Research Of EMU Level-five Maintenance Simulation Based On Flexsim

With the development of high-speed railway, EMU is continuously increasing in numbers and operating mileages, as well as the quantity of which needs advanced maintenance. According to the current EMU level-five maintenance program, it is a focus of attention for Railways and rail vehicle manufacturing enterprises to find a way out to achieve these goals: finding potential bottleneck process, making optimization adjustments for maintenance program, meeting the growing maintenance needs and ultimately ensuring the operation safety of EMU.In this thesis, based on the EMU level-five maintenance process, equipment layout of a repair center’s assembly plant is the foundation. A level-five maintenance model is constructed. In this way, the real maintenance system is simulated by Flexsim software. At the same time, the production efficiency problems of the existing maintenance line can be analyzed and improved with importantly theoretical and practical value.First, two aspects of the background are researched: the EMU level-five maintenance line and the use of Flexsim software in simulation of typical production line. Based on the particularity and process of EMU level-five maintenance project, main steps in the assembly section of the project are divided. Second, equipment layout and 3D models are made combined with the actual situation. Based on the previous work, the parameters of multiple process time and output ports on a single entity are set by label and trigger logic design. The potential collision and conflict in the process are preset as well. Then, a level-five maintenance model is constructed. Third, after simulating the model on Flexsim, both the completion of EMU maintenance tasks and the average repair cycle can be got within the system running time. The results fit the actual production condition. So the validity of the simulation model is proved. After analyzing the simulation results, optimization design for level-five maintenance program is made from two aspects: the "drum" and the "buffer" which are from the production line optimization principles of constraints theory. As a result, the majority of the repair stations’ utilization is improved; EMU maintenance cycle overall has been shortened; effectiveness and validity of optimized program is verified scientifically. In a word, by means of researching on visualization simulation and designing optimization program, the maintenance capacity of the repair center’s assembly plant is enhanced;production line level is increased; reliable recommendations can be provided for actual EMU maintenance projects to conduct efficiently.