CN103149844A - Method for controlling pull-in voltage consistency of batch products of relay - Google Patents

Abstract

The invention relates to a method for controlling the pull-in voltage consistency of batch products of a relay and aims to solve the problem of low consistency of the batch products in a manufacturing process caused by lack of a consistency control method for guiding a developer to allocate reasonable tolerances to controllable parameters in a relay product development process. The method for controlling the pull-in voltage consistency of the batch products of the relay provided by the invention comprises the following steps of: 1, performing orthogonal experimental design; 2, analyzing test data contribution ratio; 3, establishing a tolerance allocation target function; 4, determining key parameters and tolerances thereof; and 5, controlling a relay manufacturing process. The method is applied to the field of consistency control in a relay development phase.

Description

Relay batch products pick-up voltage consistance control method

Technical field

The present invention relates to relay batch products pick-up voltage consistance control method.

Background technology

The subject matter of at present existing relay product quality is not poor performance, and the dispersiveness of batch products is too large, this is due to both at home and abroad in the research and development and manufacture process of relay product, focus on the output performance of product, the output valve of characteristics such as pick-up voltage, release voltage, pickup time, release time, instruct the research staff to carry out the conforming correlation analysis of batch products and control and lack clear and definite consistance control method.

In prior art for the control of relay batch products consistance and correlative study, be mainly the reliability degree calculation method of Based on Probability statistical study.The method is according to the controllable parameter Tolerance Allocation scheme of (comprising the machined parameters of parts and the assembly parameter of assembly), usually adopt the tolerance band of Monte Carlo method split-phase relay static attractive torque characteristic and static spring load characteristic, thereby calculate fiduciary level or the accepted product percentage of batch relay product according to suction counter-force matching relationship, with this, carry out the consistance of Indirect evaluation batch products.If the fiduciary level calculated does not meet the demands, need the research staff adjust by rule of thumb the tolerance of each parameter and recalculate fiduciary level, until meet the demands.

The consistance of pick-up voltage is the important indicator of examination relay batch products mass property, existing method only can accurately calculate relay controllable parameter tolerance and specify under the manufacture grade, the fiduciary level that the static attractive force and spring force characteristics of batch products coordinates, and can't determine directly, quantitatively each parameter under current tolerance grade to the consistent sex significance degree of batch products pick-up voltage, cause the research staff to lack objectivity when the given parameters tolerance, can not reach the optimization of quality and cost.In addition, the method is to carry out the consistance of Indirect evaluation batch products by the cooperation fiduciary level of static attractive force and spring force characteristics, can not be that pick-up voltage is directly assessed with the relay dynamic output characteristic.

Owing to manufacturing dispersed outwardness, relay can not fully be processed and be assembled according to the central value of parameter of appointment in process of production, causes the mass property of product and theoretical value produce deviation and present random fluctuation.Therefore, need to retrain the fluctuation of product quality characteristics for controllable parameter distributes tolerance.All parameters are all distributed very high-precision tolerance if, and the output characteristics of product is inevitable very good, but can cause the too high working ability scope that even exceeds of production cost of product, and this is obviously worthless.Therefore, need to find the significant controllable parameter of the influence of fluctuations of output of products characteristic and distribute rational tolerance for it, and inapparent factor is still adopted to lower tolerance grade, thereby guarantee to make the consistance of batch products reach target call under existing manufacturing capacity.Yet, owing to still lacking at present relevant consistance control method, the research staff can't determine key factor in numerous controllable parameters and, for it distributes rational tolerance grade, cause the consistance of relay batch products poor, and become the main cause that affects relay product quality level.

Summary of the invention

The present invention will solve in the relay product R&D process control method that is lack of consistency to instruct the research staff to distribute rational tolerance to controllable parameter, and then cause the poor problem of batch products consistance in manufacture process, and relay batch products pick-up voltage consistance control method has been proposed.

