质量损失函数与测量系统校准研究
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摘要
现代质量管理重在结果,同时也关注过程。产品质量改进的基础是首先要对质量水平有个客观的评价,这就涉及到两个问题：一是评价质量水平的方法是否全面准确而有效；二是获取的用来评价质量的数据是否可靠,也就是基于测量系统获取的数据的质量优劣。解决第一个问题可以借助于质量损失函数相关理论,第二个问题则首先要确保有精准的测量系统,其次要对测量系统设计合理的校准周期和校准方法,还要通过测量误差损失函数来衡量测量质量水平。测量质量损失函数以及测量系统校准方法是田口测量质量工程学的重要内容之一,在表征测量质量优劣、测量系统校准、评价和改进产品质量、质量控制系统设计等方面具有极其广泛的应用。因此,本文对质量损失函数、测量误差损失函数、反馈控制系统和校准系统损失函数、非线性测量系统校准方法的研究具有很高的理论研究价值和极其深远的现实意义。
作者在前期研究中发现测量质量损失函数等相关理论本身还存在一些不完善之处,致使从田口方法诞生起,就在学术界引起广泛争议,这也在一定程度上影响了工业企业使用田口方法的积极性。本文在对相关理论进行研究的基础上,找出存在的问题,进而提出相应改进的质量损失函数以及非线性测量系统的校准方法。本文的研究内容包括：
(1)质量损失函数的改进。目前,田口质量损失函数只用一个二次项表示的,既略去了一次项,又略去了高次项,这对于望小特性和望大特性情况是不妥当的。本文提出了改进的望小特性和望大特性的质量损失函数。同时,本文还分别从单个质量特性和多个质量特性两种情况研究了动态特性情况下的质量损失函数。
(2)动态测量情况下测量误差损失函数。田口测量质量工程学对静态测量情况下测量误差损失函数进行了介绍,但实践中,被测量往往是动态变化的,本文提出了动态测量情况下的测量误差损失函数,分别从己知信号因子和未知信号因子两方面研究了测量误差损失函数。
(3)反馈控制系统损失函数的改进。田口先生在考虑测量费用、调整费用以及失控品损失的基础上设计了反馈控制系统损失函数,但田口先生所确定的反馈控制系统损失函数尚存在一些有待改善的地方,本文提出了改进的田口反馈控制系统损失函数。
(4)基于改进的反馈控制系统损失函数的控制图设计。本文通过对改进的反馈控制系统损失函数中一些参数进行变换,从而设计出使经济损失最小的基于反馈控制系统损失函数的控制图。此外,还对控制图在测量系统稳定性和偏倚分析中如何应用进行了研究。
(5)校准系统损失函数的改进。作者在找出田口校准系统损失函数存在问题的基础上,提出了改进的校准系统损失函数,并进行了实例分析。
(6)线性测量系统校准周期和校准方法研究。本文以测量尺寸三坐标为例研究线性测量系统的校准周期和校准方法,在分析测量尺寸三坐标测量仪现行校准周期和校准方法的基础上,研究应用田口测量质量工程学的理论,确定测量尺寸三坐标测量仪的最佳校准周期以及具体的周期校准方法和日常校准方法。
(7)非线性测量系统校准方法研究。绝大多数测量系统都是非线性的,尤其是含有传感器的测量系统以及测量各种流量的测量系统其非线性更加明显。对于非线性测量系统如果采用线性式关系进行处理就人为地增加了系统误差。本文通过借鉴田口测量质量工程学的理论研究了非线性测量系统校准方法,包括周期校准方法和日常校准方法。
Modern quality management emphasizes on results, while the results depend on process. The basis of product quality improvement is to objectively evaluate the quality level, which involves two problems:first, whether the method to evaluate the quality level is comprehensive, accurate and effective; Second, whether the data used to evaluate is reliable, in other words, the quality of the data from the measurement system is good or not. We can make use of some correlation theory of quality loss function to solve the first problem, while to the second, first of all, we must ensure a high quality of the measurement system, then, we ought to design the reasonable calibration cycle and calibration methods for the measurement system, what's more, we should describe the quality of measuring level through the measurement error loss function. Measuring quality loss function and the calibration methods of measuring system are the important aspect of the taguchi method, which have extremely extensive application in characterizing the quality of measuring level, determining the best calibration cycle of measuring system and the calibration method of the measurement system, evaluating and improving product quality, designing of quality control system, and so on. Thus, the study to the quality loss function, the measurement error loss function, the feedback control systems, the calibration system loss function and the calibration method of non-linear measurement system has an important value not only on theory but also on application.
