6-提高內燃機產品使用可靠性的捷徑與對策(濰柴-胡金壽)

提高內燃機產品使用可靠性的捷徑和對策THESHORTCUTANDCOUNTERMEASURESTOIMPROVETHERELIABILITYOFINTERNALCOMBUSTIONENGINE濰柴動力產品可靠性總監(jiān)ProductreliabilitydirectorofWeichaiPowerHuJinshou2014年3月30日March30th,2014一、前言Introduction二、內燃機存在的主要使用可靠性問題及原因分析Majorreliabilityproblemsofcombusionengineandcauseanalysis三、提高產品使用可靠性從失效分析抓起Improveproductreliability,startfromfailureanalysis四、設計對標是快速調高內燃機設計可靠性的捷徑Benchmarkingdesignisashortcuttoimproveproductreliability五、合理配套是確保內燃機使用可靠性的關鍵Suitablematchisthekeytoguaranteecombusionreliability六、建立產品可靠性數(shù)據(jù)庫Constructproductreliabilitydatabase七、結束語Endingwords目錄Contents前言INTRODUTION一、前言Introduction作為造福于人類的動力設備,內燃機已被廣泛應用于工程機械、卡車、發(fā)電機組、船舶、長途客車、工程用車、城市公交車以及農機等Ashuman’sbeneficialpowerequipments,combustionshavealreadybeenusedinmanyareasofengineeringmachinery、truck、generatingunit、ships、coachbus、citybus、agriculturemachinery…etc.1內燃機成為個體用戶發(fā)家致富的強有力工具,因而提高內燃機的可靠性就顯得特別的緊迫

Combustionshavebeenpowerfultoolsofindividualsubscriptionstogetrich,Withtheresultthatimprovingcombustionreliabilityseemstobeparticularlyurgency.2激烈的市場競爭是質量、服務、價格的競爭，可靠性是質量的核心，良好的可靠性會使企業(yè)、客戶、社會獲得三贏Fiercemarketcompetitionisthequality

