USST_Arts_112480743自动生产线的同步维修模型及案例分析

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摘要

自动生产线在机械制造、汽车、电子等制造类企业应用广泛，发挥着极其重

要的作用。其典型的特点是设备多且关系比较复杂，为自动生产线制定合理的维

修方式，不仅能够减少停机时间，提高设备利用率，更能为企业带来巨大的经济

效益。

本论文将维修成本和可靠性结合运用到自动生产线的同步维修模型中，主要

提出了四种维修模型，并分别计算出这四种维修模型下的最佳维修时间间隔、总

同步维修成本、总故障维修成本以及总维修成本。可以根据自动生产线中设备的

实际情况选择合适的维修模型，对于提高企业自动生产线的维修管理水平具有重

要的理论意义和实用价值。本文的主要工作分为以下几点：

1. 介绍了国内外关于自动生产线设备维修的相关研究现状，主要聚焦于多单元

系统的预防性维修计划，包括机会维修模型和块/组替换模型。提出了将成

本和可靠性结合运用到自动生产线同步维修的必要性。

2. 比较全面系统地介绍了自动生产线，包括分类、特点、组成，重点在于介绍

自动生产线的维修保养。

3. 介绍了自动生产线同步维修思想的相关基础理论，包括设备寿命周期费用理

论、设备可靠性理论、设备综合工程学理论、状态监测和故障诊断理论以及

时间延迟维修理论等，随后详细地介绍了自动生产线制定同步维修计划的操

作步骤。

4. 推导出基于成本的模型和基于可靠性的模型，在这两个模型的基础上提出了

基于成本和可靠性相结合的模型，随后又针对基于可靠性的模型的局限性，

将其修改为基于有效维修时间间隔的可靠性模型。

5. 结合案例分析，证明模型的可用性。

关键词：自动生产线同步维修成本设备可靠性

ABSTRACT

Automatic production line plays an important role and is widely used in machinery

manufacturing, automotive, electronics and other manufacturing enterprises. It consists

lots of equipments with complicated relationship and chooses a reasonable maintenance

which will reduce downtime, improve equipments utlization and bring huge economic

benefits.

This thesis will introduce cost and reliability into the synchronous maintenance

model of automatic production line. Four maintenance models are proposed and be

caculated each best maintenance intervals and overall maintenance cost. Based on the

actual situation of automated production line, the appropriated service model should be

adpotd to optimize the entire performance. It can help to improve maintenance

benchmark for automatic production line in theoretical and practical fields. The main

research contents are listed as followings:

1. Introduce relevant research on automatic production line maintenance and mainly

focus on maintenance planning for the multi-machine systems, and the opportunistic

maintenance model and block/group replacement model. Cost and reliability are

combined and necessarily used into the synchronous maintenance of automatic

production line.

2. The comprehensive and systematic introduction of automatic production line is

given, which includs classification, characteristics, composition, and particular for

maintenance.

3. Introduce the basic synchronous maintenance theroy of automatic production line,

including equipment life-cycle cost theroy, equipment reliablity theroy, terotechnology

theroy, condition monitoring and fault diagnosis theroy, and time dalay maintenance

theroy. A detailed procedure on synchronous maintenance is descriped.

4. Derived the models respectively based on cost and reliability. Then put forward a

model based on the combination of cost and reliability, and correct the model based on

reliability.

5. Prove the utility of the proposed combination model with case analysis.

Key Words: Automatic Production Line,Synchronous Maintenance,

Cost,Equipment Reliability

中文摘要

ABSTRACT

第一章绪论 ······················································································································1

1.1 研究背景及意义 ································································································· 1

1.1.1 研究背景 ·································································································· 1

1.1.2 意义 ·········································································································· 2

1.2 国内外研究现状 ································································································· 3

1.2.1 国外研究现状 ·························································································· 3

1.2.2 国内研究现状 ·························································································· 4

1.3 研究内容 ············································································································· 5

1.4 研究思路 ············································································································· 5

1.5 本章小结 ············································································································· 6

第二章自动生产线的维修管理 ···································································· 7

2.1 自动生产线的相关介绍 ····················································································· 7

2.1.1 自动生产线的特点 ·················································································· 7

2.1.2 自动生产线的组成 ·················································································· 8

2.1.3 自动生产线的分类 ·················································································· 9

2.2 自动生产线的维修 ··························································································· 10

2.3 本章小结 ··········································································································· 11

第三章同步维修理论和方法 ····································································· 12

3.1 同步维修的相关理论介绍 ··············································································· 12

3.1.1 设备寿命周期费用理论 ········································································ 12

3.1.2 设备可靠性理论 ···················································································· 14

3.1.3 设备综合工程学理论 ············································································ 16

3.1.4 状态监测和故障诊断理论 ···································································· 18

3.1.5 时间延迟维修理论 ················································································ 20

3.2 同步维修方法介绍 ··························································································· 21

3.2.1 影响同步维修计划的因素 ···································································· 21

3.2.2 同步维修计划的准备工作 ···································································· 23

3.2.3 同步维修计划制定流程 ········································································ 24

3.2.4 设备维修的步骤 ···················································································· 25

3.3 本章小结 ··········································································································· 27

第四章同步维修模型 ···································································································28

4.1 模型的假设条件 ······························································································· 28

4.2 基于成本的模型 ······························································································· 28

4.2.1 有关符号 ································································································ 29

4.2.2 模型的建立 ···························································································· 29

4.3 基于可靠性的模型 ··························································································· 30

