Adaptive Quality Control in Tolerancing and Production Strategies for the Economic Production of High Precision Products

高精度产品经济生产的公差和生产策略中的自适应质量控制

• 批准号: 431571877
• 负责人: Professorin Dr.-Ing. Gisela Lanza
• 金额: --
• 依托单位: Institut für Produktionstechnik (WBK)
• 依托单位国家: 德国
• 项目类别: Research Grants
• 财政年份: 2019
• 资助国家: 德国
• 起止时间: 2018-12-31 至 2022-12-31
• 项目状态: 已结题
• 来源: https://gepris.dfg.de/gepris/projekt/431571877?language=en
• 关键词: Adaptive; Quality; Control; Tolerancing; Production

Motivation Key functions of complex products often can only berealized by precision component use. Thus, producers are confrontedwith high quality requirements, cost pressure and a rising number ofproduct variants. Especially, micro components, which often havetolerances of less than 5 μm, are challenging. Technologicalimmanent process deviations obviate to manufacture components,meeting quality requirements at any time. Often cost-efficientrealization of precision products is a conflict of objectives in thedevelopment, manufacturing and assembly process, savingproduction cost with high throughput under higher deviations on theone hand and preventing high number of scraped units with morenarrow tolerances assuring the products functionality under highercapabili-ties on the other one. Even technological limits of themanufacturing processes are reached, produc-ing cutting-edgeproducts. In general, there are two approaches to cope with thischallenge: an adap-tive allocation of the tolerances by the productdesigner or an adaptive choice of the production strategy by theproduction planner. Both approaches provide fundamental conceptsfor producers in the market competition of producing economic qualityprecision products, which have not been sys-tematically analysed incombination. Approach A new holistic approach of tolerance allocationand adaptive production strategies will be developed, assessingtechnical and economic valuation of the product. The approach bringsthe en-gineering design requirements, product performanceindicators, probabilistic manufacturing and as-sembly deviations andinspection uncertainties together in a common model, where theeffects of adaptive tolerancing and adaptive production strategies ondesign, manufacturing, assembly and product function performancescan be evaluated quantitatively. Adaptive tolerancing serves toallocate optimal characteristic tolerances under holistic technical andeconomic aspects. Adaptive production strategies take use ofindividual real-time assessment in cyber-physical production systems,compensating component deviations with over-fulfilment of anassociated component. Thus, more narrow tolerance margins can berealized, meeting the quality requirements. The development of afunctional product model enables detailed product knowledgeintegration into the aforementioned strategies. Quantitativedependencies on manufacturing deviations affecting the productsfunctional fulfilment are contained to assess the introduced strategieson technical and eco-nomic aspects. Result Proof on the developedmethodology in quality increase and cost-efficiency will be conductedon an exemplarily industrial application. Micro gears for dentalinstruments serve as an exemplarily demonstration, includingnumerous high quality requirements and complex characteristicinteractions. Thus, the transferability and general applicability ofdeveloped methodologies on further use cases is assured.

动机复杂产品的关键功能往往只能通过精密部件的使用来实现.因此，生产商面临着高质量的要求，成本压力和越来越多的产品品种。尤其是公差小于5 μm的微型元件，更是极具挑战性。技术上不受工艺偏差的影响，随时制造零部件，满足质量要求。在开发、制造和装配过程中，实现高精度产品的成本效益往往是一个矛盾的目标，一方面要在高偏差下以高产量节省生产成本，另一方面要防止在更高的能力下以更小的公差报废大量产品，以确保产品的功能性。甚至达到了制造过程的技术极限，生产出尖端产品。一般来说，有两种方法来科普这一挑战：由产品设计师自适应地分配公差或由生产计划员自适应地选择生产策略。这两种方法都为生产者在市场竞争中生产经济质量的精密产品提供了基本的概念，但还没有系统地结合起来加以分析。方法一种新的整体方法公差分配和适应性生产策略将被开发，评估产品的技术和经济价值。该方法将工程设计要求、产品性能指标、概率性制造偏差、装配偏差和检验不确定性统一到一个通用模型中，定量评价了自适应公差和自适应生产策略对设计、制造、装配和产品功能性能的影响。自适应公差设计是在整体技术和经济条件下分配最佳特性公差的一种方法。自适应生产策略在信息物理生产系统中使用个体实时评估，通过相关组件的过度完成来补偿组件偏差。这样，可以实现更窄的公差范围，满足质量要求。功能产品模型的开发使详细的产品知识集成到上述战略。定量依赖于影响产品功能实现的制造偏差，以评估技术和经济方面的引进战略。结果证明的开发方法在质量提高和成本效益将进行一个典型的工业应用。牙科器械的微型齿轮是一个典型的示范，包括许多高质量的要求和复杂的特性相互作用。因此，保证了开发方法在进一步用例上的可移植性和普遍适用性。