基于作业疲劳度的变批量活塞生产线优化

论文总字数：24752字

摘 要

摘要：随着活塞加工的作业强度的增加，员工的作业疲劳度也随之增大，使得各种病症开始频发，严重影响了员工的身心健康。论文与以往的对活塞生产线的研究分析报告的角度不同，是从员工的作业疲劳度的角度去研究生产线，目的是降低员工的作业疲劳度，降低员工的发病率，使活塞生产线变得更可靠、安全。同时，针对活塞生产遇到的变革问题，提出了一种新的生产方式，即活塞软重构生产线，将活塞生产和可重构技术相结合，既能大批量生产，又能多品种变批量生产。

从工效学的角度出发，分析影响作业疲劳的原因，并根据这些因素建立作业疲劳度评估体系。利用RULA等方法对因子进行赋值，熵值法和层次分析法求得权重，得到作业疲劳度多指标量化模型。结果表明：影响作业疲劳度的主要有4中因素，分别是作业姿势、作业难度、用力负荷、心理负荷，其中作业难度影响最大。因此在优化时，应该优先考虑降低作业难度，比如安排熟练的员工，选用先进、易操作的器具等。最后为了验证模型的有效性，进行了血氧实验。结果表明：在p=0.01的水平上，作业疲劳度与脑氧饱和度之间的相关性系数达到0.979，表明测定的作业疲劳度是有效的模型也是有效的。

根据生产线平衡问题的优化目标，尝试建立平衡模型。在模型中，加入新的参数SI和Ω，SI表示作业疲劳负荷平滑程度，Ω表示平衡负荷损耗系数。针对生产线A和生产线B，根据平衡模型，通过遗传算法进行求解。结果显示：生产线B的SI和Ω都低于生产线A，这表示生产线B上的员工的作业疲劳负荷得到了有效的改善。

关键词：活塞；作业疲劳度；生产线平衡；变批量；软重构

Optimization of piston production line with various batch based on the job fatigue

02611223 Zhuanglei

Supervised by wuze

Abstract

Abstract:With the increase of the job strength of the piston machining,the job fatigue of workers also increases,making all kinds of illness begins to frequent a serious impact on health of workers.This paper is different from previous research analysis of the piston production lines.It studies the production line from the job fatigue of workers and aimed to reduce the job fatigue of workers,reduce the incidence of workers and make the piston production line more reliable and safety.Meanwhile,for the change of the piston production encountered problems,the paper proposes a new mode of production,namely,soft reconstruction piston production line.It combines the piston production with the reconfigurable technology.It not only achieves mass production,but also achieves multi-species change production.

This paper analyzes the causes of the job fatigue and establishes the job fatigue evaluation system based on these reasons from the perspective of ergonomics.It uses methods such as RULA to assignment the reasons and solves the weight with entropy method and AHP method and finally gives the job fatigue index quantitative model.The results shows that there are 4 reasons affecting the job fatigue,namely,job position,job difficulty,forced load,mental load,in which job difficulty has the most influence.Therefore,reducing the job difficulty should be considered firstly when optimizing the production line,such as arranging skilled workers,using advanced and easy appliances.Finally,in order to verify the validity of the model,oxygen experiment is operated.The results shows that the correlation coefficient of the job fatigue and cerebral oxygen saturation reaches 0.979 at the level of p=0.01,which shows that the job fatigue model is also effective.

Through the analysis of balance problem of production line and combining with the balance optimization goal of production line,balance model of piston production line based on the job fatigue is established.In the model, and are introduced, is on behalf of the fatigue smoothness coefficients and is on behalf of balance delay rate.Establishing the balance model according to production line A and the new production B.Calculating the results through genetic algorithm.The results shows that the new production line B need at least 5 workers,and both and are lower then that of the production line A.This means that job fatigue load of workers in the production line B is improved effectively.

Key words: piston;job fatigue;production line balance;various batch;soft reconstruction

目录

摘要 I

Abstract II

1、绪 论 1

1.1研究背景 1

1.2活塞及其生产线 1

1.2.1活塞结构 1

1.2.2生产线 1

1.3活塞生产线上的作业疲劳 1

1.3.1作业疲劳 1

1.3.2影响作业疲劳的因素 1

1.3.3作业疲劳度的评价方法 2

1.4生产线平衡 2

1.5活塞软重构 3

1.6课题研究的背景和意义 3

2、作业疲劳评估与量化 4

2.1作业疲劳评价 4

2.1.1活塞加工工序 4

2.1.2作业疲劳的影响因素 4

2.2作业疲劳多指标评价体系 4

2.2.1作业疲劳评价体系 4

2.2.2作业疲劳体系指标赋值评估 5

2.3作业疲劳度计算 10

2.3.1权重指标计算 10

2.3.2数据计算 12

2.3.3结果分析 13

2.4血氧实验 13

2.4.1实验方法 13

2.4.2实验结果分析 13

3、活塞生产线平衡 15

3.1活塞生产线平衡问题 15

3.2活塞生产线平衡 15

3.2.1模型描述 15

3.2.2模型建立 16

3.2.3遗传算法 16

3.2.4应用实例 17

4、活塞软重构技术 20

4.1活塞软重构的特性 20

4.2活塞软重构生产线的框架 20

4.3活塞软重构的关键技术 21

4.3.1活塞设计技术 21

4.3.2故障诊断技术 21

4.3.3布局规划技术 21

4.3.4生产控制与管理技术 22

4.3.5计算机网络支持技术 22

4.3.6建模与仿真技术 22

4.3.7物流自动化技术 22

5、结 论 23

致谢 24

参考文献： 25

1、绪 论

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