Relay batch products pick-up voltage consistance control method realizes according to the following steps:

One, Orthogonal Experiment and Design

Relay is set n controllable parameter X arranged ₁, X ₂..., X _n, adopt orthogonal experiment design experiment scheme:

Each controllable parameter is got three levels according to formula (1) and is carried out the gauge outfit design, and three levels are respectively central value m _iand according to the tolerance Δ _ihigher limit and the lower limit of fluctuation;

Two, test figure Contribution Rate

Calculate relay pick-up voltage y corresponding to each testing program ₁, y ₂..., y _nafter, n test figure carried out to statistical study, obtain each controllable parameter X _icontribution rate ρ _i/ %, be divided into an once contribution rate ρ _xil/ % and quadratic term contribution rate ρ _xiq/ %;

Three, set up the Tolerance Allocation objective function

By each controllable parameter X in step 2 _icontribution rate bring formula (2) into, obtain the characterising parameter tolerance from Δ _ichange into Δ ' _ithe time the corresponding output characteristics degree of consistency funtcional relationship that changes, i.e. Tolerance Allocation objective function:

$\mathrm{\δ}=\underset{i=1}{\overset{n}{\mathrm{\Σ}}}({\mathrm{\ρ}}_{\mathrm{Xil}}{\left(\frac{{\mathrm{\Δ}}_i^{\′}}{{\mathrm{\Δ}}_i}\right)}^2+{\mathrm{\ρ}}_{\mathrm{Xip}}{\left(\frac{{\mathrm{\Δ}}_i^{\′}}{{\mathrm{\Δ}}_i}\right)}^4)+{\mathrm{\ρ}}_e...\left(2\right)$

Wherein, Δ _itolerance before meaning to change, Δ ' _itolerance after meaning to change, ρ _xilexpression factor X _ionce contribution rate, ρ _xiqexpression factor X _ithe quadratic term contribution rate, ρ _emean the error term contribution rate;

Four, determine key parameter and tolerance thereof

Determine the relay key parameter according to the size of each controllable parameter contribution rate value, and determine after the tolerance of each parameter is improved the manufacture grade that should reach in the mode of formula (3);

Δ′ _i＝(1-k×ρ _i)Δ _i＝[1-k×(ρ _Xil+ρ _Xiq)]Δ _i (3)

Wherein, k is the Tolerance Allocation factor, ρ _ifor controllable parameter X _icontribution rate, by k * ρ _iweight coefficient as Tolerance Allocation; For definite coincident indicator, by changing the value of k, make the consistance of batch products be increased to target call;

Five, relay is manufactured process control

Each controllable parameter tolerance of determining according to step 4, the precision that each controllable parameter in clear and definite relay manufacture process should be satisfied, guarantee that the consistance of batch products pick-up voltage meets target call.

The invention effect:

The present invention is directed to the crucial output characteristics parameter of batch relay product---the coincident indicator of pick-up voltage, propose relay batch products pick-up voltage consistance control method, in R & D of complex, instruct the research staff complete the analysis of controllable parameter tolerance and determine.Take into account the test figure Contribution Rate by orthogonal experiment plan, according to controllable parameter, fluctuate to the consistent sex conspicuousness of batch products pick-up voltage, it is sorted, and set up the Tolerance Allocation objective function of describing corresponding relation between each parameter tolerances change and the change of pick-up voltage consistance; By setting up weight coefficient, have according to ground and distribute the tolerance grade for controllable parameter according to coincident indicator, thereby in the manufacture process of batch relay product, each controllable parameter is carried out to reasonable request, guarantee that the consistance of batch products pick-up voltage meets target call.

The accompanying drawing explanation

Fig. 1 is process flow diagram of the present invention.

