校直机设计（论文+DWG图纸）

第章 绪
11校直技术定义应
校直技术属金属加工学科分支已广泛应日金属加工业仪器仪表制造业汽车船舶飞机制造业石油化工业冶金工业建筑材料业机械装备制造业精密加工制造业校直技术广度深度方面巨发展迫切求校直理进步解决疑难问题推动开发新技术研制新设备尤十六求信息化带动工业化校直技术时代首先校直机设计制造校直程分析校直参数设定校直质量预测等方面搞软件开发次进行数字化校直设备研制校直技术走现代化道路断丰富金属校直学容
校直技术金属条材加工部工序程度决定着生产成品质量水校直技术金属加工技术样20世纪取长足发展相应校直理取进步理滞实践现象较明显例校直辊负转矩破坏作20世纪半叶解决（改集体驱动单辊驱动改刚性连接超越离合连接等）破坏作机理直20世纪80年代末阐明外校直理总体然处粗糙阶段首先基参数确定许验算法验数辊数辊距辊径压弯量校直速度等次许技术现象螺旋弯废品校直缩尺校直噪声斜辊校直特性斜辊辊形特性拉弯变形匹配特性等缺乏理阐述次理概括性够套公式仅包括种断面型材甚包括类断面尺寸材质工件弯矩校直曲率等缺少通表达式20世纪70年代校直技术校直理发展明显加快拉弯校直技术快走成熟开发成功动（万）校直技术行星校直技术全长校直技术程序控制校直技术变凸度变辊距校直技术双旋转校直技术等完善等距双曲线辊形设计法创立等曲率递减反弯辊形设计法校直耗计算法工艺参数法两种拉弯制度定性定量分析法负转矩超前接触分析法尤利相值概念种校直程进行定量分析工作中取系统化成果校直技术数字化处理基础
12国现状
合肥工业学合肥压力机械厂广泛市场调研国外产品性水基础联合攻关年努力研究成功校直力100KN单柱精密校直液压机1991年1月合肥通部级鉴定
该机采移动式手动液压伺服控制校直滑块运动行程25mm范围实现滑块位置精确调整死点定位精度005mm
该机行程控制型精度校直液压机新工短时间学会操作滑块高定位精度该机具压力行程油液温度数字显示预置功具压力超限报警油温超限报警行程超限系统卸压控制功操作方便
该机研制成功提高国型材精密校直工艺装备水汽车拖拉机机床纺织机械等行业轴类类棒料零件进行精密校直减少加工余量提高制件精度生产效率该机市场前景广阔元器件材料全部国产化价格足目前进口价15开发成功会带高济效益社会效益
国现Y41系列单柱校正压装液压机进行型材校直校直力100~1600KN约七规格七五期间均年产量千台产值约2400万元约占全国液压机总产量40总产值20产品水低重复生产采压力型验校直方式校直精度差工件质量稳定缺少附件满足精校工艺需压装工艺校直工艺设备液压系统求样放起定合理国外发达国家少见苏联批量生产目前国销售形势甚



第二章 校直设备发展分类
机械汽车电机等行业量轴类杆类零件零件原材料粗加工热处理等程中避免会出现弯曲变形果进行校直处理会直接影响工件序加工甚出现相数量废品获道工序允许切削量通精密校直保证工件达严格终设计公差求校直机成工件热处理缺少关键设备
21 校直设备发展概况
校直技术产生确切时间尚未找准确文字记载文物发掘中国春秋战国时期宝剑直度想象时手工校直整技术已达高水国古代生活生产中物品工具针锥铁杵求校直技术完成成品制造手工校直整工艺设备工具极简单锤砧台等型工件手工校直常助高温加热进行古代校直整形实践中认识物质反弹特性确立校直必须正哲理改造社会指导意义中国社会特殊条件技术停留手工状态18世纪末叶19世纪初叶欧洲进行产业革命逐步实现蒸汽动力代力机械化生产代手工作坊19世纪30年代冶铁技术发展起时英国生铁产量已7万吨增长19万吨增加27倍19世纪50年代开辟炼钢技术发展新纪元着炉炼钢技术发明钢产量增长迅速19世纪末时钢产量增加50倍钢材产量占钢产量重显著增加时已出现锻造机械轧钢机械校直机械进入20世纪电力驱动代蒸汽动力标志推动机械工业发展英国1905年制造辊式板材矫直机概国见早台校直机20世纪初已校直圆材二辊式矫直机1914年英国发明212型五辊式解决钢校直问题时提高棒材校直速度20世纪20年代日已制造斜辊矫直机20世纪30年代中期发明 222型六辊式校直机显著提高材校直质量20世纪60年代中期解决直径材校直问题美国萨顿公司研制成功313型七辊式矫直机（KTC型校直机）20世纪30~40年代国外技术发达国家型材校直机板材校直机迅速发展相继进入中国钢铁工业金属制品业新中国成立前太原鞍山冶天津海等工厂里见德英日等国家制造校直机时出现拉伸校直机20世纪50年代苏联校直机量进入中国时世界着电子技术计算机技术发展工业进步速度加快校直机品种规格结构控制系统断发展完善20世纪70年代国改革开放接触量国外设计研制成果φ16mm金属丝校直机φ600mm材校直机速度达300mmin高速校直机精度达0038mmm高精度校直机时引进许先进校直设备英国布朗克斯矫直机德国凯瑟琳校直机德马克校直机连续拉弯校直机高精度压力校直机日薄板校直机等值豪国科技界直努力提高科研设计创新力20世纪50年代起刘天明提出双曲线辊形设计精确计算法钢材校直校直力中提出校直曲率方程式6080年代辊形理方面许学者进行深入研究取十分喜成果召开全国性辊形理讨会产生等曲率反弯辊形计算法时西安重型机械研究代表科研单位太原重型机器厂代表设计制造部门完成量矫直机设计研制工作仅国生产提供设备保证培养批设计研究员进入90年代国赶超世界先进水方面迈出步新研制校直机获国家发明专利新成果获市省部级科技成果进步奖获国家发明奖年国反弯辊形七斜辊校直机斜辊薄壁转毂式校直机行辊异辊距校直机校直液压动切料机等研制方面相继取成功校直高强度合金钢方面已获校直质量校残留挠度0205mmm外20世纪60年代拉伸拉弯校直设备发展材生产起重作
传统工艺中数厂家选手动压力机较量难控制效率低难满足校直求动校直种先进生产制造工艺年着国工业整体技术水技术求提高该工艺越越广泛应机械汽车电机等行业中合肥工业学合肥压力机械厂合作广泛市场调研国外产品性水基础联合攻关年努力研究成功校直力100KN单柱精密校直液压机1991年1月合肥通部级鉴定该机研制成功提高国型材精密校直工艺装备水汽车拖拉机机床纺织机械等行业轴类类棒料零件进行精密校直减少加工余量提高制件精度生产效率
十年德国意利日等国家发展手动伺服控制精密校直液压机应较普遍全动精密校直液压机已发展完善总发展趋势：
1系列完整品种规格齐全
2行程精度高检测显示手段完善校直工件质量
3附件齐全校直工艺范围扩
4数控化柔性化动化方发展
22校直设备分类
现代校直设备品种较规格更首先工作原理划分五类第类称反复弯曲式校直机压力校直机辊式校直机压头辊子面工件进行反复压弯逐渐减压弯量直压弯量弹复量相等变直第二类称旋转弯曲式校直机工件塑性弯曲状态旋转变形方式等弯矩区等弯矩区渡走出塑性区时弹复变直旋转者工件校直工具变形方位常见斜辊校直机转毂式校直机动式校直机第三类称拉伸校直机拉伸变形原长短纤维拉城等长度进入塑性变形卸载弹复变直钳式拉伸校直机连续拉伸校直机第四类称拉弯校直机拉伸弯曲变形合成起工件两表层较拉伸集权截面拉伸变形三者事件发生全断面层纤维弹复变形时发生防止板带断裂提高校直质量第五类称拉坯校直设备拉动连铸坯行时铸坯弧形弯曲渐伸变直拉力克服外部阻力铸坯身高温状态需校直拉力较
次途进行分类：校直型材校直机型材压力校直机姓蔡辊式校直机型材拉伸校直机二板材校直机板材校直机拉弯校直机三带材校直机连续拉伸校直机拉弯校直机四棒材校直机斜辊校直机转毂校直机材拉伸校直机五线材校直机转毂校直机立辊复合校直机六薄壁异型动式校直机七拉铸拉坯校直机八特殊途校直机瓦楞板校直机圆锯片校直机钢丝绳校直机等
次结构特征进行分类：压力校直机机械压力校直机液压压力校直机微机程控压力校直机等二行辊式校直机简称辊式校直机简支辊式校直机悬臂辊式校直机三斜辊式校直机二斜辊式校直机三斜辊式校直机种样斜辊式校直机等四转毂校直机滑动模式转毂校直机滚动模式转毂校直机斜辊式转毂校直机复合式转毂校直机等五拉伸校直机机械拉伸校直机液压拉伸校直机连续拉伸校直机等六拉弯校直机机械拉弯校直机液压拉弯校直机液膜拉弯校直机等七拉坯校直机普通拉坯校直机辊拉坯校直机八特殊结构校直机行星式校直机动式校直机等
述原分类校直机进步具体途具体结构传动方式控制方式等做细化分类细化分类中规格形成产品系列