service

pricecompetition,andreliabilityisthecoreofquality.Betterreliabilitywillleadenterprises、customers、societytobeallthewinners.3要提高內燃機的使用可靠性，必須要從設計、工藝、制造、物流、儲存、主機配套以及用戶使用全過程來提高可靠性Toimprovetheusingreliabilityofcombustion,peoplemustworkfromthewholeprocessofdesigningcraftmanufacturetransportstorematchingandallcustomers’operation.4要使內燃機可靠性不斷增長，必須要有最大限度滿足用戶需要的理念，除了千方百計提高零部件本身的可靠性外，還要充分考慮用戶實際使用和保養(yǎng)的情況，盡可能地消除用戶使用和保養(yǎng)過程中可能要產生的問題，只有真正樹立“用戶第一”的思想，才能確保內燃機可靠性的不斷增長Tokeepcombustionreliabilityimprovingconstantly,wemustunderstandtheconceptofcustomers’maximumsatisfaction.Notonlydoeverythingpossibletoimprovethereliabilityofcomponentitself,butalsoconsidersituationsofcustomers’actualuseandmaintenancesufficiently,eliminatepossiblyproblemsintheprocessofuseandmaintenance.Onlyifsetupuserfirstideologycouldweensurecombustionreliabilityimprovingconstantly.5一、前言Introduction內燃機存在的主要使用可靠性問題及原因分析Majorreliabilityproblemsofcombustionengineandcauseanalysis二、內燃機存在的主要使用可靠性問題及原因分析Majorreliabilityproblemsofcombustionengineandcauseanalysis主要可靠性可分為兩大類Twomajorkindsofreliabilityproblems性能performance零部件故障（失效）Componetsfailure性能可靠性問題Performancereliabilityproblems空氣質量Airquality相關零部件如配氣機構和四配套工作表面的耗損Relevantcomponentssurfaceweared(suchasvalvemechanismandpistoncomponent)油品、天然氣氣源Fuel\oilquality使用保養(yǎng)Useandmaintenance二、內燃機存在的主要使用可靠性問題及原因分析Majorreliabilityproblemsofcombusionengineandcauseanalysis零部件可靠性問題-故障（失效）Componentreliability-broken(failure)用戶使用保養(yǎng)正確性Correctuseandmaintenance物流儲存可靠性Transportandstorereliability本身設計可靠性Designreliability油品環(huán)境適應性Fuelenvironmentadaptability工藝制作可靠性Processreliability與主機配套合理性Suitablematching二、內燃機存在的主要使用可靠性問題及原因分析Majorreliabilityproblemsofcombustionengineandcauseanalysis提高產品使用可靠性從故障（失效）分析抓起Productusereliabilityimproving,failureanalysiscomesfirst成功失敗常言道：失敗乃成功之母！三、提高產品使用可靠性從故障（失效）分析抓起Productusereliabilityimproving,failureanalysiscomesfirst要提高內燃機使用可靠性首先要提高易發(fā)生故障（失效）零部件的使用可靠性Toimprovecombustionusereliability,weshouldimprovefailureeasilycomponentsusereliabilityfirst要提高易發(fā)生故障（失效）零部件的使用可靠性必須要弄清楚零部件故障（失效）的根本原因Toimprovefailureeasilycomponentsusereliability,wemustfigureouttherootcause要找出根本原因應對故障（失效）件、故障（失效）模式進行分析，即從故障（失效）分析抓起Tofigureouttherootcause,weshouldanalysisfailurepartsandfailuremode,namelyfailureanalysiscomesfirst可靠性的核心任務是與故障（失效）作斗爭Thecoretaskofreliabilityisfailurefighting!與故障作斗爭積累出經驗和教訓Fightfailure,accumulateexperienceandlesson應用這些經驗和教訓設計極為有效It’squiteefficienttoconsummatedesignwiththeseexperienceandlesson三、提高產品使用可靠性從故障（失效）分析抓起Productusereliabilityimproving,failureanalysiscomesfirst設計可靠性案例—推桿彎曲Designreliabilitycase─pushrodbent1三、提高產品使用可靠性從故障（失效）分析抓起Productusereliabilityimproving,failureanalysiscomesfirst三、提高產品使用可靠性從故障（失效）分析抓起Productusereliabilityimproving,failureanalysiscomesfirst設計可靠性案例—繼電器易損壞Designreliabilitycase─relaybrokeneasily2三、提高產品使用可靠性從故障（失效）分析抓起Productusereliabilityimproving,failureanalysiscomesfirst3制造可靠性案例--曲軸連桿燒壞Manufacturereliabilitycase─connectingrodburned制作可靠性案例--增壓器斷軸Manufacturereliabilitycase─superchargershaftcut4三、提高產品使用可靠性從故障（失效）分析抓起Productusereliabilityimproving,failureanalysiscomesfirst三、提高產品使用可靠性從故障（失效）分析抓起Productusereliabilityimproving,failureanalysiscomesfirst制作可靠性案例--機油泵故障Manufacturereliabilitycase─oilpumpbroken5三、提高產品使用可靠性從故障（失效）分析抓起Productusereliabilityimproving,failureanalysiscomesfirst儲運可靠性案例--風扇葉片裂Storagereliabilitycase─fanbladebroken6三、提高產品使用可靠性從故障（失效）分析抓起Productusereliabilityimproving,failureanalysiscomesfirst儲運可靠性案例—吊裝不當砸壞機器Storagereliabilitycase─wronghoisting7三、提高產品使用可靠性從故障（失效）分析抓起Productusereliabilityimproving,failureanalysiscomesfirst與主機配套合理性—飛輪殼拉裂Suitablematch─flywheelcoverpulledcrack8三、提高產品使用可靠性從故障（失效）分析抓起Productusereliabilityimproving,failureanalysiscomesfirst與主機配套合理性—離合器分離力過大Suitablematch─clutchseparatingoverforced9三、提高產品使用可靠性從故障（失效）分析抓起Productusereliabilityimproving,failureanalysiscomesfirst與主機配套合理性—離合器選配不當Suitablematch─unsuitableclutch10油品環(huán)境適應性—不良油品導致連桿化瓦Oilenvironmentadaptation─bearingmilledcausebybadoil11三、提高產品使用可靠性從故障（失效）分析抓起Productusereliabilityimproving,failureanalysiscomesfirst三、提高產品使用可靠性從故障（失效）分析抓起Productusereliabilityimproving,failureanalysiscomesfirst油品環(huán)境適應性—空氣臟引起空壓泵竄油Oilenvironmentadaptation─badaircausecompressedairpumpoilexpelling12某礦用車在送車途中發(fā)生重大事故，車輛下坡途中突然聽到咔咔聲，停車后發(fā)現(xiàn)飛輪殼開裂，起動機掉地，取力器、變速器、排氣筒、傳動軸等損壞司機在空檔溜坡時誤操作誤將變速器掛入低檔三、提高產品使用可靠性從故障（失效）分析抓起Productusereliabilityimproving,failureanalysiscomesfirst用戶使用可靠性—下坡溜車掛錯擋Customerusereliability─downslopewrongshift13三、提高產品使用可靠性從故障（失效）分析抓起Productusereliabilityimproving,failureanalysiscomesfirst用戶使用可靠性—下坡溜車掛錯擋Customerusereliability─downslopewrongshift13某客車公司一批新氣體機汽車停車場停置30天后，司機在駕駛時猛加油、急加速引起爆震，沖壞缸墊。