Embodiment

Embodiment one: the relay batch products pick-up voltage consistance control method of present embodiment realizes according to the following steps:

One, Orthogonal Experiment and Design

Relay is set n controllable parameter X arranged ₁, X ₂..., X _n, adopt orthogonal experiment design experiment scheme:

Each controllable parameter is got three levels according to formula (1) and is carried out the gauge outfit design, and three levels are respectively central value m _iand according to the tolerance Δ _ihigher limit and the lower limit of fluctuation;

Two, test figure Contribution Rate

Calculate relay pick-up voltage y corresponding to each testing program ₁, y ₂..., y _nafter, n test figure carried out to statistical study, obtain each controllable parameter X _icontribution rate ρ _i/ %, be divided into an once contribution rate ρ _xil/ % and quadratic term contribution rate ρ _xiq/ %;

Three, set up the Tolerance Allocation objective function

By each controllable parameter X in step 2 _icontribution rate bring formula (2) into, obtain the characterising parameter tolerance from Δ _ichange into Δ ' _ithe time the corresponding output characteristics degree of consistency funtcional relationship that changes, i.e. Tolerance Allocation objective function:

$\mathrm{\δ}=\underset{i=1}{\overset{n}{\mathrm{\Σ}}}({\mathrm{\ρ}}_{\mathrm{Xil}}{\left(\frac{{\mathrm{\Δ}}_i^{\′}}{{\mathrm{\Δ}}_i}\right)}^2+{\mathrm{\ρ}}_{\mathrm{Xip}}{\left(\frac{{\mathrm{\Δ}}_i^{\′}}{{\mathrm{\Δ}}_i}\right)}^4)+{\mathrm{\ρ}}_e...\left(2\right)$

Wherein, Δ _itolerance before meaning to change, Δ ' _itolerance after meaning to change, ρ _xilexpression factor X _ionce contribution rate, ρ _xiqexpression factor X _ithe quadratic term contribution rate, ρ _emean the error term contribution rate;

Four, determine key parameter and tolerance thereof

Determine the relay key parameter according to the size of each controllable parameter contribution rate value, and determine after the tolerance of each parameter is improved the manufacture grade that should reach in the mode of formula (3);

Δ′ _i＝(1-k×ρ _i)Δ _i＝[1-k×(ρ _Xil+ρ _Xiq)]Δ _i (3)

Wherein, k is the Tolerance Allocation factor, ρ _ifor controllable parameter X _icontribution rate, by k * ρ _iweight coefficient as Tolerance Allocation; For definite coincident indicator, by changing the value of k, make the consistance of batch products be increased to target call;

Five, relay is manufactured process control

Each controllable parameter tolerance of determining according to step 4, the precision that each controllable parameter in clear and definite relay manufacture process should be satisfied, guarantee that the consistance of batch products pick-up voltage meets target call.

In the present embodiment step 4, for definite coincident indicator, by changing the value of k, make the consistance of batch products be increased to target call.

The present embodiment effect:

Present embodiment is for the crucial output characteristics parameter of batch relay product---the coincident indicator of pick-up voltage, propose relay batch products pick-up voltage consistance control method, in R & D of complex, instruct the research staff complete the analysis of controllable parameter tolerance and determine.Take into account the test figure Contribution Rate by orthogonal experiment plan, according to controllable parameter, fluctuate to the consistent sex conspicuousness of batch products pick-up voltage, it is sorted, and set up the Tolerance Allocation objective function of describing corresponding relation between each parameter tolerances change and the change of pick-up voltage consistance; By setting up weight coefficient, have according to ground and distribute the tolerance grade for controllable parameter according to coincident indicator, thereby in the manufacture process of batch relay product, each controllable parameter is carried out to reasonable request, guarantee that the consistance of batch products pick-up voltage meets target call.

