設計驗證和生產確認福特FORD課件

WelcomeDesignVerificationandProductionValidation設計驗證和生產確認WelcomeDesignVerificationand1FordTechnicalEducationProgram福特技術培訓項目Systems

EngineeringFundamentals系統工程基本原理Parameter

Design參數設計Tolerance

Design公差設計Global8D全球8DFMEA失效模式后果與分析Experimental

Design實驗設計FTEP福特技術培訓項目Reliability可靠性AppliedConsumerFocus應用顧客的關注DV&PV設計驗證&生產確認StatisticalEngineering統計工程學FordTechnicalEducationProgr2CourseStructure

課程結構IntroductiontoDV&PV對設計驗證及生產確認的介紹ToolsforDV&PV設計驗證及生產確認的工具VehicleLevelDV整車級別的設計驗證System/Sub-SystemLevelDV系統/子系統級別的設計驗證ComponentLevelDV零部件級別的設計驗證System/Sub-SystemLevelPV系統/子系統級別的生產確認ComponentLevelPV零部件級別的生產確認Summary總結CourseStructure

課程結構Introduct3DesignVerificationandProductionValidation

設計驗證和

生產確認DesignVerificationandProduc4DesignVerificationandProductionValidation

設計驗證和生產確認DesignVerificationandProduc5BenefittoFordMotorCompany

對福特汽車公司的益處BenefittoFordMotorCompany

6DesignVerificationand

ProductionValidation

設計驗證和生產確認DesignVerification:設計驗證asdesigned,aproductwillfunctioninthemannerthatthecustomerexpects.根據設計狀態(tài)，一個產品的功能要符合顧客所期望的方式。ProductionValidation:生產確認asmanufactured,aproductfunctionsinthemannerthatthecustomerexpectsandcanbemanufacturedatrequiredvolumes.根據制造狀態(tài)，一個產品的功能要符合顧客所期望的方式，而且能以所要求的產量進行生產。DesignVerificationand

Produ7DV&PVWithinSystemsEngineering系統工程內的DV&PVDV&PVWithinSystemsEngineeri8VerificationandSystemicThinking

驗證和系統思想CustomerWants顧客的需要EngineeringTargets工程目標DesignVerification設計驗證VerificationandSystemicThin9RequirementsCascade

需求逐級傳遞WorkinginaSystemsEngineeringcontextsupportssystemicthinking.系統工程中的工作支持系統的考慮OppositeofTraditionalapproachtoengineering.與傳統的工程方法相反RequirementsCascade

需求逐級傳遞Wor10Systems“V”Model

系統V模型DV&PVisarequirementsdrivenprocessDV和PV是一個需求驅動的過程DV&PVisbestconductedinasystemsengineeringcontextthroughthesystemsV.DV和PV在貫穿系統V模型的系統工程中得到最好的實施。

VehicleSystemSub-SystemComponentSystems“V”Model

系統V模型DV&PVi11DefiningRequirements

定義需求Therequirementscascadedowntheleftside.需求的逐級傳遞如左側Thecascadeisaniterativeprocess.該逐級傳遞是一反復的過程

VehicleSystemSub-SystemComponentITERATIVE

PLANNINGTopDown由上到下DefiningRequirements

定義需求The12VerificationBottom-up

驗證自下至上Verificationtestingisimplementedasabottom-upsequentialprocess.驗證試驗是按照自下至上的順序過程執(zhí)行的VerificationmayincludeacombinationofAnalyticalandphysicaltests.驗證可能包括分析試驗和物理試驗的組合。

VehicleSystemSub-SystemComponentITERATIVE

PLANNINGTopDown自上至下BottomUp自下至上SEQUENTIAL

DOING反復計劃工作順序VerificationBottom-up

驗證自下至上V13DV&PVandPDSAPlanPlanPlan

Plan計劃Do,Study,Act做，研究，行動

Do,Study,ActDo,Study,ActDo,Study,ActVehicle整車System系統Sub-System子系統Component零部件DV&PVandPDSAPlanPlanPlan14LowerLevelInteractions

較低級別的相互作用LowerLevelInteractions

較低級別的15SystemsApproachtoManufacturing

進行制造的系統方法VehicleSystemSub-SystemComponentPlantAssemblyOperationMachineVehicle整車System系統Sub-System子系統Component零部件ManufacturingDesignPlant工廠Assembly裝配Operation操作Machine機器設計制造SystemsApproachtoManufactur16Note-S5/P5TimingFPDSTiming

FPDS時間Vehiclelevel,Systemlevel&Sub-syslevel1DVPCreated生成整車，系統&子系統的DVPSub-syslevel2&ComponentDVPCreated生成子系統級別2&零部件DVPFullDVPCreatedReqts&TargetsFrozen生成完整的DVP需求&目標凍結Componenttestingcomplete零部件試驗完成Sub-systemandSystemtestingcomplete子系統和系統試驗完成Vehicletestingmostlycomplete:PrelimEngSignOff整車試驗大部分完成：工程預簽發(fā)Vehicletestingcomplete:FinalEngSignOff整車試驗完成：最終工程簽發(fā)DVPcompleteDVP完成Note-S5/P5TimingFPDSTiming17Design“V”andFPDSTiming

