Research and Application of Remanufacturability Evaluation Method for Mechanical Parts
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摘要: 再制造评价作为绿色再制造工程的设计基础,是开展再制造的前提。为了评价机械零部件的可再制造性,判断其是否适合进行再制造,基于层次分析法,提出一种以再制造相对加工指数为目标层的可再制造性评价模型;建立了涵盖技术、经济和环境三个方面的再制造评价指标体系及量化方法,并根据层次分析法确定各评价指标的权重,计算出再制造相对加工指数。以柴油机曲轴为案例,得到再制造相对加工指数为0.70,表明该曲轴可再制造性较好。Abstract: Remanufacturing evaluation is design basis of green remanufacturing engineering, and it is precondition of remanufacturing and key problem in remanufacturing research. In order to evaluate the remanufacturability of machine parts and determine whether it is suitable for remanufacturing, the remanufacturability evaluation model based on Analytic Hierarchy Process was proposed, in which the remanufacturing relative machining index was taken as target level. The model established remanufacturing evaluation index system and quantitative method covering three aspects of technology, cost and environment, and determined the weight of each evaluation index according to Analytic Hierarchy Process, and figured out the remanufacturing relative machining index. The proposed model was illustrated in a case of a diesel engine crankshaft, and the result showed the better remanufacturability of this diesel engine crankshaft.
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表 1 优先级判断尺度表
重要程度 同等重要 稍微重要 较强重要 强烈重要 极端重要 相邻判断中间值 量化值 1 3 5 7 9 2, 4, 6, 8 表 2 再制造相对加工指数评价模型
指数 评价方法、过程和结果 技术指数-失效指数 评语集: F→[破坏, 严重失效, 较大失效, 中度失效, 微小失效, 完好];
评价值:f→[f1, f2, f3, f4, f5, f6];
专家评判:X=[x1, x2, x3, x4, x5, x6];
失效指数:技术指数-工序指数——拆洗指数 评语集: M→[无法拆洗, 很难拆洗, 可拆洗, 较易拆洗, 便于拆洗];
评价值: m→[m1, m2, m3, m4, m5];
专家评判:Y=[y1, y2, y3, y4, y5];
拆洗指数技术指数-工序指数——检测指数 评语集: N→[无法检测, 很难检测, 可检测, 较易检测, 便于检测];
评价值: n→[n1, n2, n3, n4, n5];
专家评判:Z=[z1, z2, z3, z4, z5];
检测指数技术指数-工序指数 工序指数:μT2=α×μT2-1+(1-α)×μT2-2
式中, α为取值范围[0, 1]的权重系数, 由实际情况确定, 一般可取α=0.5。技术指数-修复指数 评语集: L→[无法修复, 很难修复, 可修复, 较易修复, 便于修复];
评价值: l→[l1, l2, l3, l4, l5];
(1)三角形隶属函数:μT3-1=li×Λi+lj×Λj;
(2)专家评判:;
修复指数:μT3=λμT3-1+(1-λ)μT3-2(式中, λ为取值范围[0, 1]的权重系数, 由实际情况确定, 一般可取λ=0.5)。技术指数 判断矩阵 ;
指标权重:ωT=ωT1, ωT2, ωT3;
技术指数:μT=ωT1μT1+ωT2μT2+ωT3μT3。经济指数 μC=1-(δ1+δ2+δ3+δ4)/δN, δN为采购或者全新制造该零部件的价格成本; δ1为旧件回收费用; δ2为清洗检测等环节费用; δ3为再制造修复加工费用; δ4为工人、管理等附加费用。 环境指数 , 式中:η1为再制造所需能源; η0为全新制造所需能源; β1为再制造大气污染排放量; β0为全新制造大气污染排放量; γ1为再制造水污染排放量; γ0为全新制造水污染排放量; ϕ1为再制造固体污染排放量; ϕ0为全新制造固体污染排放量。根据不同零部件特点, 权重系数θi(1≤i≤4)可适当调整, 且 ; 政策支持度系数取值范围:0≤θ0≤2, 默认θ0=1。 再制造相对加工指数 判断矩阵: ;
指标权重:ω=ω1, ω2, ω3;
再制造相对加工指数:μ=ω1μT+ω2μC+ω3μE;
可再制造性评判分级:0≤μ < 0.4, 可再制造性较低; 0.4≤μ < 0.6, 可再制造性一般; 0.6≤μ < 0.8, 可再制造性良好; 0.8≤μ < 1, 可再制造性优良。表 3 柴油机曲轴的再制造评价
指数 评价方法、过程和结果 技术指数-失效指数 评价值: f→[0, 0.2, 0.4, 0.6, 0.8, 1];
专家评判:X=[0, 0.05, 0.2, 0.55, 0.2, 0];
失效指数:μT1=0.58(阈值V1=0.25);
评价结果:评价等级为“中度失效”, 失效情况一般。技术指数-工序指数--拆洗指数 评价值: m→[0, 0.2, 0.5, 0.8, 1];
专家评判:Y=[0, 0.05, 0.1, 0.8, 0.05];
拆洗指数:μT2-1=0.75(阈值V2=0.25);
评价结果:评价等级为“较易拆洗”, 拆洗情况较好。技术指数-工序指数--检测指数 评价值: n→[0, 0.2, 0.5, 0.8, 1];
专家评判:Z=[0, 0.05, 0.15, 0.65, 0.15];
检测指数:μT2-2=0.76(阈值V3=0.25);
评价结果:评价等级为“较易检测”, 检测情况较好。技术指数-工序指数 工序指数:μT2=0.5×0.75+(1-0.5)×0.76=0.76(权重系数α=0.5);
评价结果:工序指数较好。技术指数-修复指数 评价值: l→[0, 0.2, 0.5, 0.8, 1];
(1)三角形隶属函数:μT3-1=0.1×0.5+0.9×0.8=0.77;
(2)专家评判结果:S=[0, 0.05, 0.15, 0.75, 0.05]; μT3-2=0.74(阈值V4=0.25)。
修复指数:μT3=0.5×0.77+0.5×0.74=0.76(权重系数λ=0.5)。
评价结果:评价等级为“较易修复”, 修复情况较好。技术指数 指标权重:ωT={0.281, 0.162, 0.557};
技术指数:μT=0.281×0.58+0.162×0.76+0.557×0.76=0.71;
评价结果:柴油机曲轴再制造的技术评价良好。经济指数 经济指数:μC=1-(110+150+1 000+210)/3 800=0.61;
评价结果:柴油机曲轴再制造的经济效益评价较好。环境指数 环境指数:μE=1.5×[0.25×(1-0.4)+0.25×(1-0.5)+0.25×(1-0.5)+0.25×(1-0.5)]=0.79;
评价结果:基于政府政策对绿色再制造的大力扶持, 柴油机曲轴再制造的环境效益评价较优。再制造相对加工指数 指标权重:ω={0.587, 0.221, 0.192};
再制造相对加工指数:μ=0.587×0.71+0.221×0.61+0.192×0.79=0.70;
评价结果:0.6≤μ < 0.8, 可再制造性良好, 即柴油机曲轴综合评价具有较高的再制造价值, 实施再制造的条件比较成熟, 再制造的成功率较高, 而且可以获取较好的经济效益和环境效益。 -
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