6-提高內(nèi)燃機(jī)產(chǎn)品使用可靠性的捷徑與對策(濰柴-胡金壽)

提高內(nèi)燃機(jī)產(chǎn)品使用可靠性的捷徑和對策THESHORTCUTANDCOUNTERMEASURESTOIMPROVETHERELIABILITYOFINTERNALCOMBUSTIONENGINE濰柴動力產(chǎn)品可靠性總監(jiān)ProductreliabilitydirectorofWeichaiPowerHuJinshou2014年3月30日March30th,2014一、前言Introduction二、內(nèi)燃機(jī)存在的主要使用可靠性問題及原因分析Majorreliabilityproblemsofcombusionengineandcauseanalysis三、提高產(chǎn)品使用可靠性從失效分析抓起Improveproductreliability,startfromfailureanalysis四、設(shè)計(jì)對標(biāo)是快速調(diào)高內(nèi)燃機(jī)設(shè)計(jì)可靠性的捷徑Benchmarkingdesignisashortcuttoimproveproductreliability五、合理配套是確保內(nèi)燃機(jī)使用可靠性的關(guān)鍵Suitablematchisthekeytoguaranteecombusionreliability六、建立產(chǎn)品可靠性數(shù)據(jù)庫Constructproductreliabilitydatabase七、結(jié)束語Endingwords目錄Contents前言INTRODUTION一、前言Introduction作為造福于人類的動力設(shè)備,內(nèi)燃機(jī)已被廣泛應(yīng)用于工程機(jī)械、卡車、發(fā)電機(jī)組、船舶、長途客車、工程用車、城市公交車以及農(nóng)機(jī)等Ashuman’sbeneficialpowerequipments,combustionshavealreadybeenusedinmanyareasofengineeringmachinery、truck、generatingunit、ships、coachbus、citybus、agriculturemachinery…etc.1內(nèi)燃機(jī)成為個體用戶發(fā)家致富的強(qiáng)有力工具,因而提高內(nèi)燃機(jī)的可靠性就顯得特別的緊迫