DV&PV

設計V形圖及FPDS時間的DV&PVLow低High高ActivityLevel活動級別Time時間=DesignVerification設計驗證=Production&ProcessValidation生產&過程確認SISCPAPRCPLRJ1Design“V”andFPDSTiming

DV&18DV&PVandFPDSDV&PVarekeyrequirementsforsignoffofavehicleprogramDV和PV對于汽車項目的簽發(fā)來說是關鍵的需求KeySignoffmilestonesare:關鍵簽發(fā)節(jié)點是：(CC)—DV(LR)—PV(LS)—PVDV&PVandFPDSDV&PVareke19InputsUsedintheVerificationandValidationProcesses

在驗證和確認過程中使用的輸入DVPlan設計驗證計劃SDSRequirementsSDS的需求LegalRequirements法規(guī)要求EngineeringSpecifications工程技術規(guī)范ConceptandDesignFMEAs概念和設計FMEARealWorldUsageProfile真正的顧客使用狀況P-DiagramP圖ExistingDVPs現有的DVPGenericDVMs一般DVMHistorical8Ds歷史上8DKeyLifeTests關鍵壽命試驗InputsUsedintheVerificatio20DV&PVasPartoftheProductCreationProcess

DV和PV作為產品創(chuàng)造過程的部分DVandPVconfirmthatComponentsandsystemrobustlymeetcustomerrequirementsDV和PV確認零部件和系統殷實可靠地符合顧客的需求。DV&PVtestingisnotexploratoryDV和PV試驗不是探險Testingshouldbeagainstexpectedresultsnottofindout“whathappensif”試驗應該是針對所預測的結果而不是去發(fā)現“如果…會怎樣”DV&PVcomesafterthedesignphasenotduringthedesignphaseDV和PV要在設計以后而不是在設計階段中進行DV&PVasPartoftheProductC21IntroductionoftheFEADExampleFEAD舉例介紹IntroductionoftheFEADExamp22FEADExample

FEAD范例AsinglesystemtheFEAD(FrontEndAccessoryDrive)willbeusedtodemonstrateDV&PV使用一個單獨的系統FEAD（前端附件驅動）來示范DV&PVFEADExample

FEAD范例Asinglesy23TheFrontEndAccessoryDrive(FEAD)–HowItWorks

FEAD-它如何工作Thesourceofpowerinthevehicleistheengine.汽車內動力的來源是發(fā)動機PartoftherotationalpoweroutputfromtheengineneedstobetransmittedtotheFEADaccessories.來自發(fā)動機轉動動力輸出的一部分需要被傳輸到FEAD附件上。TheFEADtransmitsthisenergyFEAD傳輸該能量TheFrontEndAccessoryDrive24DesignVerificationatAllLevels

所有級別上的設計驗證DesignVerificationshouldoccuratalllevelswiththeemphasisbeingatthelowerlevels.設計驗證應該重點放在較低級別的情況下在所有級別上進行。DesignVerificationatAllLev25ProductionValidation

生產確認Itisimportanttoverifythedesign驗證設計是重要的Itisequallyimportanttovalidatethattheproductionprocessusedtomanufacturethebeltisabletoproducebeltstothedesignspecification.確認制造皮帶所使用的生產過程能夠生產出符合設計規(guī)范的皮帶同等地重要。Forexample,thebeltasmanufacturedmustbeabletotransmittherequiredamountoftorque.例如，所制造的皮帶必須能轉送所要求大小的扭矩。ProductionValidation

生產確認Iti26ConfirmingRobustandReliableDesign–Robustness

確認殷實及可靠的設計-殷實可靠性ConfirmingRobustandReliable27ToolsForDV&PV

DV&PV的工具ToolsForDV&PV

DV&PV的工具28MethodsUsedinEfficientandEffectiveVerification

在有效且高效的驗證中使用的方法Someoftheimportantmethodsusedinefficientandeffectiveverificationandvalidationprocessesare在有效且高效的驗證和確認過程中所使用的一些重要方法是RobustEngineeringDesignPhilosophy(RED)殷實的工程設計基本定律FordDesignVerificationSystem(FDVS)福特設計驗證體系TestingMethodologies,試驗方法學RealWorldUsageProfilesandDutyCycles真正全球顧客使用的概況和工況AcceleratedTests,加速試驗KeyLifeTests(KLT),關鍵壽命試驗ComputerAidedEngineering(CAE)計算機輔助工程DesignofExperiment(DoE).實驗設計MethodsUsedinEfficientand29RobustEngineeringDesign