4.3.1 有关符号 ································································································ 31

4.3.2 模型的建立 ···························································································· 31

4.4 基于成本和可靠性相结合模型 ······································································· 32

4.4.1 有关符号 ································································································ 32

4.4.2 模型的建立 ···························································································· 33

4.5 基于有效维修时间间隔的可靠性模型 ··························································· 34

4.5.1 有关符号 ································································································ 34

4.5.2 模型的建立 ···························································································· 35

4.6 本章小结 ··········································································································· 36

第五章案例分析 ···········································································································37

5.1 自动生产线的基本情况 ··················································································· 37

5.2 基于成本的模型计算结果 ··············································································· 37

5.3 基于可靠性的模型计算结果 ··········································································· 38

5.4 基于成本和可靠性相结合模型计算结果 ······················································· 39

5.5 基于有效维修时间间隔的可靠性模型计算结果 ··········································· 41

5.6 本章小结 ··········································································································· 43

第六章结论与展望 ·······································································································44

6.1 结论 ··················································································································· 44

6.2 研究展望 ··········································································································· 45

参考文献 ·························································································································46

攻硕期间主要的研究成果 ·····························································································50

致谢 ·································································································································51

第一章绪论

本章首先介绍的是课题的研究背景及意义，其次回顾国内外研究现状，找出

这些研究存在的不足之处，从而引出了本课题的研究内容以及所使用的方法，最

后介绍了论文的研究思路。

1.1 研究背景及意义

1.1.1 研究背景

近几十年以来，随着经济全球化的发展，自动生产线在企业的应用越来越广

泛，所体现出来的优势也越来越明显，已经成为现代企业生产发展最重要的物质

技术基础[1]。2002 年统计的国内的大型锻造自动生产线便有120 多条，绝大部分

是属于汽车行业的。到目前为止，经过了十多年的飞速发展，自动生产线的数目

更是已经无法估计。

其中，自动生产线在机械制造、汽车、电子等制造类企业是必不可少的，发

挥着极其重要的作用[2-5]。自动生产线典型的特点是设备多且彼此联系。与非自动

生产线相比能够大大缩短生产周期，降低生产费用，加快社会生产力的发展，减

轻人力劳动，适用于流水线上大批量生产[6-8]。

通过大量调查，发现这些企业目前都遇到了一个共同的难题：即自动生产线

的维修费用问题[9-10]，企业的维修费用耗资巨大。根据调查得知：制造类企业的生

产线维护费用竟然占到总生产费用的10%-30%[11]，并且故障率高达 14.8%。

面对如此巨大的压力，为自动生产线选择合适的维修方式将会是一项巨大的

挑战。

目前，大部分企业对自动生产线所采取的维修方式是“计划预修制+点检维修

制”[12]。主要分为四种：

1. 定期派人按点检表检查各部件，发现有问题立即排除。该方式即使需要维修，

停机时间也相当短，不会影响自动生产线的正常运行。

2. 制定月度维修计划，维修当天停开全部或部分自动生产线，批量修理出现的

故障。

3. 制定年度维修计划，可能会让自动生产线长期停止运行。该维修方式类似于

大修，工作量相当大，维修费用高。

4. 对自动生产线上的关键设备采用状态监测技术。

上海理工大学硕士学位论文

这些维修方式虽然能有效提高自动生产线的维修管理水平，但是涉及到生产

线设备之间的复杂关系时，以上这些维修方式都没有全面的考虑到自动生产线协

同维修的问题。

通过对自动生产线维修方式的分析，可以制定一个合理的维修计划，改变目

前维修费用如此之高的现状，指导今后的维修行为。

本文对以往文献进行了仔细地研究和分析，推导出了基于成本和基于可靠性

的模型，发现这两种模型虽然比较适合于自动生产线的维修，但却存在着不足之

处，为了弥补这种缺陷，随后在同步维修思想的基础上提出了一种新模型，该模

型同时考虑了设备的可靠性和维修成本问题，可用于自动生产线的同步维修。最

后给出一个算法，该算法是对基于可靠性的模型的优化，目的是发展一个基于有

效维护时间间隔的同步维修方法。

1.1.2 意义

自动生产线的维修方式如果制定的不合理，将会产生比较严重的后果，不仅

会浪费大量的时间，而且更重要的是会有严重的经济损失。同时可能会影响企业

的生产计划，导致缺货，交货期延迟，这样就可能会大大降低员工的工作积极性

以及影响公司的信誉。

随着科技水平以及电子信息的进步，自动生产线的设备复杂性程度也在不断

提高，因此制定一个合理维修方式的难度也在不断攀升。

对自动生产线采取同步维修的意义[13]可概括如下：

1. 确定适当的维修间隔期。自动生产线由多种零部件组成，如果按照每一部件

的技术状态来确定自动生产线的维修间隔期，时间可能会很短，这样的话维

修管理工作也会非常复杂。采取同步维修可以找出一个最合理的维修间隔期。

2. 减少维修工作量和维修难度。自动生产线设备多且互相关联，各自维修会有

很多的重叠工作。实施同步维修可以消除重复，且有利于采用较合理的维修

工艺。

3. 生产线各零部件的技术状态是相互影响的，采取同步维修在很大程度上会延

长设备的使用寿命。

4. 减少维修停机时间，提高设备利用率。对自动生产线进行同步维修，各个部

件的维修工作是可以同时进行的，就会重叠相当一部分的维修停机时间。

5. 降低生产费用，提高产品质量。这是所有维修工作的最终目的，同部维修也

不例外。

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