Research On The Design Methodology Of Modular Product Platform Oriented To Complex Mechantronic Products

With the developing of economic globalization and product diversification, the application of advanced design and manufacturing model, modern management methods and advanced information technology is becoming the inevitable trend of manufacturing enterprise reform. Mass customization is widely respected in today's manufacturing production, and modular product platform can provide it well. However, as an advanced and systematic design management method, modular product platform needs to be based on advanced design methodology and system theory. In this paper, taking the complex mechanical and electrical products as object, on the thorough analysis of the research status of modular theory and design methodology, it puts forward the multi-level methodology system and implement process model for modular product platform (facing existing product and new product) construction. And it researchs on the key problems in different modular levels, then does the validation of the modular methodology and application of the product modularization with an actual project for existing products.In chapterâ… , it discusses the production, the development and the achievement of methodology from the philosophical level, and the related concepts and definition of design methodology are extended. Then it evaluates the research status of methodology in different country from time and space, and does comparative analysis between mainstream design theory including systematic design, axiomatic design and TRIZ theory. On this basis, it makes the definition and the related concepts of modular design clear, and combined the modular with the study of design methodology, so that the methodology strategy for modular design is proposed. Finally, summarizes the necessity and innovation of research on modular design methodology, and gives the main content and structure of this paper.In chapterâ…¡, it firstly analyses the demands of the modular design method based on modularization theory, system design method and PDM development. Then defines the concept of existing products, new products, product platform, product family, module type and modular product platform etc., which are involved in this paper, and puts forward modular product platform modeling system oriented to existing products. Around the system, based on the thorough analysis of modular products platform characteristics, it makes the key technologies clear from method layer, technical layer and data layer. After the combination of technology system and modular product platform model, it proposes the existing products'multi-level design process model which based on the extraction process of the modular main structure.In chapterâ…¢, it builds a model of existing products'modular design process in product level, and does comparative study to the new products. It analyses the characteristics of modularization in product level, the goal of each stage and methods to achieve the goals stage by stage. For the problem of product platform division and evaluation, it determines the importance of each node by using the total and average betweennesses of nodes in structure net of product family, and gets the key platform nodes with results of function analysis. Then it gets other important nodes by calculating the correlative coefficient between them and key nodes. Using the information axiom evaluates the alternative platforms at last, and realizes the design loop. At the end of this chapter, compares existing products with new products in the formation and evolution process of modular product main structure on product level.In Chapterâ…£, it does modeling for modularization design process on components level and parts level for existing products. Then it deals with a comparative study between existing products and new products, and discusses the relationship of modularization among products level, components level and parts level. The characteristics of components level modularization and parts level modularization, the goal of each stage and specific methods to achieve the goal are elaborated by stages as well. This chapter defines ATO module, MTO module and ETO module, and analyzes deeply differences between characteristics and design methods in design process of ATO module and MTO module. For evaluation problem after module division, product module fuzzy evaluation method based on the product life cycle is proposed. First of all, it does modeling for life cycle assessment elements and puts forward seven elements of life cycle for module evaluation, then evaluate comprehensively modules by means of triangular fuzzy numbers.In Chapterâ…¤, Based on the temporal correlation and function complement between morphological methods and theory of inventive problem solving (TRIZ) on generating and analyzing the principle solutions in product design process, a double-matrix integrated model which combines morphological matrix and contradiction matrix is proposed,. The model consists of concept model, process model and related model, and follows a top-down spiral design approach. The applicable scope of morphological analysis is extended to concept level by the model, so that the combination capability of principle solutions can be analyzed; the contradiction resolving principles is used on generating solutions and solving design decoupling. Taking the research on the innovative development process of a hand driller and manual razer as examples, it validates the application process of double-matrix on new product design and the implementation of the nested sub-cycle on variant design, and proves the flexibility and operability of the model when facing deferent designing problems.In Chapterâ…¥, it validates and implements this modular product platform design process model and corresponding key technologies, methods in a state-owned construction machinery enterprise. From the products level, components level and parts level, it extracted the main product modular structure of the five-ton wheel loaders, and then formed the corresponding modular product platform. And it practises the product platform division phase and fuzzy evaluation method for modules on wheel loader. On this basis, the modularization planning system is built. It supports the promotion and implementation of theory in this paper by the data model, document model and process model.The last chapter is conculsion and outlook. The achievements of the dissertation were summarized, and the innovations were pointed. The future research works were put forward to outlook.