第三章 压力校直机
31压力校直机工作原理
压力校直机辊式校直机属利反复弯曲逐渐减压弯挠度方法达校直目设备简单校直设备压力校直机工作原理带原始弯曲工件支承工作台两活动支点间压头准弯部位进行反压弯压弯量工件弹复量相等时压头撤回工件弯曲部位变直进行工件弯曲部位必全部变直达校直目然验设定压弯量难准确工件弹复量相等头次反压弯检测弹复量压弯量差值残留挠度值值修正第二次压弯量新压弯量进行次反压弯检测直校直止通常感观验确定压弯量时常需3次修正工作现代微机设定压弯量需12次修正工作速度快质量稳定
32压力校直机分类
早期压力校直机通型压力机着校直技术发展考虑校直工艺特殊性：行程需退料翻钢换支点位置调等特点设计出专校直压力机常见曲轴式压力校直机参表31连杆滑块间螺纹连接改变螺纹长度开距行程固定变进步发展曲柄偏心式压力校直机通调节曲柄轴外偏心套相位角便改变偏心距行程满足断面尺寸工件校直需提高校直工作效率述两种校直压力机具备校直力时常需庞结构尺寸满足型钢材校直需致结构尺寸产生压力行程肘杆式校直压力机型锻件钢坯校直中翻钢道麻烦工序解决翻钢问题创造卧式换压弯式校直机操作者根工件原始弯曲方决定校直需反弯方位置先开动辊道移送工件定位置然开动齿轮齿条升降机构滑块升工件凸弯处滑块变成两支点第三步开动蜗轮螺母滑块推倒工件处压第四步开动曲轴连杆机构滑块工件进行压弯达校直目工件弯曲方改变时滑块滑块支点压头作点互换原面滑块升原面滑块降果工件原始弯曲方二维弯曲时需设翻钢机构机械传动压力校直机历较长发展程规格结构品种方面许新改进基结构纳述四种典型压弯量调节采种厚度垫块操作者验机选垫块垫压头工件间获需压弯挠度然压弯精确度易保证工作效率低提高工效校直精度液压技术应压力校直机已取成功液压传动压力校直机仅意调节压量调节压力外具压力体积重量轻便控制等系列点表21中类校直机立式卧式分种压力分出许规格液压校直机已普通型发展精密型进发展程控型普通型述优点外然操作者验决定校直精度精密型配备检测仪表校踪检测检测显示弯度改进次校直压弯量直合格止支点移动两次压中间卸活重卡效率提高质量保证压弯量设定够准确全程手工操作效率提高限程控型压力校直机工料程序完成装卡检测电脑设定压弯量反弯校直旋转检测设定压弯量反弯校直检测直合格止动卸料程控压力校直机研制成功结束压力校直机工作精度低工作效率低动化程度低历史跃成高精度高技术水校直机
述液压校直机存气动压力校直机具类似优点动作快效率高







表31 压力校直机分类表





机动压力校直机
立 式
曲轴式
曲柄偏心式
肘杆式





卧


式





换压弯式
（翻钢）

液（气）动压力校直机
普 通 型





立 式
卧 式



精密型
具活动支点仪表检测
程控型
微型计算机设定压弯量程序检测修正定位压弯
33压力校直机实例介绍
331机动压力校直机
表31种4种机械传动压力校直机已广泛应校直设备结构性规格型号方面存着样性工作原理基相利曲轴（曲柄）连杆滑块机构旋转运动变成直线运动机架般采C型开式结构门形闭式结构C型开式结构中轴简支梁型悬臂梁型分结构形式规格选择根加工象特点（工件断面形状尺寸工件长度重量等）加工精度求产量等素确定
具体说C型开式结构机架具较操作空间调节支点距开距观测压弯位置更换压弯垫块移送工件翻转工件更换压头等工作较方便机架刚性较低适断面工件校直工作C型机架轴基简支梁结构悬臂梁结构两种前者轴刚度轴承磨损均匀承受较校直力者加工制造装配检修较容易广泛应中型压力校直机断面工件校直时需较工作台面然C形机架立柱受弯矩作安全门式机架具刚度机架立柱立板受拉力作强度改善表31种肘杆式校直机机架需承受较校直力门式结构型液压校直机更采门式机架常常4立柱横梁构成门形结构机座立式卧式结构分考虑改变工件移送状态进行反弯断面宽高值较工件弯曲卧态移送工件须采卧校方式
面先图31曲柄偏心式压力式压力校直机例说明结构特点台矫直机部结构名称参图面代号说明驱动系统高速端皮带传动低速端齿轮传动偏心轴通偏心套连接杆带动滑块作升降运动偏心套偏心轴相相位调两者偏心量相加时滑块行程反相减时行程压头面两支点间距手动调节两支点两侧装移送工件支撑棍工件某弯曲点校直支撑辊快速抬起操作者轻快推移工件弯曲点准压头进行新弯曲点校直

图31 偏心式压力校直机
1皮带传动2齿轮传动3行程指示盘4偏心调节电动机
5导轨压板6滑块7压头8移动支点9工作台面
10电动机（驱动）11机架12移送工件支承辊13操台
332普通液压压力校直机
普通液压压力校直机已逐步代机动压力校直机20世纪半叶发展快型材锻件校直生产中全部采液压校直机液压校直机具压力结构紧凑重量轻效率高易控制调整等系列优点适合压力校直工作求前述分立式卧式两种结构形式现分介绍
１立式液压校直机
种液压校直机生产应较中型立式液压校直机普遍机架C形开式结构型立式液压校直机较少见机架门形闭式结构现某钢厂研制1000t四柱式液压校直机例解种校直机结构特点工作原理参数
图32示该机校直调质处理φ500mm特厚壁钢长达9m机器设计压力1000t机器部件图代号说明液压站装机器顶部直接工作缸相连接工作缸柱塞推动活动横梁7行砧台8工件施加压力进行反弯校直缸两侧耳缸提升缸3缸活塞快速活动横梁抬起返回原位横梁底座间4根立柱连接形成框架封闭受力体系具刚性高强度结构紧凑振动等系列优点整校直机支承4行走车轮轨道行走工件放门形立柱间工作台校直机行走工件弯曲处压头准凸弯进行压校直凸弯相位偏离压头时翻钢

图32 1000t液压校直机简图
1液压站2工作缸3提升缸4横梁5工作柱塞
6立柱（四根）7活动横梁8砧台9横梁10工作台
11翻钢车12翻钢辊13车行走齿条14校直行走轨道
车开动翻钢辊转动工件凸弯准压头翻钢辊翻转角度意设定校翻转工件检查直度停位置翻钢辊高度助液压缸升降适应弯曲轴线变化翻钢车工作台做移位适应子长度改变改变翻钢位置
该校直机液压系统远程溢流阀保证工作压力超载工作时安全单节流阀调节校直速度适应校直工艺求工作循环中动作程序细致安排压力机快速降时压头接触工件马减速加压达需压力压量马停止进入保压状态接着进行卸荷快速提升重新停原位校直机技术性指标：
校直力 1000KN
工作缸直径 825mm
柱塞行程 650mm
柱塞行速度 20mms
柱塞回程速度 160mms
校工件尺寸 500mm
校工件长度 9000mm
四立柱轴线间距 1700*1300mm
油泵压力 20MPa
应该说明：立柱横梁底座联结预紧力校直力立式液压校直机固定式少采移动式油田钻井石油供应站里常移动式液压校直机类校直机专业性较强般金属加工厂轧钢厂少见
２卧式液压校直机　　　　　　　　　　　　　　　　　
类校直机稳定性操作性通性方面许优势占面积中型条材校直中应现日机械制作研制HPH150型卧式液压校直机例说明种校直机基结构性参数参图33机架C形结构压力1500KN校直圆钢方钢材型材钢轨等条材钢材冷弯变形机器操作台采移动式脚踏开关操作位置改变进行直观精细加工微量进容易需加工精度机架采焊接结构整体退火具足够强度刚度 支点距离手轮电动机调节支点镶块根作业需时更换改变加工品种方便复动作活塞杆加工镀鉻抛光处理防止漏油面摩擦阻力耐寿命长

图33HPH150卧式液压校直机外形图

1液压缸2压头3支撑横梁4活动支点
5液压控制板6电动机7油箱8油泵9脚踏开关
该机技术性指标参数
压力 1500KN
行程 300mm
空行程速度 351mms
加压速度 36mms
返程速度 575mms
油泵 轴柱塞式
油压 200kgcm2
流量 1656Lmin
电动机 75KW
333精密液压校直机
前面介绍普通液压校直机次压弯工件感观检查校直效果验确定否合格容易产生高低疏漏等质量问题想保证质量信需取工件专门台工具进行检查合格者重新机校费时费事效率低克服普通校直机种缺点研制出精密液压校直机检测仪表直接装两移动支点间次压弯踪检测校直效果达直度求卸工件现德国顿柯斯机械厂制造HR型液压校直机例作介绍参图34该机两部分组成：液压压弯系统二支承检测系统图中12部分机身油泵油箱等液压压弯系统普通液压校直机液
压系统基相图中4~12部分支承检测系统系统较复杂保证校直质量起重作工件夹持锥形顶头间垂直校直机压头轴线压头轴线处垂直面工件转动凸弯图35示图中3转动工件手轮4带着工件左右移动滑座需校直弯曲部位准压头操手柄（参图34中11）精确控制压头压量


图34 HR型液压校直机外形图
1液压缸部分2压头3工件4移动支点
5检测仪表6工作台7导轨8滑座9锥形顶头
10连接杆11操手柄12弹性支座

图35 液压校直机锥形顶头
1锥形顶头2紧定手柄
3手轮4滑座5连接导杆6弹性座
压头抬起仪表检测残留弯曲度（参图36中3）合格时次压旋转定角度压合格时余弯曲点移压头进行样校直程序直全长校直卸工件换新工件校直前根原始弯曲状态确定支点位置移动支点移该位置般凸弯处两支点中间压头校直时压头工件压弯工件两端必起伏时两锥形顶头装弹性支座步起伏受阻碍参图35图36适应工件校直
求移动支点锥形顶头夹头弹性支座等做成种结构形式需选HR型液压校直机已形成系列产品结构尺寸外形示图37尺寸系列技术性指标列表32中种液压校直机采仪表检测保证高校直质量时采灵敏旋钮式手柄机快速调节压量种手柄（图34中11图37中1）头部旋转柄杆中螺杆柄杆部伸出意长度调节手柄摆动角度挡块（图 中2）位置固定螺杆伸出越长手柄摆动角度越手柄螺杆顶挡块摆动角限定压头降行程已限

图36 液压校直机移动支点检测仪表
1移动支点2传感杠杆3千分表4移送手柄5连接导杆
定工件受压弯量已限定压弯量摆动角改变灵敏度高手柄端旋钮动压弯量改变操作方便心应手种实性校直机

图37 HR型液压校直机尺寸图
1手柄2挡块
334程序控制液压校直机
种校直机前述精密液压校直机增加动送取料装置计算机控制系统称全动校直机代高新技术应校直机取成功种校直机特点：首先精确检测工件原始弯度动精确测定次计算机已输入尺寸材质针已测定原始弯曲算出应设定压弯曲率压弯量第三设定压弯量控制压次压达校直目第四校直质量未达标准时残留弯度计算重复压压弯量重复述程序直达质量标准止种校直机优点：第摆脱工操作误差第二基代体力劳动第三效率高第四保证质量稳定面介绍两实例供参考
16122型全动液压校直机
前苏联6122型全动液压校直机精密校直长尺寸圆形断面工件光轴拉杆分配轴等种校直机示意图绘图38图代号说明清机器结构容组件作
该校直机尺寸技术性参数：
公称校直力 160KN
压头行程（调） 125~150mm
压头进量 001mms
压头运动速度
空程行 50mms
工作行 30~50mms
回程 168mms
工件尺寸 直径25~54mm
长度300~865mm
校直断面数（校直点数） 4
高校直精度（径跳动量） 0025mm
测量跳动量时仪表进刻度值 0001~001mm
外形尺寸（含工作台） 长（左右） 5110mm
宽（前） 2790mm
高 2540mm