In previous studies, the author found that there were still some shortages in measuring quality loss function and related theory itself, which caused widespread controversy in academia since the taguchi method was born, and to some extent, it reduced the enthusiasm of industrial enterprise to use this method. Based on the study of the related theories, we found problems and put forward the calibration method of the loss function and non-linear measuring system after some corresponding improvement. This paper is organized as follows:
(1) Improvement of quality loss function. At present, Taguchi quality loss function which without exception only by a quadratic term. It's unadvisable for the smaller the better and larger the better situations. This paper comes up with the improved quality loss function of smaller the better and larger the better characteristic. Then, this paper studies the form of dynamic quality characteristic loss function.
(2) Forms of measurement error loss function in dynamic measurements. Taguchi measurement quality engineering introduces the measurement error loss function in static measurement. However, in the practice, the measured object is always changed dynamically. This paper comes up with the measurement loss function in dynamic measurements.
(3) Improvement of feedback control system loss function. Taguchi designed the feedback control system loss function based on considering measuring cost, setup cost and loss of out-of-control product. But Taguchi's the feedback control system loss function still has rooms for improvement. This paper comes up with the improved Taguchi feedback control system loss function.
(4) Designing of the control chart based on improved feedback control system loss function. This paper transforms some parameters which in improved feedback control system loss function so as to design the control chart based on feedback control system loss function which make the least economic loss. Then studies the control chart how to apply in measurement system stability and bias analysis.
(5) Improvement of calibration system loss function. On the basis of finding out the problems which exist in Taguchi calibration system loss function, the author comes up with the improved calibration system loss function.
(6) Study on the calibration cycle and calibration method of the linear measurement system. This paper takes the CMM using in measuring dimensions as case. On the basis of analyzing the current calibration cycle and calibration method of the CMM using in measuring dimensions, this paper put forward the optimum calibration cycle and calibration method of the CMM using in measuring dimensions based on Taguchi measurement quality engineering.
(7) Study on the calibration method of non-linear measurement system. Most measurement systems are non-linear, especially the measurement systems which contains sensors and is used to measure various flow. For non-linear measurement system, it will increase system error artificially if processed by linear relation. This paper studies the non-linear calibration method of measurement system by referencing the theory in Taguchi measurement quality engineering.
作者在前期研究中发现测量质量损失函数等相关理论本身还存在一些不完善之处,致使从田口方法诞生起,就在学术界引起广泛争议,这也在一定程度上影响了工业企业使用田口方法的积极性。本文在对相关理论进行研究的基础上,找出存在的问题,进而提出相应改进的质量损失函数以及非线性测量系统的校准方法。本文的研究内容包括：
(1)质量损失函数的改进。目前,田口质量损失函数只用一个二次项表示的,既略去了一次项,又略去了高次项,这对于望小特性和望大特性情况是不妥当的。本文提出了改进的望小特性和望大特性的质量损失函数。同时,本文还分别从单个质量特性和多个质量特性两种情况研究了动态特性情况下的质量损失函数。
(2)动态测量情况下测量误差损失函数。田口测量质量工程学对静态测量情况下测量误差损失函数进行了介绍,但实践中,被测量往往是动态变化的,本文提出了动态测量情况下的测量误差损失函数,分别从己知信号因子和未知信号因子两方面研究了测量误差损失函数。
(3)反馈控制系统损失函数的改进。田口先生在考虑测量费用、调整费用以及失控品损失的基础上设计了反馈控制系统损失函数,但田口先生所确定的反馈控制系统损失函数尚存在一些有待改善的地方,本文提出了改进的田口反馈控制系统损失函数。
(4)基于改进的反馈控制系统损失函数的控制图设计。本文通过对改进的反馈控制系统损失函数中一些参数进行变换,从而设计出使经济损失最小的基于反馈控制系统损失函数的控制图。此外,还对控制图在测量系统稳定性和偏倚分析中如何应用进行了研究。
(5)校准系统损失函数的改进。作者在找出田口校准系统损失函数存在问题的基础上,提出了改进的校准系统损失函数,并进行了实例分析。
(6)线性测量系统校准周期和校准方法研究。本文以测量尺寸三坐标为例研究线性测量系统的校准周期和校准方法,在分析测量尺寸三坐标测量仪现行校准周期和校准方法的基础上,研究应用田口测量质量工程学的理论,确定测量尺寸三坐标测量仪的最佳校准周期以及具体的周期校准方法和日常校准方法。
(7)非线性测量系统校准方法研究。绝大多数测量系统都是非线性的,尤其是含有传感器的测量系统以及测量各种流量的测量系统其非线性更加明显。对于非线性测量系统如果采用线性式关系进行处理就人为地增加了系统误差。本文通过借鉴田口测量质量工程学的理论研究了非线性测量系统校准方法,包括周期校准方法和日常校准方法。
