CN115203860A - Polarized relay tolerance automatic allocation method considering manufacturing cost - Google Patents
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Abstract
A polarized relay tolerance automatic distribution method considering manufacturing cost relates to a polarized relay tolerance distribution method. Establishing a potential rule for analyzing the tolerance change, quality consistency promotion and cost change of parts by using a digital prototype model; carrying out unified decomposition on the manufacturing process according to different processing modes; designing parameters of parts and assembly processes with different tolerance combinations, testing to obtain the cost of the parts and the assembly processes, screening out the most appropriate tolerance-cost function, and determining model parameters by using least square identification; constructing an uncertainty maximum limit iteration model under the constraint of the limit capacity of the manufacturing process; analyzing the deviation between the fluctuation of the quality parameters of the current design state and a design target, establishing an automatic allowance redistribution target function, optimizing the target function and determining an optimal solution set; and sampling to verify whether the design requirements are met. The method helps to control the rise of the manufacturing cost of the polarized relay while ensuring the tolerance redistribution accuracy and efficiency.
Description
Technical Field
The invention relates to a polarized relay tolerance distribution method, in particular to a polarized relay tolerance automatic distribution method considering manufacturing cost, and belongs to the technical field of polarized relay design.
Background
The relay has the irreplaceable advantages of a series of solid-state electronic devices, such as multi-loop synchronous switching, large control and load output ratio, strong electromagnetic interference resistance, high isolation depth and the like, and is widely applied to various fields. In recent years, as equipment is miniaturized, has high sensitivity and high energy-to-volume ratio, the relay is required to have high sensitivity, low power consumption and small volume. The polarized relay designed by introducing the permanent magnet on the basis of the traditional clapper type relay has the power consumption as low as 80mW, the sensitivity can be improved to more than one time, and typical polarized relays are divided into a differential polarized magnetic system and a bridge polarized magnetic system, are successfully applied to partial fields extremely sensitive to the power consumption and become important components in a family pedigree of the relay.
The addition of the permanent magnet obviously improves the performance of the relay, and simultaneously increases the quantity of relay parts and the assembly complexity (such as permanent magnet fixation, quantitative magnetization and demagnetization and the like), so that the problem of poor quality consistency of the original relay is more prominent. Tolerance redistribution is a typical method for controlling fluctuation of manufacturing and assembling processes of parts, and consistency of manufacturing and assembling processes of the parts of the polarized relay can be improved by reducing the maximum uncertainty limit of design parameters of the polarized relay, so that consistency of performance characteristic parameters of the products of the polarized relay is improved. However, in the currently commonly used manual tolerance redistribution method based on the constant contribution rate coefficient and the empirical formula, when the variation range of the design parameter is large, a large deviation occurs in the optimization result, the accuracy of the empirical formula also has a large influence on the optimization precision, and the automatic redistribution of the tolerance of the design parameter of the polarized relay cannot be quickly and accurately realized.
Disclosure of Invention
In order to solve the problems of poor distribution efficiency, low precision and obvious increase of the manufacturing cost of the polarization relay caused by fixing a contribution coefficient, manually distributing, neglecting the manufacturing cost and manufacturing feasibility in the existing polarization relay design parameter tolerance redistribution, the invention provides the polarization relay tolerance automatic distribution method considering the manufacturing cost.