图38 6122型程控液压校直机样机示意图
1机架身2机架底座3工作台4液压工作缸
5驱动机构6减速机构7油箱组件8压头9限位端盖
10油泵11取送料装置12三角支架13取送料车
14取送料横梁15抓取机械手16车行走气缸17横梁升降气缸18机械手气缸19油泵电动机20活塞杆
该机五部分组成：压力装置工作台夹送装置数控装置配电柜图38基机架体压力装置夹送装置等三部分机架钢板焊接成单柱式C型结构件工作台3装车式移动工作台（见图39）机架部装液压工作缸4步进式驱动装置5通减速机构6带动限位端盖螺母9作升降运动螺母9停某确定位置时活塞杆粗端20降9处便限位二停止压量处调定数值套压力装置液压系统包括容量230L水冷油箱7装箱盖电动机19驱动油泵10减振动油箱装振动补偿器（缓器）需校直工件综合夹送装置11送工作台校完工作台取出夹送装置悬臂式三角支架12包括水移送气缸1616驱动前移送车13车装升降气缸17

图39 6122型程控液压校直机工作台示意图
1工作台2导轨3左滑座4右滑座56导杆
7液压放式步进机8减速器9滚珠丝杠10左顶头
11液压放式步进机12减速器13右顶头1415气缸
16砧板17活动支点18传感器19气缸20杠杆系统
17面连着横梁1414两端装钳形机械手1515气缸18（两）驱动夹紧松开工件17驱动升降工作样夹送装置抓取抬起工件送工作台降两顶头间动卡校直夹送装置工件抓取两顶头间抬出放成品架处完成循环重新抓送工件重复述程序形成连续作业
现单独工作台构造示意图绘图39中台套定心夹紧装置左右移动便接收送工件落两顶头间动夹紧移回压头面需校直部位准压头校部位移换新部位滑座3滑座4间刀杆5导杆6连接成体支撑工作台导轨2液压放式步进机7通减速箱8滚珠丝杠9带动滑座导轨2左右移送左顶头20液压放式步进机11通减速器12实现旋转动作右顶头13转气缸14气缸15分推动左右顶头夹紧松开工作砧板16固定两根导杆56砧板装置着活动支点17传感器18前者支撑校直力者通杠杆系统20接收弯度信号显示弯曲程度支点17移送气缸19完成气缸19动作数字程序控制器发指令进行工件检测断面数量（点数）取决砧板16数量砧板装活动支点传感器全部校直工艺程皆数字控制程序动完成
2全动油压校直机
日式东精机公司制造全动油压校直机示图310该机检测控制压送取工件等4部分组成校直机动检测弯度转换成计数脉信号压机构发送指令压机构指令完成压校直工作该机仅检测工件弯

图310 全动油压校直机
1 装夹检测装置2取送料机械手3压头4程序控制柜
度监测工作状态防止发生误动作修改程序
出现障损坏时更换控制柜插件迅速完成维修工作机校直精度工件效率高
该校直机工作原理检测弯曲量分布图形材料特性（屈服强度弹性模数原始弯曲加工历史等）工件特性（种尺寸柱面台肩等形状）校直安排（反弯曲率分配反弯次数压量支点位置等安排）机械功数（油压伺服系统结构刚度机械精度等）存入数库确定采相应校直方法原始曲率残留曲率均化根加工历史确定应力应变关系强化特性弯矩曲率关系强化性弯矩曲线计算校直需压弯曲率递减情况少反弯次数达校直效果完成佳控制现述控制流程图介绍
开 始
装 夹 工 件
检 测 弯 曲 量
数 处 理
弯度达标准否？
取 工 件
识弯曲图形
计算控制量
压力机量工作
否
停 机


台机器检测性参数
检测弯度（挠度） 0005mm
检测断面（点）数 1~5点
检测速度 约2s次














第四章 JZI型校直机
41 途
JZI型校直机校直单体支柱油缸活柱坯料热处理造成变形校直类似杆类类零件备胎具钢板调压弯压装等工作机专单体液压支柱活柱油缸般变形校直
42 技术特征
JZI型校直机液压校直机具足够压力强度备灵活实工件悬挂装置配方便完善操控制系统
加载油缸直径 200mm
额定工作压强 2018MPa
额定压力 1MN
回程力 036MN
行程 300mm
加压速度 36mms
返程速度 575mms
工作台长 1400mm
工作介质 乳化液机油
外形尺寸 2423（高）×2500×1200mm
质量 35mg
43 结构特点
图41 示单悬臂式JZ校直机加载油缸[1]机身[2]工件悬挂装置[3]工作台[4]操控制系统[5]垫铁[6]明电气[7]等部分组成
图41
431加载油缸
油缸液压传动系统中实现复运动360°回摆运动液压执行元件具结构简单工作制造容易维护方便低速稳定性等优点广泛应工业生产部门应：工程机械中挖掘机装载机铲装机构提升机构起重机械中汽车起重机伸缩臂支腿机构矿山机械中液压支架采煤机滚筒调高装置建筑机械中桩机冶金机械中压力机汽车工业中卸式汽车高空作业车智机械中模拟驾驶舱机器火箭发射装置等直线复运动油缸推力油缸进步研究改进液压缸设计制造提高液压缸工作寿命性更利液压传动具十分重意义
JZI校直机加载油缸采煤矿200mm直径油缸密封导元件活塞杆直径130mm较低泵压2018MPa获高达1MN压力采两油缸串联串缸特殊设计压力

1液压缸壁厚确定
缸体液压缸中重零件承受液体压力通常缸体采缝钢制成薄壁筒壁厚薄壁圆筒公式计算：

式中——液压缸壁厚（m）
D——液压缸径（m）
Py——试验压力般取工作压力（125~15）倍（Mpa）[]——缸筒材料许应力值：锻钢： []110~120铸钢：[]100~110缝钢：[]100~110高强度铸铁：[]60灰铸铁：[]25
根述公式计算出该液压缸壁厚20mm取225
2导长度确定
活塞杆全部外伸时活塞支承面中点缸盖滑动支承面中点距离H称导长度果导长度液压缸初始挠度增影响液压缸稳定性设计时必须保证定导长度
般液压缸导长度H应满足求

式中L——液压缸行程
D——液压缸径
式出H115取H120mm
3计算工作时液压缸需流量
287Lmin
626Lmin
4泵流量确定
液压泵流量应：

式中 ——液压泵流量
——时动作执行元件需流量值
——系统泄露系数般取11~13现取12

根述结果现选CBQ外啮合单级齿轮泵该泵基参数：转排量20~63mLr额定压力20Mpa 电动机转速2500rmin
液压泵匹配电动机选Y160M12型电动机额定功率11KW额定转速2930rmin
432机身
机身采钢板钢组焊接件图42示强度工作寿命久加载油缸安装部镗孔里工作台螺栓固定机身部台座机身校直机承受作力部件强度刚度均较高校直机工作时机身部受力工作稳振动需基础校直机安放车间里需位置垫悬挂装置时衡


图42 JZI校直机机身结构
433工件挂悬装置
工件悬挂装置工件悬挂起加载时工件悬挂成脱离工作台垫铁助悬挂装置轴承滚轮帮助豪费力手轴移动转动工件便测量寻找压部位样工件悬挂压垫铁方便移动垫铁寻求合适支点位置压头压工件时悬挂装置压性工件接触面垫铁校直反力面垫铁承受会压坏悬挂装置压头回升工件悬挂装置动悬起校直机检查测量工件寻找加压部位调整垫铁位置非常方便加操作者脚踏操压头升降整校直操作需校直油缸活柱时应选应悬挂装置
434工作台
工作台组焊件较抗弯强度刚度放垫铁检测量具侧面安装支加工件悬挂装置
435操控制系统
图43示机操控制系统序号21QJ16球形截止阀通户制三通高压油接通序号20Φ16回液单阀


真

值

表
状态
A
B
动作
1
0
0
停
2
1
1
快降
3
1
1
慢降
4
1→0
1→1
慢升
5
0→0
0→1
快升
图43 JZI校直机操控制系统图
通户制三通回液连通脚踏阀3加载油缸间配阀
组7交单阀11便实现五种工况
真值表状态1AB踏压力液脚踏阀隔断压头动作
真值表状态2踏B踏A压力液A5分6路阀组7部元件发生关系右左：71节流阀流少量压力液状态流二单阀72隔断三液控切换二位二通截止阀73四畅通液体8进交单阀11液压作交单阀处封闭回液路状态高压液流入加载油缸活塞腔实现快降压头趋工件初始加压五已处常闭状态二位二通阀74关闭六开液控单阀75便活塞杆腔液体利流回油箱
真值表状态3AB处踏状态压力液仅A进入
阀组7B路4进入阀组7分三路阀组7部元件发生作左右液控二位二通阀74液控面积面弹簧力二位二通阀74处关闭状态会压力液二路通74进入加载油缸活塞杆腔三液控73该液控面积弹簧帮助确保二位二通阀73处关闭状态样压力液通节流阀71进入加载油缸活塞腔实现慢速降校直工件控制变形量节流阀调根实际需调锁紧防止变化时加载油缸回液路未发生变化
真值表状态4AB处踏止转A复位刻A复位路56路处卸压状态73然处关闭状态74弹簧失控制压力导通液控单阀失控制压力关闭B路4高压工作液二位二通阀74进入加载油缸活塞杆腔活塞腔液体动高压变成排液背压事先处封闭回液口交单阀处回液口封闭状态回液节流阀71单阀72A回油箱单阀72节流阀71总液断面然加载油缸压头处高背压升起实现慢升减少振动
真值表状态5AB未踏位置状态1少许时间转B处踏位置时交单阀11已弹簧作处开回液通道状态时踏阀B高压液体二位二通阀74处通位置高压液流入加载油缸活塞杆腔活塞腔液体87172回油箱通通道回液路17通畅回油箱实现快升动作快速离开工件便更换工件
436垫铁
适应校直弯曲较工件机配备垫铁装安全键防止弯曲较工件校直中转动崩出垫铁伤安全键置工作台沟槽垫铁沟槽中校直弯曲度较工件确信工件会转动时安装安全键操作者根具体情况定校直工件选垫铁
44校直机维修调整
校直机然基安放需位置必须垫确保悬挂装置遇衡
工作台安装保证加载油缸轴线通悬挂标准件中心线面误差02mm调拧紧工作台安装螺栓
需拆加载油缸时需先卸工作台调住加载油缸卸加载油缸托板加载油缸降取加载油缸付半环然加载油缸提高抽出拔掉加载油缸中部六连接销加载油缸解体