Modern quality management emphasizes on results, while the results depend on process. The basis of product quality improvement is to objectively evaluate the quality level, which involves two problems:first, whether the method to evaluate the quality level is comprehensive, accurate and effective; Second, whether the data used to evaluate is reliable, in other words, the quality of the data from the measurement system is good or not. We can make use of some correlation theory of quality loss function to solve the first problem, while to the second, first of all, we must ensure a high quality of the measurement system, then, we ought to design the reasonable calibration cycle and calibration methods for the measurement system, what's more, we should describe the quality of measuring level through the measurement error loss function. Measuring quality loss function and the calibration methods of measuring system are the important aspect of the taguchi method, which have extremely extensive application in characterizing the quality of measuring level, determining the best calibration cycle of measuring system and the calibration method of the measurement system, evaluating and improving product quality, designing of quality control system, and so on. Thus, the study to the quality loss function, the measurement error loss function, the feedback control systems, the calibration system loss function and the calibration method of non-linear measurement system has an important value not only on theory but also on application.
In previous studies, the author found that there were still some shortages in measuring quality loss function and related theory itself, which caused widespread controversy in academia since the taguchi method was born, and to some extent, it reduced the enthusiasm of industrial enterprise to use this method. Based on the study of the related theories, we found problems and put forward the calibration method of the loss function and non-linear measuring system after some corresponding improvement. This paper is organized as follows:
(1) Improvement of quality loss function. At present, Taguchi quality loss function which without exception only by a quadratic term. It's unadvisable for the smaller the better and larger the better situations. This paper comes up with the improved quality loss function of smaller the better and larger the better characteristic. Then, this paper studies the form of dynamic quality characteristic loss function.
(2) Forms of measurement error loss function in dynamic measurements. Taguchi measurement quality engineering introduces the measurement error loss function in static measurement. However, in the practice, the measured object is always changed dynamically. This paper comes up with the measurement loss function in dynamic measurements.
(3) Improvement of feedback control system loss function. Taguchi designed the feedback control system loss function based on considering measuring cost, setup cost and loss of out-of-control product. But Taguchi's the feedback control system loss function still has rooms for improvement. This paper comes up with the improved Taguchi feedback control system loss function.
(4) Designing of the control chart based on improved feedback control system loss function. This paper transforms some parameters which in improved feedback control system loss function so as to design the control chart based on feedback control system loss function which make the least economic loss. Then studies the control chart how to apply in measurement system stability and bias analysis.
(5) Improvement of calibration system loss function. On the basis of finding out the problems which exist in Taguchi calibration system loss function, the author comes up with the improved calibration system loss function.
(6) Study on the calibration cycle and calibration method of the linear measurement system. This paper takes the CMM using in measuring dimensions as case. On the basis of analyzing the current calibration cycle and calibration method of the CMM using in measuring dimensions, this paper put forward the optimum calibration cycle and calibration method of the CMM using in measuring dimensions based on Taguchi measurement quality engineering.
(7) Study on the calibration method of non-linear measurement system. Most measurement systems are non-linear, especially the measurement systems which contains sensors and is used to measure various flow. For non-linear measurement system, it will increase system error artificially if processed by linear relation. This paper studies the non-linear calibration method of measurement system by referencing the theory in Taguchi measurement quality engineering.
引文
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