test schemes by using a rapid calculation model; calculating the contribution rate of each factor according to the orthogonal test result;
s3: reducing the tolerance according to the contribution rate of each factor and a certain tolerance step length to obtain a new tolerance range of the key factor; performing an orthogonal test according to the new tolerance range, and calculating the contribution rate of each factor;
s4: based on the monte carlo method, generating a virtual sample in the new tolerance range of the key factors determined in the step S3, calculating the output characteristic distribution of the virtual sample by using a rapid calculation model, and solving the fluctuation range of the output characteristic corresponding to the new tolerance range of the key factors;
s5: and (4) checking whether the output characteristic fluctuation range obtained in the step (S4) meets the tolerance optimization standard, if not, repeating the operation of the steps (S3) -S5 until the output characteristic fluctuation range meets the tolerance optimization standard or the tolerance range of each key factor reaches the lower limit of the machining precision of the equipment in the actual production process, and at the moment, the tolerance range of each key factor is the final result of the step-by-step tolerance optimization.
The second embodiment is as follows:
in step S1, a criterion for optimizing tolerance of the output characteristic parameter, that is, a range of fluctuation of the output characteristic parameter, is determined according to the requirement of quality consistency of the specific output characteristic parameters (such as pull-in voltage, release voltage, etc.) of the electromagnetic relay product; then, according to the relationship between the key factors (i.e. design parameters) and the output characteristics, the tolerance range of the key factors is determined, namely, if the influence of the variation of the key factors on the output characteristics is small, a larger tolerance range can be allocated, and if the influence of the variation of the key factors on the output characteristics is large, a smaller tolerance range can be allocated, and the allocated tolerance ranges are within the allowable range of the processing capacity.
In step S2, the number of levels of the key factor is determined to be 3 levels, and the central value, the central value + the upper tolerance limit, and the central value-the lower tolerance limit each account for 1Horizontal; selecting an orthogonal table according to the number of key factors and the horizontal number, arranging test schemes, calculating each group of test schemes through a dynamic characteristic rapid calculation model of the electromagnetic relay, and solving an output characteristic value yiThen, the contribution ratio is calculated by substituting the following formula:
Figure BDA0000943871470000041
wherein n is the total number of the experimental schemes; rhoil、ρiqAre respectively key factors xiA first term contribution rate and a second term contribution rate corresponding to the output characteristic y; rhoeIs the error term contribution rate; sil、SiqAre respectively key factors xiThe square sum of the fluctuation of the primary term and the square sum of the fluctuation of the secondary term corresponding to the output characteristic y; seIs the sum of the squares of the error terms; veIs the error variance; sil、Siq、Se、VeThe calculation formula of (a) is as follows:
Figure BDA0000943871470000042
in the formula T1i、T2i、T3iIn the test results, the key factors x are respectively correspondediThe sum of three horizontal portions; df is aeIs the degree of freedom of the error term. If S isilAnd SiqMiddle to average ratio VeSmall items exist, which need to be merged to SeAnd each merging term, dfe1 needs to be added; sTThe sum of the squares of the total deviations of the output characteristics is calculated as follows:
Figure BDA0000943871470000043
in the formula
Figure BDA0000943871470000044
Is an output characteristic average value.
The tolerance step size in step S3 can be set to be larger in the initial stage of tolerance optimization to speed up the optimization, and should be set to be smaller in the final stage of tolerance optimization to achieve the goal of optimal result. Therefore, an acceleration coefficient capable of meeting the above requirement is introduced into the tolerance step calculation, and then the contribution ratio is combined to obtain a calculation formula of the tolerance step:
Ii+1＝αρiMi
in the formula Ii+1The step length of the step (i + 1); rhoiThe contribution rate calculated for the ith step; miα is an acceleration coefficient, and is calculated according to the following formula:
Figure BDA0000943871470000051
formula (III) ηiAnd (4) representing the ratio of the output characteristic fluctuation range calculated in the ith step to the tolerance optimization standard.