结
通两月收集整理资料断学断复断老师学请教问题设计JZI型校直机利完成
文通校直机校直原理校直理结合四年学相关知识完成台校直机设计整设计程分三部分：1工厂参观实目深入生产第线充分解检测整程2广泛收集资料途径：图书馆查资料充分利现资源节省收集时间网搜索处方便效率高节省费通解信息够较快掌握行业发展动态工厂解资料包括工师傅口述资料安心作设计
说明书中校直机机械结构控制系统进行设计机械结构设计中着重机身结构设计中控制系统设计中应液压缸工作原理种阀工作原理等知识
通毕业设计锻炼寻找资料问题锻炼遇问题思考问题解决问题力时弥补学知识欠缺确立发展方定帮助







致谢
学时光弥足珍贵学四年学生活时丰富彩充实意义学四年直学着着极兴趣机械专业专业课方面提高设计中掌握量关机械设计制造方面理知识毕业实中量理知识运实践毕业设计实践基础强化专业知识实际运力收获颇丰
文导师牛曙光副教授精心指导帮助完成没辛勤培育老师没天取切成绩间老师学严格求生活关怀终身难忘表示诚挚感谢崇高敬意外位领导老师次毕业设计中予帮助学表示衷心感谢愿敬爱老师工作利身体健康









参考文献
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艺师2000(9)：36～3


专题 精密校直机控制系统
概述
机械汽车电机等行业量轴类杆类零件零件原材料粗加工火热处理等程中避免会出现弯曲变形果进行校直处理会直接影响工件序加工甚出现相数量废品获道工序允许切削量通精密校直保证工件达严格终设计公差求校直机成工件热处理缺少关键设备传统工艺中数厂家选手动压力机校直量难控制效率低难满足校直求动校直种先进生产制造工艺年着国工业整体技术水技术求提高该工艺越越广泛应机械汽车电机等行业中
动校直技术通数控精密校直液压机（简称精校机）完成轴棒等类零件校直种先进制造技术机械加工程中保证产品质量重工序广泛应汽车拖拉机工程机械机床纺织机械等机械制造行业发达国家该项技术研究起步较早已开发出具国特色动精校机产品国领域刚刚起步目前国应部分精校机国外引进着国机械工业发展机械产品质量求断提高项技术重性日益显现出迫切需动校直技术成套设备实现轴类零件精密校直提高轴类零件加工精度
二BUM系列轴类动校直机
）设备说明
该产品适范围包括：转齿条凸轮轴曲轴半轴齿轮轴电机轴减震器杆活塞杆车桥壳等轴杆类零件该系列产品消化吸收国外技术时针国客户情况校直原理测量方式机交互特殊工件处理方面作量创新设计普通零部件国设计加工关键器件选日韩国德国等国家著名公司进口产品保证利国产品价格拥世界级动校直机整体品质
该系列产品特性：
1高性高精度测量系统测量精度±5μm显示分辨率1μm
2 修正量适应调整系统精密液压控制动分析计算修正量 工件缺陷（中心偏心椭圆毛刺等）特殊处理解决假性弯曲问题
3先进WINDOWS测量系统友机话界面较实现操作者设备机交互
4简洁方便工件夹持定位装置户快速方便调整工装满足工件生产求
5声发射装置供选择检测出工件裂纹缺陷
6高效生产效率满足批量生产求
7存储种工件参数满足种类产品校直需
二）部分介绍
1液压控制系统
泵站液压阀组执行油缸液压控制回路等组成校直机液压系统液压系统关键部件采世界著名公司产品保证液压系统工作精确性稳定性性校直机机工作时独节卸荷方式设计较节约源
2气动控制单元
气动三联件压力继电器集装阀组执行气缸组成气动控制回路构成校直机气动单元气动单元控制执行工件夹紧定位分选运送等动作执行气缸位置检测开关系统反馈动作执行情况便动作流程控制障诊断排查气动元件选日韩国公司产品动作灵敏寿命长
3工件跳动检测单元
机械杠杆式测量放机构高精度位移角度传感器精密速度控制电机测量探头构成工件跳动检测单元测量探头采超硬圆棒式测量挺杆全开半开包容式测量片高精度标准齿轮等种方式分轴杆类工件纯圆截面D型截面齿轮花键分度圆等部位径跳动实现准确测量复杂周密设计保证测量精确性实性
4编程控制中心（PLC）
编程控制中心校直机关键组成部分校直机繁杂序动作程序控制执行完成PLC计算机处理系统相互通讯协调控制执行部件序进行夹紧测量校直部位选择加压实施修正等动作系统采日MITSUBISHI系列编程控制器（根户求选日OMRON德国SIEMENS等公司产品）电气操作执行元件采MITSUBISHIFUJIOMRON等公司产品工作稳定
5计算机处理系统
超高精度数采集系统安全输入输出系统带屏幕彩色液晶显示器工业体化工作站高专业水准软件包全中文机交互界面丰富彩图文显示印数统计输出等构成校直机计算机处理系统软件设计方面鉴国外专业厂家先进验基础增加独特校直理念中点振式修正加快校直速度量分解式修正专门针带D形截面表面局部淬火工件（转器齿条）开发设计类工件通常外形规方热处理均匀导致方机械特性存差异果传统校正方式难达产品技术求量分解式修正方建立修正模型进行校正出色解决类工件难校直问题意扩展工件参数存储满足机求完善障诊断系统操作员迅速排查设备障测量动态波形显示非常直观发现工件圆度误差毛刺凹坑等工件表面缺陷
6工件特殊缺陷处理
般工件存三种缺陷：中心偏心表面椭圆毛刺凹坑针三种缺陷公司软件硬件采特殊处理方式缺陷进行处理隐藏许假性弯曲问题针中心偏心问题支撑端加装两套测量装置直接测量出偏心通计算机演算测量点假性弯曲针表面椭圆问题测量波形进行波形分解处理通计算真正圆针毛刺凹坑问题测量波形进行滑处理凸点凹点掉消毛刺凹坑产生影响
三ASC系列动轴类校直机
）设备说明
ASC系列校直机长春试验机研究日国际计测器株式会社（KOK公司）合作生产产品动半动两种机型该机采日技术关键零部件长春试验机研究生产机装配实行中国市场价格极高性价格
机械汽车电机等行业量种轴类杆类零件零件锻造冷加工回火淬火调质程中避免会出现弯曲变形种情况果进行校直处理会影响工件序加工甚会出现废品校直机正克服种良影响设计制造
1994年日国际计测器株式会社(KOK)公司技术合作开始生产轴类校直机目前形成ASC定型系列产品ASC系列校直机种集机械液压气动控制技术检测技术计算机分析体高科技产品具优良技术性测量精度高生产节拍快工件适应力强形状特异零部件套成熟程序
二）部分介绍
该系列样直机智化分析测量系统程控电机电气机械液压空压控制系统等组成具灵活机话界面操作方便快捷
1承载机架
校直机机结构形式分C型门型C型机具结构简单制造加工容易部安装移动工作台带动工件支承工作台左右移动工件移修正部位加压油缸体固定机器部活塞计算机计算修正量工件进行校直门型机具封闭机框架机刚性易加入动生产线组成真正全动校直机称FASC系列门型机架固定工作台加压油缸移动式两种机架工作台件更换式台部件适应种动支承测量单元摩擦驱动装置顶尖式回转中心安装
2液压控制系统
泵站阀组执行油缸组成校直机液压控制系统泵站普通交流电机拖动柱塞式液压泵校直机提供动力源电磁阀组编程控制中心指令进行序快进快退工进修正进等动作校直机种工作压力动作频繁执行精度高复杂设备动作稳定准确校直机控制系统提出高求国际计测器公司专测量放系统具较高性放器设置分步动作功利操作者维护员检查机器动作液压系统中针中国域辽阔生产场温差特点采取节卸荷方式保证工作油较合适工作温度连续运转
3气动控制单元
校直机控制系统普通工程压力控制机器辅助零部件执行动作集装阀组执行气缸组合构成校直机气动单元执行气缸敏感元件PLC系统反馈动作执行情况气动单元控制回转中心前进退摩擦驱动压杆升降动支承组合升降中心孔部件顶尖清洁等功
4工件径跳检测单元
校直机工作半取决工件径跳检测称TIR测量纯圆工件测量径跳做工件回转驱动弯曲位移检测弯曲变形发生角度测量工件停止弯曲点位置精密速度控制电机单元驱动工件旋转定位停止角位移传感器准确出工件弯曲变形发生角度工件需停止角度精确弯曲位移测量传感器差动变压器式位移传感器充工业现场种干扰传感器动作频繁校直机采带信号放器传感器解决信号传递引起噪声针形状异工件安装探头诸柱形挺杆 R型测量子板式测量片开式圆形测量子等
5编程控制中心
校直机核心部件程序控制指挥包括CPU执行部件序进行夹持检测修正系统中采日OMROM系列编程控制器动作准确工业状况种卡接式安装易局部更换部件编程验户行编制户程序ASC系列校直机PLC中心设计时全部执行器件信息反馈确保执行动作准确效避免误动作保证工件设备安全
6计算机分析处理系统
ASC系列校直机计算机日国际计测器公司专型产品操作者通键盘输入工作参数根种传感器数采集进行分析计算确定工件修正部位修正量PLC单元提供数采集处理程中解决工件表面缺陷毛刺引起测量误差椭圆形工件正确找出真实弯曲变形解决花键齿轮节圆径跳测量问题形状特异工件转机齿条系统矢量分割方法校工作面进行效校正正ASC系列校直机软件包独处该单元通显示器提供高清晰度图文显示通印机进行功统计输出
四ASCⅡ系列动校直机
）简介
长春试验机研究着年国外厂商合作生产动校直机验年精心钻研博采众家长推出ASCⅡ系列轴类动校直机该系列产品消化吸收国外技术时针国市场校直原理测量方式机交互提示中文操作界面机电子图文帮助等方面作量完善改进更加适中国惯现场条件采元器件严格筛选关键器件选日德国等国家著名公司进口产品保证动校直机整体品质性优异性价会新老户带丰厚回报
特性：
1高性高精度测量系统测量精度±5μm显示分辨率1μm
2修正量适应调整系统动分析计算修正量
3简法工件夹持定位装置户快速方便调整工装
4友机话界面较实现操作者设备机交互
5必设备安全防护措施
6种供选择功部件：声发射裂纹检测装置实现全动生产动送料带
7达时30180件高校直生产效率实际工作效率工件精度求决定
二）ASCⅡ系列校直机部分简介
智化分析测量系统程控电机电气机械液压气动控制系统ASCⅡ系列校直机成技术门类复杂技术产品校直机丰富直观机界面户开放技术条件提高整机工作效率创造极方便部分机配合设备整体性出类拔萃
1承载机架
动校直机机结构形式分C型校直机门型校直机两种C型校直机开式框架结构具结构简单制造加工容易机刚性差超长轴杆类工件适应性等特点般超长工件工料操作半动校直机门型校直机封闭式框架结构具外观匀称结构紧凑机刚性占面积易线安装动流水线等特点选动料机构实现全动校直工作方式C型校直机采压头机构位置固定通电机驱动齿轮齿条机构控制移动工作台方式切换工件轴校直点门型校直机采工作台固定通电机驱动滚珠丝杠副控制移动压头机构方式切换工件轴校直点C型校直机移动工作台机构质量较系统惯量控制灵敏动作灵活性差切换工件轴校直点时定位稳定门型校直机移动压头机构质量较系统惯量控制更灵敏动作更灵活切换工件轴校直点时定位稳定性锁性均门型校直机结构较C型校直机更合理工作性更稳定精度更效率更高校直机工作台定位夹紧部件采积木式设计适应种动支承测量单元摩擦驱动装置顶尖式回转中心安装调整时方便易损零部件维修更换更利户新产品零部件校直工序切换扩展机械系统关键部件采日THKORIENTALNISSEI德国ROHM等世界著名公司产品校直机运行精度保持性长久
2液压控制系统
泵站液压阀组执行油缸液压控制回路等组成校直机液压系统液压系统关键部件采日YUKEN意利ATOS台湾NORTHMAN等世界著名公司产品保证液压系统工作精确性稳定性性校直机机工作时独节卸荷方式设计更适合国广阔区气候差异保证动校直机区较合适工作温度连续运行
3气动控制单元
气动三联件压力继电器集装阀组执行气缸组成气动控制回路构成校直机气动单元气动单元控制执行工件夹紧定位分选运送等动作执行气缸位置检测开关系统反馈动作执行情况便动作流程控制障诊断排查气动元件选日SMC德国FESTO台湾SHAKO等世界著名公司产品动作灵敏寿命长
4工件径跳检测单元
机械杠杆式测量放机构高精度位移角度传感器精密速度控制电机测量探头构成工件径跳检测单元测量探头采超硬圆棒式测量挺杆全开半开包容式测量片高精度标准齿轮等种方式分轴杆类工件纯圆截面D型截面齿轮花键分度圆等部位径跳动实现准确测量复杂周密设计保证测量精确性实性
5编程控制中心（PLC）
编程控制中心校直机关键组成部分校直机繁杂序动作程序控制执行完成PLC计算机处理系统相互通讯协调控制执行部件序进行夹紧测量校直部位选择加压实施修正等动作系统采日OMRON系列编程控制器（根户求选日MITSUBISHI德国SIEMENS等公司产品）电气操作执行元件采日MITSUBISHIFUJIOMRONMATSUSHITA法国SCHNEIDER等公司产品工作稳定
6计算机处理系统
超高精度数采集系统安全输入输出系统带屏幕彩色液晶显示器工业体化工作站高专业水准软件包全中文机交互界面丰富彩图文显示印数统计输出等构成校直机计算机处理系统软件设计方面鉴国外专业厂家先进验基础增加独特校直理念中点振式修正加快校直速度量分解式修正专门针带D形截面表面局部淬火工件（转器齿条）开发设计类工件通常外形规方热处理均匀导致方机械特性存差异果传统校正方式难达产品技术求量分解式修正方建立修正模型进行校正出色解决类工件难校直问题软件实现采C++ BUILDER 60 编程C语言应工业控制领域卓越表现软件包代码执行速度稳定性方面表现出色全中文机交互界面更加符合中国惯时操作员更加容易理解掌握详线电子图文帮助系统初学者迅速掌握操作领意扩展工件参数存储满足机求完善障诊断系统操作员迅速排查设备障测量动态波形显示非常直观发现工件圆度误差毛刺凹坑等工件表面缺陷难贵拥整套系统开发力技术队伍甚针特殊工件户提出合理求进行专门设计达户技术互动便出色发挥设备功效率
五结束语
手动伺服控制型精密校直液压机适应种轴类零件附件调整操作方便较精度高减少序加工量节约材料提高生产效率制件精度均积极效果国外发达国家已普应国液压机行业调整产品结构中应减少Y41系列单柱校直液压机生产积极开发技术附加价值高精密校直液压机系列成套附件完善检测装置样产品代进口出口提高济效益具广阔前景
全动精密校直液压机生产效率高国早已提出需应组织国关科研单位高校工厂联合攻关争取早出产品
着社会进步科技发展全动精密校直机逐渐取代传统普通型校直机















