Abstract
For intelligent manufacturing systems, there are many deviations in operational characteristics, and the coupling effect of harmful operational characteristics leads to the variations in quality of the work-in-process (WIP) and the degradation of the reliability of the finished product, which is reflected as a loss of product manufacturing reliability. However, few studies on the modeling of product manufacturing reliability and mechanism analysis consider the operating mechanism and the coupling of characteristics. Thus, a novel modeling approach based on quality variations centered on the coupling of operational characteristics is proposed to analyze the formation mechanism of product manufacturing reliability. First, the PQR chain containing the co-effects among the manufacturing system performance (P), the manufacturing process quality (Q), and the product manufacturing reliability (R) is elaborated. The connotation of product manufacturing reliability is defined, multilayered operational characteristics are determined, and operational data are collected by smart sensors. Second, on the basis of the coupling effect in the PQR chain, a multilayered product quality variation model is proposed by mining operational characteristic data obtained from sensors. Third, an integrated product manufacturing reliability model is presented on the basis of the variation propagation mechanism of the multilayered product quality variation model. Finally, a camshaft manufacturing reliability analysis is conducted to verify the validity of the proposed method. The method proposed in this paper proved to be effective for evaluating and predicting the product reliability in the smart manufacturing process.
Highlights
In intelligent manufacturing systems, with the widespread application of intelligent technology and advanced sensors, traditional resources are converted into intelligent data and information [1].Intelligent manufacturing systems, which involve men, machines, materials, methods, environments, and measurements, are complicated
The manufacturing reliability of the camshaft was presumed to be based on the normal levels of the machines, processes and WIP that provide a reference for controlling the degradation of product manufacturing reliability in advance
The results show that fully considering the coupling effect of operational characteristics and the degradation mechanisms of the machine, process, and WIP improves the characteristics and the degradation mechanisms of the machine, process, and WIP improves the accuracy of product manufacturing reliability to a certain extent, which can reduce product losses and accuracy of product manufacturing reliability to a certain extent, which can reduce product losses provide a reference for subsequent machine maintenance plans
Summary
With the widespread application of intelligent technology and advanced sensors, traditional resources are converted into intelligent data and information [1]. Given that the variation propagation of harmful characteristics in the manufacturing system can lead to the degradation of product quality, the Quality–Reliability co-effect model is used to construct the interaction relationship between manufacturing process quality and output product reliability [19]. Considering that variations in the operational characteristics in the manufacturing system are continuously transmitted and coupled during the machining process, the quality of WIP is eventually reduced, and the reliability of the finished product after the manufacturing process is degraded. Multilayered product quality variation models considering the coupling effect of operational characteristics, which include machine operation status, processing fluctuation, and WIP quality degradation, are established.
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