In order to realize the purpose, the invention adopts the following technical scheme:
an automatic polarized relay tolerance assignment method considering manufacturing cost, comprising the steps of:
s1, analyzing the structure and part characteristics of a polarized relay according to a drawing and a working principle of the polarized relay, determining the assembling process characteristics of the polarized relay, establishing a digital prototype model of the polarized relay, and analyzing the potential rules of part tolerance variation, quality consistency improvement and cost variation;
s2, analyzing the polarization relay parts and the manufacturing process machining mode according to the polarization relay parts and the assembling process characteristics determined in the S1, and performing unified decomposition on the manufacturing process of the polarization relay into five types, namely an excircle characteristic, an inner hole characteristic, an outer hole characteristic, a positioning characteristic, a plane characteristic and a surface coating characteristic according to different machining modes;
s3, designing parameters of parts and assembly processes with different tolerance combinations based on an orthogonal test method, obtaining the cost of the parts and the assembly processes through tests, screening out a tolerance-cost function which is most suitable for polarizing the parts and the assembly processes of the relay, and determining model parameters of the tolerance-cost function by using least square identification;
s31, aiming at the characteristics of the parts and the assembly process determined in the S1 and the manufacturing process unified decomposition result determined in the S2, combining a cost function form, selecting five levels of a central value, plus or minus 10 percent and plus or minus 20 percent from the manufacturing process of each part to manufacture an orthogonal test table, and counting the manufacturing process cost of the parts;
s32, based on the test result in the S31, selecting a tolerance-cost function of the most proper polarized relay part and the assembly process from the exponential function, the logarithmic function, the exponential and fractional compound model, the exponential and reciprocal compound model and the reciprocal exponential and compound model, performing approximate fitting on unknown parameters in the tolerance-cost function by using a least square method to establish the tolerance-cost function of five types of manufacturing characteristics, analyzing the relation between the assembly tolerance and the assembly cost, and establishing the tolerance-cost model of the part and the assembly process;
s33, counting and analyzing the quantity of the polarized relay parts based on the parts and assembly process tolerance-cost model in the S32, analyzing the manufacturing characteristic quantity of each part, calculating the manufacturing cost of the polarized relay under different tolerances, and establishing a polarized relay manufacturing cost model:
wherein n is par Indicates the total number of polarized relay components,
n cha represents the number of five manufacturing characteristics of a certain part of the polarized relay,
t tor showing the tolerances of the components of the polarized relay,
P i mat. represents the cost of the material of the polarized relay parts,
n pos express assembly featuresThe total number of the characters is verified,
n time representing the total number of assembly times;
s4, under the constraint of the limit capability of the model building and manufacturing process established based on S3, automatically redistributing an acceleration step function by considering the tolerance of the variation of the contribution rate of the design parameters and the variation of the manufacturing cost caused by the tolerance variation of the polarized relay, and building an uncertainty maximum limit iterative model;
s41, analyzing the quality consistency requirement L of the polarized relay obj And the current jth design parameter of the design, the fluctuation range of the quality consistency at the end of the ith iteration
The acceleration function which realizes the automatic configuration of the step length according to the quality fluctuation and the target approach degree is constructed
S42, constructing an acceleration step function model:
wherein the content of the first and second substances,
represents the j design parameter, the contribution rate at the beginning of the (i + 1) th iteration,
s43, analyzing the limit capacity of the relay manufacturing process, and constructing an uncertainty maximum limit iteration model:
wherein, let the jth parameter y j Has a central value of y j (0) The uncertainty tolerance during the ith iteration is M yj (i) The tolerance value of the manufacturing process capacity limit is gamma, and the design parameter y is designed when the (i + 1) th iteration optimization is carried out j+1 Uncertainty tolerance of
S5, analyzing the deviation between the quality parameter fluctuation of the current design state of the polarized relay and a design target based on the model established in the S4, establishing an automatic polarized relay tolerance redistribution target function, optimizing the target function by using an intelligent algorithm, and determining an optimal polarized relay tolerance solution set;
s6, generating batch virtual polarization relay samples by a sampling method, establishing a digital prototype model, calculating the variance of the quality characteristic parameters of the samples and the change condition of the manufacturing cost, and verifying whether the improvement range of the standard deviation of the quality parameters of the polarization relays meets the design requirements.
Compared with the prior art, the invention has the beneficial effects that: the invention solves the problem that the manufacturing cost variation cannot be quantized by using the manufacturing process uncertainty information of the polarized relay in the design parameter tolerance redistribution process, so that the uncertainty maximum boundary is difficult to accurately and automatically redistribute, and realizes the high-precision and high-efficiency automatic distribution of the design parameter tolerance of the polarized relay by establishing a manufacturing cost model and a tolerance redistribution self-adaptive step size model of the polarized relay, and constructing a polarized relay tolerance automatic redistribution target function model and a manufacturing process limit capacity constraint condition by using the manufacturing process limit capacity of a polarized relay manufacturer, the quality consistency information of the current batch products and an intelligent optimization algorithm, thereby achieving the purpose of obviously improving the manufacturing feasibility and the economical efficiency.