附录 基网络快速原型制造
摘：篇文提出新基快速原型快速产品开发集成系统发展通充分利迅速发展计算机网络信息技术网络制造服务系统系统提供更中型企业中快速产品开发支持提出制造业网络化服务体系架构外关键问题包括模型规划制造链选择行合作厂家排列制造务利步协作工作环境建立适合理台等问题述运行java解决办法网络技术建立样网络服务系统提供种服务应系统实例
关键词：快速原型制造服务系统
1．简介
信息技术时代 信息技术影响社会领域影响传统工业现代企业正面新挑战快速反应商机——直视保证公司竞争力重素制造业发展走数字化网络全球化效响应变化生产策略根市场情况客户需求时时变化改变策略应该厂商更力应付样需求减少生产时间提高质量速度够全球客户提供优质产品改善交通运输系统[1]定事实设计制造中利计算机获工业生产力提供重机会未制造业组织信息化知识驱动联系全球信息网络动化动控制目前已广泛认满足产品快速发展需求种新技术逆工程(RE)快速Prototyping(RP)快速工具制造(RT)等出现视够缩短产品研制时间制造键利工具例说RP节省新产品开发费70市场时间90设备中型企业(SMEs) 太贵许技术3D固体模型RP规划程形式表面重建等需高技完成中企业产品开发程充分利技术特困难量中企业产品快速制造发展提供支持 许RP事务局(SBS)仅制造物理原型快速原型工具提供工程服务已建立起2001年 世界500SBS需SB处理设计制造力必须效运外部资源更满足客户需求通常定义时联合企业计算机网络支持虚拟企业建立满足商机起分享技核心力资源SB处理核心务需量合作伙伴完成SB时完成工作强调服务质量新思路变成制造业21世纪赢全球竞争基方略远距离服务针厂商顾客服务问题新兴领域数字制造业技术进步快数字服务没阻碍进入综合数字系统设计制造结合计算机媒体特网商业制造业远程融合协作提供巨潜力SBsSMEs完成网络制造台加速生产效率非常紧迫篇文部分组织：1第二部分回忆相关研究工作2第3部分介绍基RP完整快速发展系统第四部分叙述网络制造服务体系流程功设计第5部分介绍系统运行台配置第6部分讨互联网应设计第7部分研究案例第8部分文总结
2 相关研究
伴着计算机网络信息技术发展网络制造技术制造业中发挥着越越重作年世界学术界工业团体支持网络制造研究实践(全球制造者远程制造)作量投资战略框架已提出 AbdelMalek等[8]描述架构公司生产设计活动通互联网发展模式协助公司选择代技术功限度发挥灵活性Montreuil等[9]提出战略框架提出设计制造灵活营网络动态掌握合作计划控制理日常环境Tso等介绍代理式协作支持服务系统 通专门设计虚拟代理信息网络够满足制造服务求Chen等[11]提出基网络设计制造综合框架基javaCORBA技术OffodileAbdelMalek 利虚拟制造模式制造业信心产业融合战略框架Huang等提出虚拟企业架构控制机制框架O’Sullivan[14]描述信息结构相关资料解处理商业发展AkkermansaHORSTC[15]讨信息技术基标准化公司理方指出战略框架指导理者基原济理理作出明智决定交易费理组织设计成熟发展阶段Jin等[16]提出研究关键技术应解决方案中包括确保网络数成员间传输安全策略基WebDotd数理(分布象技术)XML标准够保证结构环境数交换提供类服务转换文件网络台 WoernerWoern网络服务提出新发展台提供虚拟工程合作生产方法
充分认识全球化制造业远程工程前市场形势客户需求全球生产网络已建立中包括社会生产工程师LockheedMartin(AIMSNET)[19]3M(3M创新全球网络)
天产业正面严重快速发展带全球海外活动集成制造环境结构性问题服务维修公司保持制造业生产力国外区客户满意变极重传统服务台固问题公司已开始发展网线客户服务支撑体系Foo等综合描述客户服务台互联网服务支持Lee讨远程服务系统设计制造设备产品支持概念框架生命周期已建立示范远程客户支持系统FCSA证明Glober项目体系目效满足客户远程支持维修设备
加州学研究发展项目称远程制造厂(TMF)建立特网动快速生产 户TMF提供业机会维持系统动排队时动检查StL许缺陷设计制造程中RP技术带巨处需效利处处完全开发全球RP技术解非常困难快出现新改进方面工作帮助选择合适快速制造程 已开发许快速原型系统选择工作Quickpartscom私拥制造服务公司致力提供客户网电子商务系统采购量低高生产量关税区形成种系统QuickQuoteQuickQuote顾客生产部件快速报价3D系统公司早RP制造商提供通互联网服务
调查文字显然部份研究集中战略总体结构网络制造功模块没次全面comprebanausic网络制造服务体系支持快速产品开发 基前工作新研究网络基础生产服务体系产品迅速开发建立
3 快速制造综合系统结构
初概念设计产品商业性发展程包括产品设计 性分析安全性性 产品原型试验评价 设计修改新产品开发步进程产品市场化时间产生直接影响产品开发体系设计师设计组必须考虑方面产品设计制造销售回收初期设计周期设计制作轻易改变效反馈越流畅该系统成功性越高设计制造(DFM)行工程(CE)求产品设计开发程时发展序
产品快速发展综合系统三单元组成数字原型物理原型快速制造装备系统功系统产品开发利3维CAD软件制造3D立体模型开始阶段产品形状定义美学尺寸种样数字原型功完成3D模型设计创作程产品部件3D CAD系统直接设计(ProEUnigraphicsCATIAIDEA等) 果实体零件 模型逆工程技术建造 (RE)RE种利现零件建立物理模型方法建立数字模型然制造部件果提高产品性设计RE减少开发周期设计师采模拟创造新设计进步利数分析设计制造制造模拟模型逆工程三步骤数字化特征提取特征扩展3维 CAD模型完成零件数字化仪器接触非接触式种商业化数字化仪测量系统协调机(CMM)激光扫描机超声波仪分两类接触非接触式激光扫描三角(LTS)磁振影(MRI)计算机断层(CT)常非接触式装置接触式CMM截面图象测量(CIM)特征提取通常通数捕捉捕捉表面特征零件模型通填充适数面完成减少重复设计原型试验周期提高生产程增加机器性必须通CAE指导生产优化设计制造程
CAD模型利RP直接转化实际原型RP新成型零件制造程通计算机控制层层堆积直接3D模型短时间完成传统加工方法相反数快速原型制造系统基堆积程非材料切 种方法受规机械加工限制素限制常设计制造程中RP带巨处缩短产品市场化时间降低成提高质量10年已广泛应工业领域商业化RP技术包括业stereolithgraphy(ST)selectivelasersintering(SLS)融合沉积制造(FDM)胶合物体制造(LOM)弹道微粒制造(BMP)三维印刷(3D印刷)等
RT种技术RP零件转化功部件特金属零件外 RPRT融合推动公司行工程发展许RP系统制造模具生产程发展RT方法致分直接间接软硬切削间接RT需掌握某种模式种模式常规方法(HSM等)获者RPSLSLS获直接RT顾名思义直接RP系统制造消中间产生步骤格局根述技术新产品开发综合系统迅速建立起详细结构图1



