| Under the pressure brought by globalization, restricted environment/resources and fast change of high technology, the mechanical manufacturing enterprise should change the traditional practice of only selling physical products and provide products with more value-added services, so as to meet personalized customer demand and to obtain more sustainable profits. It has become a tendency that a manufacturer provides its customers with service solution packages of "physical products and/or product services", which is known as generalized products. Module design is an important way to provide speedy, low-cost, and personalized products and services. With the review of existing present study on manufacturing services, product-service system and module design of generalized product, this dissertation analyzes problems in module design of generalized product both in China and abroad and examines the methodology system of mainstream designs at present. It is proposed that module design of generalized product should be comprised of two levels, service solution level and physical level. Based on the above analysis, this dissertation constructs a methodology system for module design of generalized products and studies the main modular structure and configuration design method for generalized products. The main research results and innovative points are as follows:(1) Analyzing the classification, forming process and characteristics of generalized product, according to relationships between tangible physical structure and intangible service of generalized products. Based on the definition, classification and characteristics of generalized module are given, the theoretic framework and technology system of generalized product module partition and fusion are proposed based on two levels, which are the services solution layer and physical layer. The new theory and technology system are beneficial to form the generalized modular product platform, also support the configuration design for different types of generalized product.(2) Building a three-stage interactive module partition process model for generalized product and providing a specific module partition method at every stage. The three stages are the service module partition based on "Top-Down", the physical module partition based on "Top-Down" and the service module partition based on "Bottom-Up". The HoQ (House of Quality) method is used to evaluate the consistency between different generalized modules, which are examined separately to ensure the reasonableness and consistency of module partition. Then, bi-level module programming is used to analyze generalized product. First, the types of modules for the generalized products of different types are fixed based on Kano model. Then, based on combined analysis, regulations are given to the customer decision-making modules with their attributes and the manufacturer decision-making modules with their attributes for the generalized products of different types, which provide the foundation for the optimization method of generalized product configuration.(3) Studying modular structure modeling method of generalized products. Firstly, the modular main structure modeling and the modular instance structure modeling of generalized product are constructed. Then, service is treated as a "Parts" object without the increase of business objects. The generalized product data model is described by increasing the attributes of "Parts" main record and the connection objects between "Parts" are studied. Finally, through the secondary development based on PLM software system, the generalized product data model and modular instance structure of the generalized transformer product are realized. The research achievements in this section enrich and enlarge the traditional integrated product meta-model, providing support for generalized product module configuration design.(4) Building an optimization model of generalized product module configuration design based on bi-level programming. The generalized product module configuration design process refers to the iteration and cycling between the service scheme level and the physical module level. Based on the bi-level programming, this dissertation builds an optimization decision-making model for configuration design. Based on the case of generalized transformer, the genetic algorithm (GA) is used to solve the decision-making model based on bi-level programming, which provides a new approach for the optimization model of generalized product configuration design. |
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