Embodiment:

Take certain model balanced armature formula electromagnetic relay is example, and the relay batch products pick-up voltage consistance control method that application the present invention proposes instructs the research staff to carry out analysis and control to the consistance of batch products pick-up voltage:

One, determine the main controllable parameter of relay

Relay is comprised of electromagnetic system and tactile spring system, altogether comprise twenties parts and numerous controllable parameter, need to filter out wherein main parameter and carry out test design, for the balanced armature formula electromagnetic relay of studying in this example, its electromagnetic system controllable parameter is all the parts machining parameter, and prove through relative theory analysis, when fluctuation occurs in the electromagnetic system controllable parameter in current tolerance grade, very little on the conforming impact of batch products, touch spring system controllable parameter and comprise the machined parameters of parts and the assembly parameter of assembly, its parameter fluctuation is very large on the conforming impact of batch products, the main controllable parameter of determining through theoretical analysis is five assembly parameters: quiet resultant pressure, contactor gap, magnetic gap, no-load voltage and over travel, and four machined parameters: reed width, movable contact spring thickness, the quiet spring thickness of dynamic circuit connector and quietly close quiet spring thickness, each controllable parameter is got three levels according to formula (1) and is carried out the gauge outfit design, three levels are respectively central value m _iand according to the tolerance Δ _ihigher limit and the lower limit of fluctuation,

Controllable parameter and water-glass thereof are as shown in table 1:

The main controllable parameter of table 1 and water-glass thereof

Two, determine the orthogonal test scheme

According to the number of controllable parameter and the horizontal number of parameter, choose L ₂₇(3 ¹³) orthogonal arrage, the employing simulating analysis, set up the realistic model of relay physical construction and calculate its dynamic perfromance, thereby obtain the output characteristics value of relay pick-up voltage, and testing program and test findings are in Table 2:

Table 2 testing program and test findings

Three, test figure is carried out to Contribution Rate

Calculate relay output characteristics corresponding to each testing program---pick-up voltage y, and obtain test figure y ₁y ₂..., y _nafter, n test figure carried out to statistical study.Because the level value of controllable parameter is equally spaced, the fluctuation that therefore can utilize the orthogonal polynomial regression theory that each parameter is caused is decomposed into once a fluctuation quadratic sum and quadratic term fluctuation quadratic sum, and obtains corresponding contribution rate.

Suppose that A is arranged, B, tri-controllable parameters of C, each parameter is got three levels, total mass property fluctuation, the output characteristics parameter fluctuation that the total Test factor causes is

$S_T^{\′}=\underset{i=1}{\overset{n}{\mathrm{\Σ}}}{\left(y_i\right)}^2=S_m+S_{\mathrm{Al}}+S_{\mathrm{Aq}}+S_{\mathrm{Bq}}+S_{\mathrm{Cl}}+S_{\mathrm{Cq}}+S_e$

Wherein, S _mfor the sum of square of deviations of output average, when carrying out tolerance analysis, this common value is 0;

S _al, S _aqfor an once fluctuation quadratic sum and the quadratic term fluctuation quadratic sum of factor A, S _bl, S _bqfor an once fluctuation quadratic sum and the quadratic term fluctuation quadratic sum of factor B, S _cl, S _cqfor once fluctuation quadratic sum and the quadratic term fluctuation quadratic sum of factor C, its computing formula is in Table 3, T in formula _1A, T _2A, T _3Abe respectively test figure y ₁, y ₂..., y _nr the test figure sum (the horizontal number of each experimental factor of r=n/) of middle corresponding factor A the 1st level, the 2nd level and the 3rd level, T _1B, T _2B, T _3Bbe respectively test figure y ₁, y ₂..., y _nr test figure sum of middle corresponding factor B the 1st level, the 2nd level and the 3rd level, T _1C, T _2C, T _3Cbe respectively test figure y ₁, y ₂..., y _nr test figure sum of middle corresponding factor C the 1st level, the 2nd level and the 3rd level;

S _efor error sum of squares, its computing formula is;

S _e＝S′ _T-S _m-S _Al-S _Aq-S _Bl-S _Bq-S _Cl-S _Cq

Based on above calculating, and the tolerance of finally determining each controllable parameter by table 3 is divided into once a contribution rate and quadratic term contribution rate to the consistent sex contribution rate of relay batch products:

Table 3 Contribution Rate table

Annotate: when carrying out error analysis, need to be by S _m, S _al, S _aq, S _bl, S _bq, S _cl, S _cqin compare V _elittle item merges to error sum of squares S _ein, obtain new error sum of squares (S _e) and degree of freedom, suppose S in table 3 _m, S _bqand S _cqfor merging item;

The Contribution Rate method proposed according to table 3, carry out statistical study to test findings, and data results is in Table 4:

Table 4 test figure Contribution Rate is statistical form as a result

Four, set up the Tolerance Allocation objective function of pick-up voltage

According to the Contribution Rate result, obtain describing the controllable parameter tolerance from Δ _ichange into Δ ' _ithe time the corresponding output characteristics degree of consistency funtcional relationship that changes, i.e. Tolerance Allocation objective function:

$\mathrm{\δ}=\underset{i=1}{\overset{n}{\mathrm{\Σ}}}({\mathrm{\ρ}}_{\mathrm{Xil}}{\left(\frac{{\mathrm{\Δ}}_i^{\′}}{{\mathrm{\Δ}}_i}\right)}^2+{\mathrm{\ρ}}_{\mathrm{Xip}}{\left(\frac{{\mathrm{\Δ}}_i^{\′}}{{\mathrm{\Δ}}_i}\right)}^4)+{\mathrm{\ρ}}_e...\left(2\right)$

Wherein, Δ _itolerance before meaning to change, Δ ' _itolerance after meaning to change, ρ _xilexpression factor X _ionce contribution rate, ρ _xiqexpression factor X _ithe quadratic term contribution rate, ρ _emean the error term contribution rate;

By each controllable parameter X _icorresponding contribution rate coefficient ρ _i/ % brings formula (2) into, obtains the objective function of Tolerance Allocation:

$\mathrm{\δ}=1.864{\left(\frac{{\mathrm{\Δ}}_A^{\′}}{{\mathrm{\Δ}}_A}\right)}^4+2.039{\left(\frac{{\mathrm{\Δ}}_B^{\′}}{{\mathrm{\Δ}}_B}\right)}^4+0.910{\left(\frac{{\mathrm{\Δ}}_B^{\′}}{{\mathrm{\Δ}}_B}\right)}^4+2.807{\left(\frac{{\mathrm{\Δ}}_C^{\′}}{{\mathrm{\Δ}}_C}\right)}^4+$

$2.301{\left(\frac{{\mathrm{\Δ}}_D^{\′}}{{\mathrm{\Δ}}_D}\right)}^2+1.987{\left(\frac{{\mathrm{\Δ}}_E^{\′}}{{\mathrm{\Δ}}_E}\right)}^2{+1.229\left(\frac{{\mathrm{\Δ}}_G^{\′}}{{\mathrm{\Δ}}_G}\right)}^2+3.139{\left(\frac{{\mathrm{\Δ}}_G^{\′}}{{\mathrm{\Δ}}_G}\right)}^4+$

$46.91{\left(\frac{{\mathrm{\Δ}}_H^{\′}}{{\mathrm{\Δ}}_H}\right)}^2+1.419{\left(\frac{{\mathrm{\Δ}}_H^{\′}}{{\mathrm{\Δ}}_H}\right)}^4+35.395$

Five, determine key parameter and tolerance thereof

By contrasting the contribution rate coefficient ρ of each controllable parameter _i, can determine that simply, intuitively the key parameter in relay manufacture process is: no-load voltage (controllable parameter H); Other controllable parameters are very little on the conforming impact of batch products pick-up voltage.