Drawings
FIG. 1 is a flow chart of the present invention;
FIG. 2 is a flowchart of a typical polarized relay manufacturing process;
FIG. 3 is a graph of tolerance versus consistency and manufacturing cost for an embodiment, taking as an example the diameter and length of a small shaft of a polarized relay;
part a) of fig. 4 is a schematic diagram of an iterative process of quality consistency fluctuation in a specific embodiment;
part b) of fig. 4 is a schematic diagram of the contribution rate change process of the tolerance automatic redistribution process in the embodiment;
FIG. 5 is a diagram illustrating a normalized tolerance variation process in the automatic redistribution process for tolerances, in accordance with an embodiment.
Detailed Description
The technical solutions in the present invention will be described clearly and completely with reference to the accompanying 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 invention, rather than all embodiments, and all other embodiments obtained by those skilled in the art without any creative work based on the embodiments of the present invention belong to the protection scope of the present invention.
As shown in fig. 1 to 5, an automatic polarized relay tolerance allocation method considering manufacturing costs includes the steps of:
s1, analyzing the structure and part characteristics of a polarized relay according to a drawing and a working principle of the polarized relay, determining the assembling process characteristics of the polarized relay, establishing a digital prototype model of the polarized relay, and analyzing the potential rules of part tolerance variation, quality consistency improvement and cost variation;
s11, analyzing the structure, parts and assembly process characteristics of the polarized relay by combining a drawing and a manufacturing process file of the polarized relay, wherein the manufacturing process flow of a typical polarized relay is shown by referring to FIG. 2, main parts of the polarized relay comprise an armature, a yoke, an iron core, a movable spring, a static spring, a movable spring, a support and the like, and the main assembly process comprises a buckle piece combination, a support combination, an electromagnet combination, permanent magnet quantitative magnetizing and demagnetizing, initial pressure debugging, contact gap debugging and the like;
s12, establishing a digital prototype model of the polarized relay according to the structure, parts and assembly process characteristics of the polarized relay obtained by the analysis of the S11, wherein the specific implementation mode adopts the step of establishing a calculation model of quality characteristic parameters (pull-in time, release time, pull-in voltage, release voltage and contact breaking speed) of the polarized relay in ANSYS Workbench;
s13, analyzing the change conditions of the consistency and the manufacturing cost of the polarized relay when the tolerance of parts and the assembly process is changed based on the digital prototype model of the polarized relay established in the S12, wherein the specific embodiment takes the diameter and the length of a small shaft of the polarized relay as an example (at the moment, other parts and assembly process parameters of the polarized relay are set as central values, and the manufacturing cost is the cost for producing 100 small shafts provided by a polarized relay manufacturer), and the relation between the tolerance, the consistency and the manufacturing cost is shown in a reference figure 3, so that the consistency of the polarized relay is gradually improved along with the continuous reduction of the tolerance, but the manufacturing cost also presents a certain degree, and therefore, the manufacturing cost needs to be fully considered in the tolerance redistribution process;
s2, analyzing the polarization relay parts and the manufacturing process machining mode according to the polarization relay parts and the assembling process characteristics determined in the S1, and performing unified decomposition on the manufacturing process of the polarization relay into five types, namely an excircle characteristic, an inner hole characteristic, an outer hole characteristic, a positioning characteristic, a plane characteristic and a surface coating characteristic according to different machining modes;
s21, the machining process of the polarized relay part mainly comprises the steps of obtaining the size parameters of the part through excircle machining, obtaining hole positions and bending characteristics of the part through hole machining, conducting machining positioning for ensuring machining accuracy, conducting plane polishing and cleaning after the part is machined, and plating the surface of the part with metal related to nickel for ensuring the corrosion resistance and the working reliability of the polarized relay;
s22, according to different processing modes of size parameters, hole site and bending characteristics, processing and positioning, plane polishing and cleaning and surface metal plating in the S21, carrying out unified decomposition on the manufacturing process of the polarized relay into five types of excircle characteristics, inner and outer hole characteristics, positioning characteristics, plane characteristics and surface plating characteristics;