Combustionshavebeenpowerfultoolsofindividualsubscriptionstogetrich,Withtheresultthatimprovingcombustionreliabilityseemstobeparticularlyurgency.2激烈的市場競爭是質(zhì)量、服務(wù)、價格的競爭，可靠性是質(zhì)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(nèi)燃機(jī)的使用可靠性，必須要從設(shè)計(jì)、工藝、制造、物流、儲存、主機(jī)配套以及用戶使用全過程來提高可靠性Toimprovetheusingreliabilityofcombustion,peoplemustworkfromthewholeprocessofdesigningcraftmanufacturetransportstorematchingandallcustomers’operation.4要使內(nèi)燃機(jī)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(jì)提高零部件本身的可靠性外，還要充分考慮用戶實(shí)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(chǎn)生的問題，只有真正樹立“用戶第一”的思想，才能確保內(nèi)燃機(jī)可靠性的不斷增長Tokeepcombustionreliabilityimprovingconstantly,wemustunderstandtheconceptofcustomers’maximumsatisfaction.Notonlydoeverythingpossibletoimprovethereliabilityofcomponentitself,butalsoconsidersituationsofcustomers’actualuseandmaintenancesufficiently,eliminatepossiblyproblemsintheprocessofuseandmaintenance.Onlyifsetupuserfirstideologycouldweensurecombustionreliabilityimprovingconstantly.5一、前言Introduction內(nèi)燃機(jī)存在的主要使用可靠性問題及原因分析Majorreliabilityproblemsofcombustionengineandcauseanalysis二、內(nèi)燃機(jī)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(zhì)量Airquality相關(guān)零部件如配氣機(jī)構(gòu)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(nèi)燃機(jī)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(shè)計(jì)可靠性Designreliability油品環(huán)境適應(yīng)性Fuelenvironmentadaptability工藝制作可靠性Processreliability與主機(jī)配套合理性Suitablematching二、內(nèi)燃機(jī)存在的主要使用可靠性問題及原因分析Majorreliabilityproblemsofcombustionengineandcauseanalysis提高產(chǎn)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(chǎn)品使用可靠性從故障（失效）分析抓起Productusereliabilityimproving,failureanalysiscomesfirst要提高內(nèi)燃機(jī)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(yīng)對故障（失效）件、故障（失效）模式進(jìn)行分析，即從故障（失效）分析抓起Tofigureouttherootcause,weshouldanalysisfailurepartsandfailuremode,namelyfailureanalysiscomesfirst可靠性的核心任務(wù)是與故障（失效）作斗爭Thecoretaskofreliabilityisfailurefighting!與故障作斗爭積累出經(jīng)驗(yàn)和教訓(xùn)Fightfailure,accumulateexperienceandlesson應(yīng)用這些經(jīng)驗(yàn)和教訓(xùn)設(shè)計(jì)極為有效It’squiteefficienttoconsummatedesignwiththeseexperienceandlesson三、提高產(chǎn)品使用可靠性從故障（失效）分析抓起Productusereliabilityimproving,failureanalysiscomesfirst設(shè)計(jì)可靠性案例—推桿彎曲Designreliabilitycase─pushrodbent1三、提高產(chǎn)品使用可靠性從故障（失效）分析抓起Productusereliabilityimproving,failureanalysiscomesfirst三、提高產(chǎn)品使用可靠性從故障（失效）分析抓起Productusereliabilityimproving,failureanalysiscomesfirst設(shè)計(jì)可靠性案例—繼電器易損壞Designreliabilitycase─relaybrokeneasily2三、提高產(chǎn)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(chǎn)品使用可靠性從故障（失效）分析抓起Productusereliabilityimproving,failureanalysiscomesfirst三、提高產(chǎn)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(jī)油泵故障Manufacturereliabilitycase─oilpumpbroken5三、提高產(chǎn)品使用可靠性從故障（失效）分析抓起Productusereliabilityimproving,failureanalysiscomesfirst儲運(yùn)可靠性案例--風(fēng)扇葉片裂Storagereliabilitycase─fanbladebroken6三、提高產(chǎn)品使用可靠性從故障（失效）分析抓起Productusereliabilityimproving,failureanalysiscomesfirst儲運(yùn)可靠性案例—吊裝不當(dāng)砸壞機(jī)器Storagereliabilitycase─wronghoisting7三、提高產(chǎn)品使用可靠性從故障（失效）分析抓起Productusereliabilityimproving,failureanalysiscomesfirst與主機(jī)配套合理性—飛輪殼拉裂Suitablematch─flywheelcoverpulledcrack8三、提高產(chǎn)品使用可靠性從故障（失效）分析抓起Productusereliabilityimproving,failureanalysiscomesfirst與主機(jī)配套合理性—離合器分離力過大Suitablematch─clutchseparatingoverforced9三、提高產(chǎn)品使用可靠性從故障（失效）分析抓起Productusereliabilityimproving,failureanalysiscomesfirst與主機(jī)配套合理性—離合器選配不當(dāng)Suitablematch─unsuitableclutch10油品環(huán)境適應(yīng)性—不良油品導(dǎo)致連桿化瓦Oilenvironmentadaptation─bearingmilledcausebybadoil11三、提高產(chǎn)品使用可靠性從故障（失效）分析抓起Productusereliabilityimproving,failureanalysiscomesfirst三、提高產(chǎn)品使用可靠性從故障（失效）分析抓起Productusereliabilityimproving,failureanalysiscomesfirst油品環(huán)境適應(yīng)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(jī)掉地，取力器、變速器、排氣筒、傳動軸等損壞司機(jī)在空檔溜坡時誤操作誤將變速器掛入低檔三、提高產(chǎn)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(chǎn)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(jī)汽車停車場停置30天后，司機(jī)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(jī)，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(jìn)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(chǎn)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(chǎn)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(shè)計(jì)對標(biāo)是快速提高內(nèi)燃機(jī)設(shè)計(jì)可靠性的捷徑Benchmarkingdesignisashortcuttoimproveproductreliability一個正確的設(shè)計(jì)不能憑空產(chǎn)生，他是前人經(jīng)驗(yàn)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(chǎn)品結(jié)構(gòu)設(shè)計(jì)的持續(xù)改進(jìn)是一個永恒的話題。Arightdesignationdoesn’tgenerategroundless.Itdependsonpredecessors’accumulatedexperience.Amaturepartalsoloseefficacybythechangingenvironmentandusingsituation.Sustainedimprovingofproductstructuredesignationwillbeaforevertopic.

