Research On Configuration Design Method For Complex ETO Products

Mass customization aims to meet the diverse requirements of customers with low cost and high efficiency,and is the mainstream production mode of manufacturing enterprises in the 21 st century.According to the customer order decoupling point,it can be divided into several types: sale-to-order,assemble-to-order,make-to-order,and engineer-to-order.Among them,engineer-to-order(ETO)is a kind of production mode with the highest complexity and the deepest degree of customization.Complex products such as rail transit vehicles,aircraft,and steam turbines all adopt this production mode.Affected by its complexity and deep customization,the rapid development of complex ETO products faces the challenges of difficult data modeling and low efficiency of custom design.In actual production,complex ETO products still have problems such as long R&D cycle,high cost,and difficulty in adapting to diverse requirements,and the goal of mass customization has not yet been achieved.Product configuration design is one of the key enabling technologies for mass customization.It realizes product customization by modeling and reusing predefined components and related design knowledge.For products make-to-order and assemble-to-order,the configuration design method is relatively mature,but relatively little attention has been paid to the configuration design of complex ETO products,and the space and time complexity of its configuration model are still insufficiently considered,the solving efficiency and quality of complex configuration problems also need to be improved.Therefore,this dissertation focuses on the configuration design of complex ETO products,and conducts research from two aspects: configuration modeling and configuration design oriented to order requirements,and combines the subway bogie to verify related methods.The main research contents are as follows:(1)Configuration modeling of complex ETO products.To describe configurable objects such as functions,technical solutions,physical modules,and related attributes and relationships in complex ETO products,a configuration modeling method based on axiomatic design and metamodel is proposed.According to the domain mapping process of axiomatic design,the product family architecture model is constructed by means of function,technical solution,and physical module correlation mapping,and based on this,the product family customer requirements,product instances,design process model and configuration rules are analyzed and modeled,to form the architecture of the configuration model.In order to facilitate the standardized expression and computer management of the configuration model,the meta-model method is used to express the configuration model.(2)Dynamic update of the configuration model.Analyze the update contents of the complex ETO product configuration model and the relationships between them,changes in customer requirements and industry technology development are the source factors for the update.For customer requirements,the steps of customer text acquisition,text denoising,text clustering and requirements preference calculation are used to mine new customer requirements from the social network platform.For industry technology,the steps of patent documents acquisition,technology and efficacy word sets definition,technology and efficacy items definition,and patent documents subject analysis are used to mine the current status of industry technology from patent documents.The configuration model is updated based on the new requirements and new technologies that are mined.(3)Design and evaluation of product engineering characteristics for order requirements.Taking life cycle cost as design goal,an engineering characteristics design method based on constraint satisfaction problem and Bayesian network is proposed.According to the product family architecture model,configuration rules,expert experience,etc.,the design space of engineering characteristics,the constraint satisfaction problem model and the life cycle cost estimation model based on Bayesian network are constructed.Taking customer requirements as input,solving the constraint satisfaction problem to obtain feasible engineering characteristics design schemes,and using Bayesian network to evaluate life cycle cost of the feasible schemes to select the best scheme.The architecture of the order product can be determined based on the engineering characteristic design scheme.(4)Product physical module configuration for order requirements.The physical module configuration of complex ETO products is realized through the module key parameters design,physical module multi-objective optimal configuration,and physical module configuration change.Design module key parameters according to the order product architecture,top-level design parameters,and design process model.Build the production cost and delivery time estimation model and the technical requirements matching degree calculation model,use normal distribution and 3σ principle to describe the uncertainty of cost and time.A multi-objective optimization configuration model of physical modules is constructed with the goal of minimum production cost,shortest delivery time,and maximum technical requirements matching degree.NSGA-II is used to solve the optimization model,and TOPSIS is used to select the recommended configuration scheme.Change the inaccurate configuration in recommended configuration scheme by means of configuration replacement,variant design,etc.to obtain the final configuration scheme.(5)Development and verification of subway bogies custom design system.According to the research results of complex ETO products configuration design method,take the subway bogie as object,research and develop its custom design system.Analyze the application background of the system,and investigate its functional requirements in combination with actual projects.Design the logical architecture,physical architecture and specific functional module scheme of the system.Using C/B/S architecture to develop the subway bogies custom design system.Finally,the application process of the system is expounded,and a subway bogie project is taken as an example to verify the system.The research on complex ETO product configuration design method in this dissertation complements and improves the ETO products design method.The developed custom design system can strengthen the organization and reuse of enterprises design knowledge,helps to improve the ability to respond the diverse requirements,and promote the research and implementation of complex ETO products mass customization.