4 工作流程功设计
工作流程生产服务体系网络图2 第步登陆SB网站户名称密码进入没登记核准进入系统限观资料例系统公开＇典型案例＇进入户密码系统验证进入网站成功系统会动核者安全程度确定模块进入根认证制度户分四类般户(未注册)潜客户真正客户系统理员接受客户求SB首先进行规划程务分解落实选择合适加工方法未做续工作前户必须产品排队初步生产时间 果接受样结果初阶段SB进步户进行电视会议方确认合户成真正客户户提出生产务SB做实施果SB没样制造力时完成 充分利外部资源源进行未完成务效方法步选择合适合作厂商形成虚拟企业分配制度完成务工作外监测安排确保生产利生产户合作生产企业必须快实现基信息生产进度时间表生产监落符合质量标准公司受严格审查时采取预防补救措施提前预测损害
提述流程网络化服务体系数字远程服务体系功求服务体系包括九功模块技术研究典型案例信息咨询协议(应服务提供者)套工具客户理电子商务制造服务导航系统 详细结构见图3

九部分阻碍努力实现目标提供时效服务产品台支持中企业发展迅速中目研究技术户更加解相关知识产品快速发展帮助读者更解运新技术系统说明真实案例技术研究典型案例提供助服务户根专家支配SB回答客户问题户沟通解决问题信息咨询模块
ASP五项成分组成 RERPRT进程规划STL检查维护零件优化控制 生产结构支撑零件优化计算逆工程方法种前描述RPRT种特点适范围情况务求选择合适加工方法时非常困难根ASP模式3种选择器RE selectorRP selectorRT selector StL固体模型建立减少约10时间表明动检查错误重业务RP控制室非常重根提供网络资源验知道 没设计者网站进行错误动检查时特重某情况已制定种算法发现动拓扑修补缺陷两＇防火墙＇发现缺陷结合户操作外服务器台理功定位较狭窄 StL果致命缺陷者移交期间失部分档案资料必须客户选择材料组成部分制造程中质量策划方法
5 结未研究
满足目前快速产品开发集成系统需求 提出种新基快速原型快速制造融合系统 提出更适合中型企业产品快速发展网络服务系统种方法JAVA制造网络化服务体系建设基础建造三层浏览器服务器模式java引入项技术容易扩展基础设施标准服务体系包括技术信息台电子商务台制造服务台提供生产协作环境户服务局部分制造资源效帮助中型企业产品快速发展



















附录二 A webbased manufacturing service system
for rapid product development
Hongbo Lana Yucheng Dinga* Jun Honga Hailiang Huangb Bingheng Lua
Abstract
This paper proposes a novel integrated system of rapid product development based on rapid prototyping and develops anetworked manufacturing service system which offers better support for the rapid product development in small and mediumsized enterprises by taking full advantage of the quickly evolving computer network and information technologies The architecture of the networked manufacturing service system is presented Furthermore some of the key issues includingmodelling and planning a manufacturing chain selecting feasible collaborative manufacturers queuing a manufacturing task using the synchronously collaborative work environment and constructing a suitable running platform are described in detail Javaenabled solution together with web techniques is employed for building such a networked service system Finally an actual example is provided illustrating the application of this service system
Keywords
Rapid product development Rapid prototyping Service system Webbased application
1 Introduction
This is the era of information technology Informationtechnology has influenced every realm of society and dramatically impacted on the traditional industryCurrent industries are facing the new challengesquick response to business opportunity has been consideredas one of the most important factors to ensurecompany competitiveness manufacturing industry isevolving toward digitalization network and globalizationIn order to respond to the change effectivelymanufacturing strategy has to be modified from timeto time in accordance with the market situation andcustomer demand Any change of strategy should enable manufacturers to be better equipped themselveswith capabilities to cope with demands suchas a faster response to market changes a shortenedlead time of production improved quality and speedthe ability to deliver quality products to global customersand improved communications and transportationsystem [1] It is an established fact that the useof computers in design and manufacturing constitutesthe most significant opportunity for substantial productivitygain in industry It has now been widelyaccepted that the future of manufacturing organizationswill be informationoriented knowledge drivenand much of their daily operations will be automatedaround the global information network that connectseveryone together [2] In order to meet the demand ofrapid product development various new technologiessuch as reverse engineering (RE) rapid prototyping (RP) and rapid tooling (RT) have emerged and areregarded as enabling tools with abilities to shorten theproduct development and manufacturing time Forexample it has been claimed that RP can cut newproduct development costs by up to 70 and the timeto market by 90 [3] However these equipments aretoo expensive for the small and medium sized enterprises(SMEs) and many techniques such as 3D CADsolid modelling RP process planning freeform surfacesreconstruction etc require the high skilled personnelto complete Therefore it is especially difficultfor the SMEs to take full advantage of these technologiesin the product development process In order tooffer the support of rapid product development fornumerousSMEsmanyRPservice bureaus (SBs)whichcan not only manufacture physical prototype and rapidtooling but also provide other engineering serviceshave been established By 2001 there are more than500 SBs all over the world But not every SB canpossess all design and manufacturing capabilitiesrequired it must employ effectively the externalresource to better satisfy client requirements Namelya virtual enterprise which usually defined as a temporaryalliance of enterprises that come together to sharetheir skills core competencies and resource in order tobetter respond to business opportunities whose cooperationis supported by computer networks [4–6] is tobe founded Every SBconducts only the tasks of its corecompetencies and depends on numerous partners tocarry out the remaining tasks that this SB has no such manufacturing capabilities to accomplish in timeWhile a new thought emphasizing service quality is becoming a basic strategy by which manufacturing industries can win global competition in the 21st century Teleservice engineering is an emerging fieldwhichaddresses service’’ issue for manufacturers and customers As digital manufacturing technique progresses quickly digital service will be integrated seamlessly into the digital design and manufacturing system [7] The internet incorporating computers and multimedia has provided tremendous potential for remote integration and collaboration in business and manufacturing applications In order to provide a production collaborative environment for many SMEs and SBs to implement the networked manufacturing it is especially urgent for many SBs and SMEs to construct a service platform of networked manufacturing to speed up the product development process of the SMEs
The rest of this paper is organized as followsRelated research work is reviewed in Section 2 In Section 3 we introduce an integrated system of rapid product development based on RP Section 4 describes the workflow and functional design of the networked manufacturing service system The configuration of system running platform is presented in Section 5 In Section 6 we discuss the design of internet application A case study is demonstrated in Section 7 Finally Section 8 concludes the paper
2 Related research
With the development of computer network and information technologies the networked manufacturing techniques are playing a more and more important role in manufacturing industry Substantial investments have been made to support the research and practice of networked manufacturing (telemanufacturing or global manufacturing) from both the academic community and industrial bodies all over the world in recent years A number of strategies and frameworks have been proposed AbdelMalek et al [8] described a structure within which a company can outsource several of its production and design activities via internet and developed a model to aid a company in selecting among the available technological and functional alternatives to maximize its flexibility Montreuil et al [9] presented a strategic framework for designing and operating agile manufacturing networks enabling to collaboratively plan control and manage daytoday contingencies in a dynamic environment Tso et al [10] introduced the architecture of an agentbased collaborative service support system which is able to carry out service requests in a manufacturing information network through some specially designed virtual agents Cheng et al [11] put forward an integrated framework for webbased design and manufacturing which is developed based on Java solution and CORBAORG broking technologies Offodile and AbdelMalek [12] introduced a framework for integrating IT and manufacturing strategies using the virtual manufacturing paradigm Huang et al [13] presented a holonic framework for virtual enterprises and control mechanisms of virtual enterprises under this framework O’Sullivan [14] described an information architecture and associated toolset for understanding and managing the process of business development Akkermansa and Horstc [15] discussed managerial aspects of information technology infrastructure standardisation in networked manufacturing firms and presented a strategic framework to guide managers in making sensible decisions regarding IT infrastructure standardisation based on a number of preexisting economic and management theories such as transaction cost theory organisational design and IT maturity growth stages Jin et al [16] presented a research on key application technologies and solutions which includes a network safety strategy which ensures data transfer among the leaguer members production data management based on WebDOT (distributed object technology) and XML criteria which ensure data exchange in structurevariance characteristic environments the network platform which provides the conversion service of different types of CAD files Woerner and Woern [17] introduced a new web service based platform providing developed methods for cooperative plant production within virtual engineering
To full realize the teleservice engineering in today’s globalized manufacturing industry and meet the current market situation and customer demand a number of global manufacturing networks have been established by among others the Society of Manufacturing Engineer [18] Lockheed Martin (AIMSNET) [19] and 3M (the 3M Innovation Global Network) [20]
Today’s industries are facing serious structural problems brought about by their rapid development of overseas activities under a global integrated manufacturing environment Service and maintenance are becoming extremely important practices for companies to maintain their manufacturing productivity and customer satisfaction in foreign regions Due to the inherent problems of traditional help desk support some companies have started developing webbased online customer service support system Foo et al [21] described an integrated help desk support for customer service via internet Lee [7] discussed the concept and framework of a teleservice engineering system for the life cycle support of manufacturing equipment and products A system for remote customer support has been created in the FCSA demonstrator of the Globerman 21 project [22] The purpose of these systems above is to provide effective and responsive remote support to customers in the use maintenance and troubleshooting of their equipment
University of California is studying and developing a project called the TeleManufacturing Facility (TMF) which is to create an automated RP capability on the Internet TMF allows users to easily submit jobs and have the system automatically maintain a queue While it can automatically check many flaws in STL files and in many cases fix them [23] RP potentially offers great benefits when used during the design and manufacturing process However RP must be used in an effective manner if these benefits are to be fully exploited The RPnovices have a lot of difficulties in getting a global view of the RP technique and in tackling well founded decision for investment or outsourcing of RP tasks because of the very quick appearance of new and improved processes in this field In order to help novices select a suitable RP process the rapid prototyping system selector has been developed by many researchers [24–27] Quickparts com which is a privately held manufacturing services company dedicated to providing customers with an online Ecommerce system to procure lowvolume and highvolume custom manufactured parts has developed a QuickQuote system The QuickQuote system enables customers to get instant customerized quotations for the production of their parts [28] 3D Systems Company which is the earliest and biggest RP equipment manufacturer has provided RP&M service for customer via Internet [29]
From these literatures survey it is clear that most of studies mainly focused on the strategy and overall architecture of networked manufacturing as well as individual function module there is still no comprehensive and banausic networked manufacturing service system to support rapid product development Built on the emerging researches and our earlier work (eg Refs [3031]) a webbased manufacturing service system for rapid product development is to be established
3 Architecture of the integrated system ofrapid product development
The development process from initial conceptual design to commercial product is an iterative process which includes product design analysis of performance safety and reliability product prototyping for experimental evaluation and design modification Therefore any step of new product development process has a direct and strong influence on timetomarket A good product development system must enable designers or design teams to consider all aspects of product design manufacturing selling and recycling at the early stage of a design cycle So that design iteration and changes can be made easily and effectively The more fluent the feedback is the higher possibility success of the system has Design for manufacturing (DFM) and concurrent engineering (CE) require that product and process design be developed simultaneously rather than sequentially [32]
The integrated system of rapid product development is composed of three modules digital prototype physical prototype and rapid tooling and functional part manufacturing system The product development starts from the creation of a 3D model using a 3D CAD software package At that stage the product geometry is defined and its aesthetic and dimensional characteristics are verified The main function of digital prototype is to perform 3D CAD modelling The product and its components are directly designed on a 3D CAD system (eg ProEngineer Unigraphics CATIA IDEAS etc) during the creative design process If a physical part is available the model can be constructed by the reverse engineering (RE) technique RE is a methodology for constructing CAD models of physical parts by digitizing an existing part creating a digital model and then using it to manufacturing components [33] RE can reduce the development cycle when redesigns become necessary for improved product performance Preexisting parts with features for improved performance can be readily incorporated into the desired part design When a designer creates a new design using mockup it is also necessary to construct the CAD model of the mockup for further use of the design data in analysis and manufacturing The three primary steps in RE process are part digitization features extraction and 3D CAD modelling Part digitization is accomplished by a variety of contact or noncontact digitizers There are various commercial systems available for part digitization There systems range from coordinate measuring machine (CMM) laser scanners to ultrasonic digitizers They can be classified into two broad categories contact and noncontact Laser triangulation scanner (LTS) magnetic resonance images (MRI) and computer tomography (CT) are commonly used noncontact devices Contact digitizers mainly have CMM and crosssectional imaging measurement (CIM) Feature extraction is normally achieved by segmenting the digitized data and capturing surface features such as edges Part modelling is fulfilled through fitting a variety of surface to the segmented data points [34] In order to reduce the iterations of designprototypetest cycles increase the product process and manufacturing reliability it is necessary to guide in optimization of the product design and manufacturing process through CAE
The CAD model can be directly converted to the physical prototype using a RP technique RP is a new forming process which fabricates physical parts layer by layer under computer control directly from 3D CAD models in a very short time In contrast to traditional machining methods the majority of rapid prototyping systems tend to fabricate parts based on additive manufacturing process rather than subtraction or removal of material Therefore this type of fabrication is unconstrained by the limitations inherent in conventional machining approaches [35] RP potentially offers great benefits when used during the design and manufacturing process It can help shorten timetomarket improve quality and reduce cost Over the last 10 years RP machines have been widely used in industry The RP methods commercially available include Stereolithgraphy (SL) Selective Laser Sintering (SLS) Fused Deposition Manufacturing (FDM) Laminated Object Manufacturing (LOM) Ballistic Particle Manufacturing (BMP) and Three Dimensional Printing (3D printing) [36] etc
RTis a technique that transforms the RP patterns into functional parts especially metal parts Furthermore the integration of both RP and RT in development strategy promotes the implementation of concurrent engineering in companies Numerous processes have been developed for producing dies fromRP system The RT methods can generally be divided into direct and indirect tooling categories and also soft (firm) and hard tooling subgroups Indirect RT requires some kinds of master patterns which can be made by conventional methods (eg HSM) or more commonly by an RP process such as SL or SLS Direct RT as the name suggests involves manufacturing a tool cavity directly on the RP system hence eliminating the intermediate