s3, designing parameters of parts and assembly processes with different tolerance combinations based on an orthogonal test method, obtaining the cost of the parts and the assembly processes through tests, screening out the most suitable tolerance-cost function of the polarized relay parts and the assembly processes from an exponential function, a logarithmic function, an exponential and fractional composite model, an exponential and reciprocal index composite model and a reciprocal exponential product composite model, and determining the model parameters of the tolerance-cost function by using least square identification;
s31, aiming at the characteristics of the parts and the assembly process determined in the S1 and the manufacturing process unified decomposition result determined in the S2, combining a cost function form, selecting five levels of a central value, plus or minus 10 percent and plus or minus 20 percent from the manufacturing process of each part to manufacture an orthogonal test table, and counting the manufacturing process cost of the parts;
s32, based on the test result in S31, selecting a tolerance-cost function of the most proper polarization relay parts and the assembly process from the exponential function, the logarithmic function, the exponential and fractional compound model, the exponential and reciprocal compound model and the reciprocal exponential and exponential compound model, performing approximate fitting on unknown parameters in the tolerance-cost function by using a least square method to establish the tolerance-cost function of five types of manufacturing characteristics, and analyzing the relation between the assembly tolerance and the assembly cost (including the assembly time cost) to establish the tolerance-cost model of the parts and the assembly process;
s33, counting and analyzing the quantity of the polarized relay parts based on the parts and the assembly process tolerance-cost model in the S32, analyzing the manufacturing characteristic quantity of each part, calculating the manufacturing cost of the polarized relay when the tolerances are different, and establishing a polarized relay manufacturing cost model:
wherein n is par Indicates the total number of polarized relay components,
n cha represents the number of five types of manufacturing characteristics of a certain part of the polarized relay,
t tor showing the tolerances of the components of the polarized relay,
P i mat. represents the cost of the material of the polarized relay parts,
n pos the total number of assembled features is indicated,
n time representing the total number of assembly times;
s4, under the constraint of the limit capability of the model building and manufacturing process established based on S3, automatically redistributing an acceleration step function by considering the tolerance of the variation of the contribution rate of the design parameters and the variation of the manufacturing cost caused by the tolerance variation of the polarized relay, and building an uncertainty maximum limit iterative model;
s41, analyzing the quality consistency requirement L of the polarized relay obj And the current jth design parameter of the design and the quality consistency fluctuation range at the end of the ith iteration
The acceleration function which realizes the automatic configuration of the step length according to the quality fluctuation and the target approach degree is constructed
S42, combining a tolerance design contribution rate function, a quality loss function and a quality fluctuation acceleration function, constructing an acceleration step function model:
wherein the content of the first and second substances,
represents the j design parameter, the contribution rate at the beginning of the (i + 1) th iteration,
s43, analyzing the limit capacity of the relay manufacturing process, and constructing an uncertainty maximum limit iteration model:
whereinLet us note the jth parameter y j Has a central value of y j (0) The uncertainty tolerance during the ith iteration is M yj (i) The tolerance value of the manufacturing process capacity limit is gamma, and the design parameter y is designed when the (i + 1) th iteration optimization is carried out j+1 Uncertainty tolerance of
S5, analyzing the deviation between the quality parameter fluctuation of the current design state of the polarized relay and a design target based on the model established in the S4, establishing an automatic polarized relay tolerance redistribution target function, optimizing the target function by using an intelligent algorithm, and determining an optimal polarized relay tolerance solution set;
s51, designing an orthogonal test scheme according to the requirements of the service environment and the quality characteristics of the polarized relay, and screening out tolerance automatic redistribution key parameters from the part parameters and the assembly process parameters of the polarized relay by using a contribution rate analysis method;
s52, calculating tolerance according to the current design state of the polarized relay, and automatically redistributing the manufacturing cost ratio at the initial moment, the consistency fluctuation level, the quality consistency preset requirement and the limit manufacturing process capability of the critical parameter of the tolerance design;