Inonebuscompany,abatchofnewgasenginebusesstopinparkinglotfor30days.Driversspeedupheavilyduringdriving,causedetonation,headgasketrushed.LNG發(fā)動機，在氣罐中，甲烷位于上層，而丙烷、丁烷下沉，位于下層。位于氣罐下部的出氣管使下層的丙烷、丁烷進入燃燒室燃燒，易造成爆震

LNGengine:thegas-holderinterior,methaneuptothetoplayer,propane

andbutanesinktobottom.outletpipebelowthegas-holderconveypropane

andbutanetocombustor,causingknockeasily.三、提高產品使用可靠性從故障（失效）分析抓起Productusereliabilityimproving,failureanalysiscomesfirst用戶使用可靠性—猛加速引起爆震，沖壞缸墊Customerusereliability─heavilyspeedingupcausedetonation,rushingheadgasket14三、提高產品使用可靠性從故障（失效）分析抓起Productusereliabilityimproving,failureanalysiscomesfirst用戶使用可靠性—猛加速引起爆震，沖壞缸墊Customerusereliability─heavilyspeedingupcausedetonation,rushingheadgasket14設計對標是快速提高內燃機設計可靠性的捷徑Benchmarkingdesignisashortcuttoimproveproductreliability一個正確的設計不能憑空產生，他是前人經驗的積累和繼承。一個成熟的部件也會由于環(huán)境和使用工況的變動而失效，產品結構設計的持續(xù)改進是一個永恒的話題。Arightdesignationdoesn’tgenerategroundless.Itdependsonpredecessors’accumulatedexperience.Amaturepartalsoloseefficacybythechangingenvironmentandusingsituation.Sustainedimprovingofproductstructuredesignationwillbeaforevertopic.