step of generating a pattern [37] On the basis of abovetechniques a novel integrated system of rapid product development is to be established Its detailed structure is shown in Fig 1
4 The workflow and function design
The workflow of the service system of networkedmanufacturing is shown in Fig 2 The first step is to log in to the website of SB Users have to enter their names and passwords Those without registration or authorization can also enter into the system but they are limited to viewing the information that is open to the public such as typical cases’’ in this system The password entered by the user will be verified by the system After entering the SB website successfully the system will check the security level of users and determine which modules they can access or employ According to authentication for the system all usersa re to be divided into four categories general users (without registration) potential clients real clients and system administrator Received job requests from clients the SB will perform firstly process planning which fulfills the task decomposition and selects the most suitable process methods It is necessary for users to get the preliminary product quote and manufacturing time from the SB before the followup process continues If such results may be accepted initially The SB will negotiate further with users by Videoconferencing system Once come to term each other a contract is to be confirmed and the user becomes a real client The manufacturing tasks submitted by real clients had better be implemented in the SB However if the SB has no such manufacturing capabilities or can not accomplish then in time it is an effective way that the SB takes full advantage of external sources to carry out the remaining tasks

The next step is to select the appropriate collaborative manufacturing enterprises to form a virtual enterprise to complete the tasks by the task assignment decision system In addition in order to monitor the manufacturing schedule to ensure smooth production both collaborative manufacturing enterprises and SB itself must provide as quickly as possible the essential information related to production progress and schedule for the module of production monitor So any companies falling behind schedule or failing to meet quality standards will be closely examined by SB and users to ensure that precautionary or remedial measures are made ahead of time or any damaging effects are predicted
Referring to the workflow of networked service system above and the functional requirement of the digital teleservice system the service system consists of nine functional modules the technique research typical cases information consultation ASP (application service provider) tool set client management

Electronic commerce manufacturing service system navigation Its detailed structure is shown in Fig 3
These nine components work together seamlessly to achieve the common objectives ie to provide an effective and prompt service platform to support the rapid product development of SMEs One of the purposes of the technique research is to enable users to increase awareness of the relevant knowledge of rapid product development In order to help users better understand and apply these new techniques the system illustrates a number of reallife cases Both the technique research and typical cases mainly provide selfhelp service for users Depending on the predominance of specialty and expert the SB can answer the queries of clients and communicate with novices to solve their problems by the information consultation module
The ASP tool set provides five useful components below the process planning of RERPRT STL checking and fixing the optimization of part orientation the support structure generation and the optimization of part slicing There are various process methods for RE RP and RT as previously described each of them has its characteristics and the scope of application It is especially difficult for many novices to select the most suitable process methods according to the individual task requirement and condition Three selectors based on ASP mode namely RE selector’’ RP selector’’ and RT selector’’ have been developed to perform process planning automatically in the Web Serverside In [38] Miller states that STL files created from solid models have anomalies about 10 of the time and those created from surface models have problems about 90of the time Error rates in this range make it clear that automated error checking is important for all RP operations Based on our experience with supplying networkbased resources we know that it is especially crucial to perform automatic error checking when the RP operation is not at the designer’s site We have developed various algorithms to detect and in some cases automatically fix geometric and topological flaws There are two firewalls’’ to detect those flaws one is integrated with the online pricing engine that will be operated by the user before the STL file is submitted to the SB while the other is to run on the SB’s Serverside after the STL file is submitted Because the function of fixing is quite restricted if a STL file has fatal flaws or loses some data during transferring it would have to be uploaded again from the Clientside Parts formed using RP technique can vary significantly in quality depending on the manufacturing process planning The process planning of RP is performed to generate the tool paths and process parameters for a part that is to be built by a particular RP process The steps required are the part orientation support structure generation slicing path planning and process parameter selection Therefore it is also very important for remote users that SB can provide these process planning techniques Three submodules including the optimization of part orientation support structure generation and the optimization of part slicing have been developed to aid effectively users in setting RP process variables in order to best achieve specific build goals and desired part characteristic Both potential clients and real clients can employ freely the ASP tool set
Electronic commerce module is composed of foursections the online quote buildtime estimation online business negotiation and electronic contract management Conventionally the SB may quote according to the client’s offerings (eg CAD models 2D drawings or physical prototypes) utilizing their experiences or just get payment after the RP model has been built But for teleservice it is necessary for the remote users to inquire about the service expense of making RP prototype before the followup process continues Hence an online pricing engine (OPE) has been developed The details of the OPE Stereolithography oriented have been discussed in [39] The accurate prediction of the buildtime required is also critical for various activities such as the job quoting the job scheduling the selection of build parameters (eg layer thickness and orientation) benchmarking etc Two buildtime estimators based on sliced process and STL have been exploited respectively Ref [40] presents the principle of a buildtime estimation algorithm for Stereolithograpy based on model geometrical features After clients accept initially the quote they may negotiate with SB on the business and technological details The Microsoft NetMeeting which can set up a collaborative environment to fulfill information sharing file transferring Video and Audio communication etc provides an ideal tool for the online negotiation It is also seamlessly integrated IE Browser thus clients can call SB at any moment As a result of negotiation an electronic contract is to be signed To effectively manage andoperate these electronic contracts the system alsoprovides a contract management component It is especially convenient and prompt for clients to submit inquire and search contract through this module
The manufacturing service module which covers the job management collaborative manufacturing process monitor and collaborative enterprises management is regarded as one of the most important function modules in the service system When a contract is confirmed clients will formally submit their job requirements (eg RE 3D CAD modelling CAE RP prototype or rapid tooling) and sources (eg object parts digitized data cloud 2D models 3D models or STL files) In order to help many novices submit quickly and easy the manufacturing tasks various job and source templates have been created while the client can search modify and even delete the manufacturing tasks itself if the occasion arises The Collaborative Manufacturing System (CMS) is responsible for the selection of collaborative enterprises (CE) In addition it is extraordinarily important and necessary to monitor the manufacturing schedule and control product quality to ensure smooth production In the past a SB had to spend much time on dealing with a lot of inquires from the clients by via phone calls or Faxes Now the Process Monitor System (PMS) provides various facilities which canguarantee the tasks to be completed timely Any partners falling behind schedule or failing to meet quality standards will be closely examined by SB and users to ensure that precautionary or remedial measures are made ahead of time or any damaging effects are predicted
All information (no matter if it is a real client being ready for a contract with the SB or just a potential one showing his intent or inquiry) involved in the whole service process are managed and maintained by a special Database These data provide strong supports for both online business and manufacturing service To create a collaborative environment among SB users and CE we have to rely fully on the multimedia and Internet Therefore the service system offers three enabling tools Video conferencing system Electronic whiteboarding and FTP In order to make use of the system as quickly as possible users can get help from the system navigation module These nine components form a fullyintegrated system that is able to carry out tasks in an efficient and effective way
On the basis of the workflow and function module of service system the system framework can be constructed as shown in Fig 4 Fig 5 illustrates the networked structure of service system