s53, obtaining a next step value distributed by the maximum uncertainty limit of the polarization relay by using a formula (3), optimizing an iteration process by using an intelligent algorithm (such as a particle swarm or a differential evolution algorithm and the like) based on the formula (4) until the ratio of the quality consistency fluctuation to a preset requirement is 1, and determining the optimal tolerance combination of the key parameters for automatic redistribution of the tolerance of the polarization relay, wherein in the specific implementation mode, a schematic diagram of the quality consistency fluctuation iteration and contribution rate variation process is shown by referring to FIG. 4, and a schematic diagram of the normalized tolerance iteration variation is shown by referring to FIG. 5;
s54, based on the result of S53, standardizing the optimal tolerance range according to the national standard and the process control specification of a polarized relay manufacturer to obtain a polarized relay standardized tolerance combination;
s6, generating batch virtual polarization relay samples by a sampling method, establishing a digital prototype model, calculating the variance of sample quality characteristic parameters and the change condition of manufacturing cost, and verifying whether the improvement amplitude of the standard deviation of the polarization relay quality parameters meets the design requirements or not;
s61, based on the optimization result of S54, generating batch virtual polarization relay samples by a sampling method (such as Monte Carlo, uniform sampling, latin hypercube sampling and the like), and establishing a digital prototype model of the batch samples;
s62, calculating the quality parameters (pull-in release time, pull-in release voltage and service life) of the polarized relay by using a digital prototype model, carrying out statistical analysis on the standard deviation of the quality parameters and the manufacturing cost, and comparing the calculation result with the calculation result before uncertainty redistribution to verify whether the calculation result meets the design requirements.
It will be evident to those skilled in the art that the invention is not limited to the details of the foregoing illustrative embodiments, and that the present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. Any reference sign in a claim should not be construed as limiting the claim concerned.
Furthermore, it should be understood that although the present description refers to embodiments, not every embodiment may contain only a single embodiment, and such description is for clarity only, and those skilled in the art should integrate the description, and the embodiments may be combined as appropriate to form other embodiments understood by those skilled in the art.
Claims (5)
1. A polarized relay tolerance automatic allocation method considering manufacturing cost, characterized in that: the method comprises the following steps:
s1, analyzing the structure and part characteristics of a polarized relay according to a drawing and a working principle of the polarized relay, determining the assembly process characteristics of the polarized relay, establishing a digital prototype model of the polarized relay, and analyzing potential rules of part tolerance variation, quality consistency improvement and cost variation;
s2, analyzing the polarization relay parts and the manufacturing process machining mode according to the polarization relay parts and the assembling process characteristics determined in the S1, and performing unified decomposition on the manufacturing process of the polarization relay into five types, namely an excircle characteristic, an inner hole characteristic, an outer hole characteristic, a positioning characteristic, a plane characteristic and a surface coating characteristic according to different machining modes;
s3, designing parameters of parts and assembly processes with different tolerance combinations based on an orthogonal test method, obtaining the cost of the parts and the assembly processes through tests, screening out a tolerance-cost function which is most suitable for polarizing the parts and the assembly processes of the relay, and determining model parameters of the tolerance-cost function by using least square identification;
s31, aiming at the characteristics of the parts and the assembly process determined in the S1 and the manufacturing process unified decomposition result determined in the S2, combining a cost function form, selecting five levels of a central value, plus or minus 10 percent and plus or minus 20 percent from the manufacturing process of each part to manufacture an orthogonal test table, and counting the manufacturing process cost of the parts;
s32, based on the test result in the S31, selecting a tolerance-cost function of the most proper polarized relay part and the assembly process from the exponential function, the logarithmic function, the exponential and fractional compound model, the exponential and reciprocal compound model and the reciprocal exponential and compound model, performing approximate fitting on unknown parameters in the tolerance-cost function by using a least square method to establish the tolerance-cost function of five types of manufacturing characteristics, analyzing the relation between the assembly tolerance and the assembly cost, and establishing the tolerance-cost model of the part and the assembly process;
s33, counting and analyzing the quantity of the polarized relay parts based on the parts and assembly process tolerance-cost model in the S32, analyzing the manufacturing characteristic quantity of each part, calculating the manufacturing cost of the polarized relay under different tolerances, and establishing a polarized relay manufacturing cost model:
wherein n is par Indicates the total number of polarized relay components,