According to the contribution rate coefficient of each controllable parameter, the present embodiment proposes to determine after its tolerance is improved the manufacture grade that should reach in the mode of formula (3); Wherein, k is the Tolerance Allocation factor, ρ _ifor controllable parameter X _icontribution rate, by k * ρ _iweight coefficient as Tolerance Allocation; For definite coincident indicator, by changing the value of k, make the consistance of batch products be increased to target call;

Δ′ _i＝(1-k×ρ _i)Δ _i＝[1-k×(ρ _Xil+ρ _Xiq)]Δ _i (3)

In this example, using 50% target promoted as consistance, relay is carried out to Tolerance Allocation.By changing the value of k, utilize formula (3) to change the tolerance of each experimental factor, and utilize the definite Tolerance Allocation objective function of step 4, verify whether coincident indicator corresponding to this Tolerance Allocation scheme meets target call.Thereby while determining k=1.72, after improving, the consistance of batch relay product pick-up voltage can be promoted to originally 50.67%, and the Tolerance Allocation process finishes.After improving, the Tolerance Allocation scheme of each controllable parameter is in Table 5.

Table 5 be take the Tolerance Allocation table that the pick-up voltage consistance is target

Claims (1)

1. relay batch products pick-up voltage consistance control method is characterized in that relay batch products pick-up voltage consistance control method realizes according to the following steps:

One, Orthogonal Experiment and Design

Relay is set n controllable parameter X arranged _1,x ₂..., X _n, adopt orthogonal experiment design experiment scheme:

Each controllable parameter is got three levels according to formula (1) and is carried out the gauge outfit design, and three levels are respectively central value m _iand according to the tolerance Δ _ihigher limit and the lower limit of fluctuation;

Two, test figure Contribution Rate

Calculate relay pick-up voltage y corresponding to each testing program ₁, y ₂..., y _nafter, n test figure carried out to statistical study, obtain each controllable parameter X _icontribution rate ρ _i/ %, be divided into an once contribution rate ρ _xil/ % and quadratic term contribution rate ρ _xiq/ %;

Three, set up the Tolerance Allocation objective function

By each controllable parameter X in step 2 _icontribution rate bring formula (2) into, obtain the characterising parameter tolerance from Δ _ichange into Δ ' _ithe time the corresponding output characteristics degree of consistency funtcional relationship that changes, i.e. Tolerance Allocation objective function:

$\mathrm{\δ}=\underset{i=1}{\overset{n}{\mathrm{\Σ}}}({\mathrm{\ρ}}_{\mathrm{Xil}}{\left(\frac{{\mathrm{\Δ}}_i^{\′}}{{\mathrm{\Δ}}_i}\right)}^2+{\mathrm{\ρ}}_{\mathrm{Xip}}{\left(\frac{{\mathrm{\Δ}}_i^{\′}}{{\mathrm{\Δ}}_i}\right)}^4)+{\mathrm{\ρ}}_e...\left(2\right)$

Wherein, Δ _itolerance before meaning to change, Δ ' _itolerance after meaning to change, ρ _xilexpression factor X _ionce contribution rate, ρ _xiqexpression factor X _ithe quadratic term contribution rate, ρ _emean the error term contribution rate;

Four, determine key parameter and tolerance thereof

Determine the relay key parameter according to the size of each controllable parameter contribution rate value, and determine after the tolerance of each parameter is improved the manufacture grade that should reach in the mode of formula (3);

Δ′ _i＝(1-k×ρ _i)Δ _i＝[1-k×(ρ _Xil+ρ _Xiq)]Δ _i (3)

Wherein, k is the Tolerance Allocation factor, ρ _ifor controllable parameter X _icontribution rate, by k * ρ _iweight coefficient as Tolerance Allocation; For definite coincident indicator, by changing the value of k, make the consistance of batch products be increased to target call;

Five, relay is manufactured process control

Each controllable parameter tolerance of determining according to step 4, the precision that each controllable parameter in clear and definite relay manufacture process should be satisfied, guarantee that the consistance of batch products pick-up voltage meets target call.

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