5 Configuration of running platform
In order to run this system effectively constructing asuitable running platform is necessary and especially crucial An operating system (OS) is one of the most basic software components for running this system The operating systems commonly founded onWeb Servers are UNIX OS Linux and Windows etc Windows 2000 Advanced Server is a better platform for running business application Better SMP scalability improved networking performance and support for more physical memory have a profound impact on the performance of Windows 2000 Advanced Server in an application server environment Hence we select Windows 2000 Advanced Server as the operating systemof the running platform Web Servers including Apache IIS iPlanet CERN and IBM WebSphere are frequently installed websites at the present time Internet Information Services (IIS) 50 which is integratedWindows Advanced 2000 Server is a new release Web Server of Microsoft Company Not only being a Server it also provides a number of other Internet services such as FTP News WWW and SMTP etc With tighter integration between the operating system and IIS it offers performance gains and higher availability for Web Servers and sites Normally IIS can not execute Servlet and Java Server Pages (JSP) configuring IIS to use Tomcat redirector plugin will let IIS send Servlet and JSP requests to Tomcat (and thisway serve them to clients) Tomcat32 of the Apache Software Foundation is selected to act as the engine of JSP and Servlets Database Server adopts SQL Server 2000 Relational Database Exchange Server 55 is to be used to implement the mail service function In order to prevent hacking system two firewalls based on package filtration and proxy Server namely Cisico2511 router and Proxy Server 20 have been established The overall configuration of Web platform is shown in Table 1
6 Design of internet application
61 Browseserver model
The model of information service based on WWW falls into two broad categories ClientServer (abbreviation CS) and BrowserServer (BS) CS is a twotier model where a connection is built directly between the Client and Database Server In comparison BS is a threetier model where a connection is built between the Servlet or Application Server and Database Server and the Clients obtain the data from the Servlet or Application Server In the threetier model it is the middle tier of Servlet or Application Server objects that deal with all Database access operations BS has the same benefits (eg highly interactive graphical user interface aids productivity) as CS but avoids the enormous distribution and maintenance problem Besides an operating system and personal productivity software the only software that the userend needs is a Web Browser that can run Java Applets The BS architecture allows developing professionals to focus on development and maintenance tasks on the Server side in spite of the increasing number of distributed customers Therefore there are a number of advantages for a BS model thin Client (platform independent) central software storage and control high interactivity economy in system development maintenance and upgrade Due to the distributed and heterogeneous nature of clients and collaborative enterprises this service system is based on BS structure which can fit the distributed and heterogeneous environment of networked manufacturing The structure of BS model is shown in Fig 6
62 Choosing a serverside language
Creating dynamic Web pages that interact with the user showing customized information is the pith of Web application for BS model With the rapid development and prevalence of Internet a variety of solutions have appeared which enables the development of Web application to become more and more simple convenient and effective Four Serverside scripting languages including Common Gateway Interface (CGI) Active Server Pages (ASP) Person Home Pages (PHP) and Java Server Pages (JSP) are frequently used now
CGI scripts are inefficient and difficult to be used for writing Server extensions Each time someone hits a CGI script a new process is created on the Server if a script is written in an interpreted language like Perl the Server has to start up another Perl interpreter consuming more processing time and memory The situation gets even worsewhen it resides on a site that is getting a few thousand hits a day Another disadvantage with CGI is that a CGI program can not interact with the Web Server during its execution because it is running in a separate process Microsoft attempted to change all this when they introduced Active Server Pages which allows developers to use simple scripting to access the Server and its extensions ASP is almost as efficient as writing code directly to the Server’s application program interface and it is more efficient than CGI because it runs as a service and can take advantage of multithreaded architectures But while ASP provides an efficient way to return dynamic content it essentiallylimits one to Microsoft platforms and even the


simplest of scripting mistakes can crash or hang the Web Server [41] PHP is an opensource Serverside scripting language for creating dynamicWeb pages for Web applications A particular strength is that it can be used to develop Websites on a desktop system and deploy then on secure Servers such as those found commonly only running UNIX or Linux The PHP drawbacks that we have found are predominantly in its weak abstraction for Databases (each Database backend is accessed through a different interface In other words PHP is limited to using a small handful of free Database APIs none of which are compatible with each other) underdeveloped library mechanism (lacking Peril’s true module’’ concept) and occasional linguistic quirks [42]
In response to ASP Sun Microsystems gave the world Java Server Pages (JSP) technology which is based entirely upon Sun’s popular Java programming language and gives developers the advantages of developing in Java in a more relaxed scriptlike environment JSP is a better solution generating dynamicWeb pages in contrast to ASP PHP and CGI Together JSP and Servlets provide an attractive alternative to other types of dynamic Web scriptingprogramming that offers platform independence enhanced performance separation of logic fromdisplay ease of administration extensibility into the enterprise and most importantly ease of use [43] JSPServlets has been widely applied by many electronic commerce providers such as the famous EBusiness EJBtJSPtServlets are almost to be a standard of developing electronic commerce Hence it is a better decision to develop dynamic Web pages by JSP and Servlets
63 Constructing development platform
The running and development environment of JSP and Servlets is especially complicated The running


and development framework of JSP and Servlets is described in Fig 7 The application development platform is shown in Table 2 The development kits of application are reported in Table 3 Figs 8–11 illustrate the Home pageWeb page for manufacturing service Web page for remote STL checking and Web page for client management The web page for user interface of online pricing engine (OPE) in Internet Explorer 50 and a case of online quote are illustrated in Figs 12 and 13 respectively
7 Case study
To illustrate exactly how the service system works and the benefits it can bring to the users and servicebureaus an actual example is now presented Let us assume that a company was working on a new design of the curing coryza apparatus for which a number of physical models would be required The model was purely for the purpose of design visualization and would be used as a means of communication with other functional departments in the organization The task requirement and relevant resources were submitted to SB by the job management module of the service system After receiving the job requirement the system would firstly perform the process planning by which the job was to be decomposed into the 3D CAD modelling and making prototype and SL wasselected as the most suitable process for building the mockups through the RP selector’’ while the service system offered the preliminary product quote and manufacturing time for the user Accepted initially such results the user continued to negotiate further with SB by Videoconferencing system Once a commercial a contract was to be confirmed in the end Subsequently the 3D CAD modelling and prototype making were assigned to the Shaanxi Productivity Promote Center and Chongqi Productivity Promote Center respectively to complete Finally the green parts would be checked online and delivered to the end user The detailed workflow is represented in Fig 14 The result of process planning is reported in Table 4 The 3D CAD models submitted by the Shaanxi Productivity Promote Center are illustrated in Fig 15 The mockups fabricated by the Chongqi Productivity Promote Center are shown in Fig 16 In contrast to the traditional development mode it can cut the new product costs by up to 50 and the timeto market by 75 Consequently the costs and lead times are substantially reduced using this service system to develop new products
8 Conclusions and future research
In order to meet the current demand of rapid product development a novel integrated system of rapid product development based on rapid prototyping is proposed and a networked service system which offers better support for the rapid product development of small and medium sized enterprises is established A Java solution is used for constructing the networked manufacturing service system based on the threetier BrowserServer mode Since Java technology is introduced to this research the infrastructure can be easily extended into a standard JINI computing model in the future The service system which includes the technology information platform Ecommerce platform and manufacturing service platform provides a production collaborative environment for users and service bureaus enables the share of manufacturing resource and can effectively aid the rapid product development of small and medium sized enterprises This system has been employing in the Northwest Productivity Promotion Center It has been shown from a number of case studies that the system has a high potential to speed up the new product development As a result the implementation of such a system will represent afundamental shift of enterprise strategy and manufacturing paradigms in organization
Networked manufacturing and manufacturing service system based on Web are new manufacturing mode in term of mission structure infrastructure capabilities and design process which need more detailed research and theory building Many renowned companies and universities have been involving in the further development and new application of networked manufacturing service system The significantcontribution of this paper is to construct an actual networked manufacturing service system to support rapid product development and demonstrate how to develop a networked service system based on Javaenabled solution Further research will be focused on the product collaborative commerce (CPC) the collaborative service support and the detailed structure and formulation of the centralmonitoring mechanism of such a partnership system
Acknowledgements
This project was supported by The National High Technology Research and Development Program (863 Program) under the title RP&M networked service system’’(No 2002AA414110) and the Tenth Five years’’ National Key Technologies R&D Program of China under the title Research and demonstrator of rapid manufacturing integrated system based on rapid prototyping’’ (No 2001BA205B10CMTT1001)
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