n cha represents the number of five types of manufacturing characteristics of a certain part of the polarized relay,
t tor showing the tolerances of the components of the polarized relay,
P i mat. represents the cost of the material of the polarized relay parts,
n pos the total number of features of the assembly is indicated,
n time representing the total number of assembly times;
s4, under the constraint of the limit capability of the model building and manufacturing process established based on S3, automatically redistributing an acceleration step function by considering the tolerance of the variation of the contribution rate of the design parameters and the variation of the manufacturing cost caused by the tolerance variation of the polarized relay, and building an uncertainty maximum limit iterative model;
s41, analyzing the quality consistency requirement L of the polarized relay obj And the current jth design parameter of the design, the fluctuation range of the quality consistency at the end of the ith iteration
The acceleration function which realizes the automatic configuration of the step length according to the quality fluctuation and the target approach degree is constructed
S42, constructing an acceleration step function model:
wherein, the first and the second end of the pipe are connected with each other,
represents the j-th design parameter, the contribution rate at the beginning of the (i + 1) -th iteration,
s43, analyzing the limit capacity of the relay manufacturing process, and constructing an uncertainty maximum limit iteration model:
wherein, the jth parameter y is recorded j Has a central value of y j (0) Uncertainty tolerance during the ith iterative optimization is M yj (i) The tolerance value of the manufacturing process capacity limit is gamma, and the design parameter y is designed when the (i + 1) th iteration optimization is carried out j+1 Uncertainty tolerance of
S5, analyzing the deviation between the quality parameter fluctuation of the current design state of the polarized relay and a design target based on the model established in the S4, establishing a polarized relay tolerance automatic redistribution target function, optimizing the target function by using an intelligent algorithm, and determining an optimal solution set of the polarized relay tolerance;
s6, generating a batch of virtual polarized relay samples by a sampling method, establishing a digital prototype model, calculating the variance of the quality characteristic parameters of the samples and the change condition of the manufacturing cost, and verifying whether the improvement range of the standard deviation of the quality parameters of the polarized relays meets the design requirements.
2. A manufacturing cost-considered automatic polarized relay tolerance assignment method according to claim 1, wherein: the S5 comprises the following steps:
s51, designing an orthogonal test scheme according to the requirements of the service environment and the quality characteristics of the polarized relay, and screening out tolerance automatic redistribution key parameters from the part parameters and the assembly process parameters of the polarized relay by using a contribution rate analysis method;
s52, calculating tolerance according to the current design state of the polarized relay, and automatically redistributing the manufacturing cost ratio at the initial moment, the consistency fluctuation level, the quality consistency preset requirement and the limit manufacturing process capability of the critical parameter of the tolerance design;
s53, obtaining a next step value of the maximum uncertainty boundary distribution of the polarization relay by using a formula (3), optimizing the iterative process by using an intelligent algorithm based on a formula (4) until the ratio of the quality consistency fluctuation to a preset requirement is 1, and determining the optimal tolerance combination of key parameters of automatic redistribution of the tolerance of the polarization relay;
and S54, based on the result of S53, standardizing the optimal tolerance range according to the national standard and the process control specification of a polarized relay manufacturer to obtain the standardized tolerance combination of the polarized relay.
3. A manufacturing cost-considered automatic polarized relay tolerance assignment method according to claim 2, wherein: the intelligent algorithm in the S53 is a particle swarm or a differential evolution algorithm.
4. A method for automatically assigning tolerances of a polarized relay considering manufacturing costs according to claim 1, characterized in that: the S6 comprises the following steps:
s61, based on the optimization result of S54, generating a batch of virtual polarized relay samples by a sampling method, and establishing a digital prototype model of the batch of samples;
s62, calculating the quality parameters of the polarized relay by using a digital prototype model, counting and analyzing the standard deviation of the quality parameters and the manufacturing cost, and comparing the calculation result with the calculation result before the redistribution of uncertainty to verify whether the calculation result meets the design requirements.
5. A manufacturing cost-considered automatic polarized relay tolerance assignment method as claimed in claim 4, wherein: the sampling method in S61 is Monte Carlo, uniform sampling or Latin hypercube sampling.
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