提高產(chǎn)品的使用可靠性最關(guān)鍵的是要提高產(chǎn)品的設(shè)計(jì)可靠性，而要提高產(chǎn)品的設(shè)計(jì)可靠性最快捷的方法是“設(shè)計(jì)對標(biāo)”。

Thekeytoimproveproductusereliabilityistoimproveproductdesignreliability,andtheshotcutwaytoimproveproductdesignreliabilityis“benchmarkingdesign”.綜述overview四、設(shè)計(jì)對標(biāo)是快速提高內(nèi)燃機(jī)設(shè)計(jì)可靠性的捷徑Benchmarkingdesignisashortcuttoimproveproductreliability“設(shè)計(jì)對標(biāo)”就是與其它系列的產(chǎn)品進(jìn)行結(jié)構(gòu)設(shè)計(jì)對比，從結(jié)構(gòu)設(shè)計(jì)的角度找出產(chǎn)品使用中發(fā)生故障的真正原因，參照其它產(chǎn)品成熟的設(shè)計(jì)來改善自己的產(chǎn)品?！癇enchmarkingdesign”isthecomparisontootherseriesproductofstructuredesign.Findoutrealfailurecausethroughproductusingfromtheangleofstructuredesign.Consultothermaturedesigntoimproveourselves.“設(shè)計(jì)對標(biāo)”不僅改進(jìn)速度快，而且風(fēng)險極小，能以最短的時間迅速提高產(chǎn)品的使用可靠性?！癇enchmarkingdesign”,notonlyimprovefast,butalsosafety,couldspeedilyimproveproductusereliabilitywithintheshortesttime.綜述四、設(shè)計(jì)對標(biāo)是快速提高內(nèi)燃機(jī)設(shè)計(jì)可靠性的捷徑Benchmarkingdesignisashortcuttoimproveproductreliability飛輪殼裂紋問題flywheelcrackle1對標(biāo)四、設(shè)計(jì)對標(biāo)是快速提高內(nèi)燃機(jī)設(shè)計(jì)可靠性的捷徑Benchmarkingdesignisashortcuttoimproveproductreliability傳動皮帶易開裂問題transmissionbeltcracking

2對標(biāo)四、設(shè)計(jì)對標(biāo)是快速提高內(nèi)燃機(jī)設(shè)計(jì)可靠性的捷徑Benchmarkingdesignisashortcuttoimproveproductreliability增壓器止推片異常磨損superchargerthrustplateabnormalwear3四、設(shè)計(jì)對標(biāo)是快速提高內(nèi)燃機(jī)設(shè)計(jì)可靠性的捷徑Benchmarkingdesignisashortcuttoimproveproductreliability風(fēng)扇托架失效問題fanbracketfailure

4四、設(shè)計(jì)對標(biāo)是快速提高內(nèi)燃機(jī)設(shè)計(jì)可靠性的捷徑Benchmarkingdesignisashortcuttoimproveproductreliability對標(biāo)合理配套是確保內(nèi)燃機(jī)使用可靠性的關(guān)鍵Suitablematchisthekeytoguaranteecombustionreliability為了確保內(nèi)燃機(jī)的使用可靠性，內(nèi)燃機(jī)與主機(jī)的配套合理性極為關(guān)鍵Toguaranteecombustionusereliability,asuitablematchisquiteimportant合理性問題過去以主機(jī)廠研究為主，現(xiàn)在是買方市場，應(yīng)主動與主機(jī)配套好SuitablematchmainlyrelyonOEM’sresearchinthepast,nowitsbuyers’market,weshouldmatchinitiatively.

配套不良造成的零部件機(jī)械故障。如水箱與風(fēng)扇之間的距離安裝不合適引起柴油機(jī)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(dāng)引起柴油機(jī)早期磨損等

Componentmechanicalfailurecausedbyunsuitablematch.suchasunsuitabledistancebetweenwatertankandfancauseabnormalwatertemperature,externalexhaustmanifoldwithoutsupportcausesuperchargerbrokenandunsuitableairfiltercausedieselengineprematurewear…etc.五、合理配套是確保內(nèi)燃機(jī)使用可靠性的關(guān)鍵Suitablematchisthekeytoguaranteecombustionreliability五、合理配套是確保內(nèi)燃機(jī)使用可靠性的關(guān)鍵Suitablematchisthekeytoguaranteecombustionreliability要進(jìn)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(diǎn)：一是將常規(guī)的要求編進(jìn)去;二是把過去失敗的經(jīng)驗(yàn)總結(jié)編進(jìn)去

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

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

seriesdieselenginefirstmatchingevaluatechecklist五、合理配套是確保內(nèi)燃機(jī)使用可靠性的關(guān)鍵Suitablematchisthekeytoguaranteecombustionreliability建立產(chǎn)品可靠性數(shù)據(jù)庫Constructproductreliabilitydatabase六、建立產(chǎn)品可靠性數(shù)