The tolerance limits for step i +1 are:
Figure BDA0000943871470000052
in the formula Mi+1The tolerance limit value of the step i + 1; the actual processing capacity is a lower limit value. [ -Mi+1,Mi+1]I.e., the new tolerance (or range of tolerances).
In step S4, 100 key factor virtual samples conforming to normal distribution are generated based on the monte carlo idea within each key factor tolerance range, then random combination is performed to obtain 100 electromagnetic relay virtual samples, the output characteristic value yk of the virtual sample is obtained through calculation of the relay dynamic characteristic fast calculation model, and the output characteristic value yk is substituted into a standard deviation calculation formula to obtain a standard deviation capable of reflecting the output characteristic fluctuation range.
Those of ordinary skill in the art will understand that: the figures are merely schematic representations of one embodiment, and the blocks or flow diagrams in the figures are not necessarily required to practice the present invention.
Those of ordinary skill in the art will understand that: modules in the devices in the embodiments may be distributed in the devices in the embodiments according to the description of the embodiments, or may be located in one or more devices different from the embodiments with corresponding changes. The modules of the above embodiments may be combined into one module, or further split into multiple sub-modules.
Finally, it should be noted that: the above examples are only intended to illustrate the technical solution of the present invention, but not to limit it; although the present invention has been described in detail with reference to the foregoing embodiments, it will be understood by those of ordinary skill in the art that: the technical solutions described in the foregoing embodiments may still be modified, or some technical features may be equivalently replaced; and such modifications or substitutions do not depart from the spirit and scope of the corresponding technical solutions of the embodiments of the present invention.

Claims (2)

1. A step tolerance optimization method of an electromagnetic relay based on a variation contribution rate is characterized by comprising the following steps:
s1: determining a tolerance optimization standard according to the quality consistency requirement of the electromagnetic relay product; determining the tolerance range of the key factor according to the relationship between the key factor and the output characteristic and the actual processing capacity;
s2: determining the number of levels of the key factor from the tolerance range determined in step S1; designing orthogonal tests according to the number of the key factors and the horizontal number, and calculating the output result of each group of orthogonal tests by using a rapid calculation model; calculating the contribution rate of each key factor according to the output result;
s3: reducing the tolerance of the contribution rate according to a certain tolerance step length to obtain a new tolerance range of the key factors; performing an orthogonal test according to the new tolerance range, and calculating the contribution rate of each key factor again;
s4: based on the monte carlo method, generating a virtual sample in the new tolerance range determined in the step S3, calculating the output characteristic distribution of the virtual sample by using a fast calculation model, and calculating the output characteristic fluctuation range of the corresponding new tolerance range;
s5: checking whether the output characteristic fluctuation range obtained in the step S4 meets the tolerance optimization standard, if not, repeating the steps S3-S4 until the output characteristic fluctuation range meets the tolerance optimization standard or the new tolerance range of each key factor reaches the lower limit of the machining precision of the equipment in the actual production process, wherein the new tolerance range of each key factor is the final result of the step tolerance optimization,
step S3 further includes introducing an acceleration coefficient meeting the setting of the tolerance step into the tolerance step calculation, and then obtaining a calculation formula of the tolerance step by combining the contribution ratio:
Ii+1＝αρiMi
in the formula Ii+1The step length of the step (i + 1); rhoiThe contribution rate calculated for the ith step; miThe tolerance limit value of the step i, α is an acceleration coefficient, and the calculation is carried out according to the following formula
Figure FDA0002438088380000011
Formula (III) ηiRepresenting the ratio of the output characteristic fluctuation range calculated in the ith step to the tolerance optimization standard;
tolerance limit M of step i +1i+1Comprises the following steps:
Figure FDA0002438088380000012
wherein the lower limit value of the actual processing capacity is shown in the formula; [ -Mi+1,Mi+1]I.e. the new tolerance range.
2. The optimization method according to claim 1, wherein in step S3, the tolerance step size set at the initial stage of tolerance optimization is larger than the tolerance step size set at the final stage of tolerance optimization.
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