提高產品的使用可靠性最關鍵的是要提高產品的設計可靠性，而要提高產品的設計可靠性最快捷的方法是“設計對標”。

Thekeytoimproveproductusereliabilityistoimproveproductdesignreliability,andtheshotcutwaytoimproveproductdesignreliabilityis“benchmarkingdesign”.綜述overview四、設計對標是快速提高內燃機設計可靠性的捷徑Benchmarkingdesignisashortcuttoimproveproductreliability“設計對標”就是與其它系列的產品進行結構設計對比，從結構設計的角度找出產品使用中發(fā)生故障的真正原因，參照其它產品成熟的設計來改善自己的產品?！癇enchmarkingdesign”isthecomparisontootherseriesproductofstructuredesign.Findoutrealfailurecausethroughproductusingfromtheangleofstructuredesign.Consultothermaturedesigntoimproveourselves.“設計對標”不僅改進速度快，而且風險極小，能以最短的時間迅速提高產品的使用可靠性。“Benchmarkingdesign”,notonlyimprovefast,butalsosafety,couldspeedilyimproveproductusereliabilitywithintheshortesttime.綜述四、設計對標是快速提高內燃機設計可靠性的捷徑Benchmarkingdesignisashortcuttoimproveproductreliability飛輪殼裂紋問題flywheelcrackle1對標四、設計對標是快速提高內燃機設計可靠性的捷徑Benchmarkingdesignisashortcuttoimproveproductreliability傳動皮帶易開裂問題transmissionbeltcracking

2對標四、設計對標是快速提高內燃機設計可靠性的捷徑Benchmarkingdesignisashortcuttoimproveproductreliability增壓器止推片異常磨損superchargerthrustplateabnormalwear3四、設計對標是快速提高內燃機設計可靠性的捷徑Benchmarkingdesignisashortcuttoimproveproductreliability風扇托架失效問題fanbracketfailure

4四、設計對標是快速提高內燃機設計可靠性的捷徑Benchmarkingdesignisashortcuttoimproveproductreliability對標合理配套是確保內燃機使用可靠性的關鍵Suitablematchisthekeytoguaranteecombustionreliability為了確保內燃機的使用可靠性，內燃機與主機的配套合理性極為關鍵Toguaranteecombustionusereliability,asuitablematchisquiteimportant合理性問題過去以主機廠研究為主，現(xiàn)在是買方市場，應主動與主機配套好SuitablematchmainlyrelyonOEM’sresearchinthepast,nowitsbuyers’market,weshouldmatchinitiatively.

配套不良造成的零部件機械故障。如水箱與風扇之間的距離安裝不合適引起柴油機水溫不正常，外接排氣總管沒有支撐易引起增壓器損壞以及空氣濾清器選用不當引起柴油機早期磨損等

Componentmechanicalfailurecausedbyunsuitablematch.suchasunsuitabledistancebetweenwatertankandfancauseabnormalwatertemperature,externalexhaustmanifoldwithoutsupportcausesuperchargerbrokenandunsuitableairfiltercausedieselengineprematurewear…etc.五、合理配套是確保內燃機使用可靠性的關鍵Suitablematchisthekeytoguaranteecombustionreliability五、合理配套是確保內燃機使用可靠性的關鍵Suitablematchisthekeytoguaranteecombustionreliability要進行配套合理性評定必須要有一個評定的規(guī)范Astandardmustbesettoevaluatematchsuitability.規(guī)范編寫的依據(jù)有兩點：一是將常規(guī)的要求編進去;二是把過去失敗的經驗總結編進去

therearetwopointstowritestandard:oneistowriteconventionalrequest,anotheristowritefailureexperienceinthepast.把過去發(fā)生過的各種失效模式和解決方法進行總結變成評定的規(guī)范summarizeallkindsoffailuremodeandsolutionsinthepastandmakethemtobeevaluatestandard.派有經驗的人員按規(guī)范的要求并結合自己的實踐經驗對配套合理性進行評定

Accordingtostandardrequirementdispatchexperiencestaffandcombineyourownexperiencetoevaluatematchsuitability.系列柴油機首次與整車配套安裝評定檢查表

seriesdieselenginefirstmatchingevaluatechecklist五、合理配套是確保內燃機使用可靠性的關鍵Suitablematchisthekeytoguaranteecombustionreliability建立產品可靠性數(shù)據(jù)庫Constructproductreliabilitydatabase六、建立產品可靠性數(shù)