(RED)殷實的工程設計RobustEngineeringDesign

(RED30RobustTestPlans

殷實可靠的試驗計劃RobusttestplansinDV&PVincorporateNoisefactorsandtheireffectsinordertoensurethattheproductwillmeetitsdesignintentunderallconditions.Noisefactorscanbegroupedintofivecategories:為了確保該產品在所有條件下都符合其設計意圖，DV和PV中殷實的試驗計劃合并了干擾因素及其他們的影響。干擾因素可以分成5類：Piece-to-PieceVariation件與件間的變差ChangesOverTime隨著時間過去的變化CustomerUsage顧客的使用ExternalEnvironment外部環(huán)境SystemInteractions系統間的交互作用RobustTestPlans

殷實可靠的試驗計劃Rob31NoiseFactorManagement

干擾因素的管理NoiseFactorManagement

干擾因素的管32RobustEngineeringDesign

殷實可靠的工程設計RobustEngineeringDesign(RED)isprimarilyadesigntool殷實的工程設計主要是一種設計工具REDmustbeconsideredinDV&PVasREDwilldrivethetypeofDV&PVteststhatneedtobeundertaken在DV和PV中必須考慮到RED，因為RED將決定需要采取的DV&PV試驗的類型。REDfocusesonidentificationandmanagementofnoisefactorsRED著重于干擾因素的識別和管理RobustEngineeringDesign

殷實可靠33RobustEngineeringDesign

殷實可靠的工程設計REDisinherentinthesystemsVandrunsthroughallphasesoftheVRED是系統V內固有的，并且貫穿系統V的所有階段REDisateambasedprocessRED是以小組為基礎的過程REDappliesthroughoutFord(DesignandManufacturing)andatsuppliersRED應用于整個福特（設計和制造）以及供應商。RobustEngineeringDesign

殷實可靠34ApplyingRED

應用REDREDallowstestingatthelowestpossiblelevelRED允許在最低可能性級別進行測試Cautionmustbeused必須使用警示ApplyingRED

應用REDREDallowst35RedAppliedtoVehicleLevelTesting

Red應用于整車級別的測試RedAppliedtoVehicleLevelT36REDAppliedatSub-SystemLevel

RED應用于子系統級別WhendevelopingDesignVerificationMethodsatthesystem/sub-systemorcomponentlevel,itisimportanttoensurethattheeffectsofSystemInteractionNoisefactorsthatarepresentinthetotalvehicleenvironmentareincluded.當開發(fā)系統/子系統或零部件級別的設計驗證方法時，重要的是確保要包括整個汽車環(huán)境中出現的系統交互作用干擾因素的影響。REDAppliedatSub-SystemLeve37REDAppliedatComponentLevel

RED應用于零部件級別Atthecomponentleveltestingismostefficentbutinteractionswithothercomponentsarelost零部件級別的試驗是最有效的，但失去了與其他零件的交互作用Testplansmustcompensateforthislossbyreproducingthekeystressesfromtheinteractions試驗計劃必須通過再制造來自交互作用的關鍵應力彌補這一損失Muchcomponenttestingmaybedoneatsuppliers.許多零部件試驗可能在供應商處進行。SuppliersmustapplythesameREDmethodolgies供應商必須應用相同的RED方法Tosupportthis,Fordengineersneedtocascadenoisefactorstothesupplier為了支持這個，福特工程師需要逐層傳遞干擾因素直到供應商REDAppliedatComponentLevel38REDintheDesignProcess

設計過程中的RED

NoiseFactors干擾因素PiecetoPiece件與件Aging/Wear老化/磨損CustomerUsage顧客使用Environment環(huán)境SubsystemInteraction子系統交互作用Sourcesthatdisruptidealfunctionthatcannotbecontrolled(e.g..columnfriction)不可控制的，破壞理想功能的來源（例如..轉向柱磨擦）P-DiagramReliabilityChecklist

可靠性檢查清單Reliability/RobustnessDemonstrationMatrix可靠性/殷實可靠性實證矩陣圖Signal信號Energyputintothesystemstomakeitwork(e.g..Steeringwheelangle)能量進入系統使其工作（例如..方向盤轉角）ControlFactorsFeaturesofthedesignthatcanbecontrolled(e.g..Torsionbarrate)控制因素可以控制的設計特性（例如..扭桿比率）ErrorStates異常狀態(tài)UndesirableoutputorFailureModes(e.g..Tireslip)不需要的輸出或失效模式（例如..輪胎打滑）ErrorStates異常狀態(tài)

NoiseFactors干擾因素

AvailableTests有用的試驗DVP&RTest試驗CriticalNoiseFactors關鍵干擾因素Failuremodetotesttraceability失效模式試驗可追查性

NoiseFactorsManagementStrategySystem(SteeringSystem)系統（轉向系統）IdealFunction理想功能Primaryintendedfunctionofthedesign設計的主要意圖功能(e.g.Lateralaccelerationofvehicle)（例如..車輛的橫向加速度）FMEASDSWCRDOE(ifnecessary如果有必要)KLTWCRFailureMode失效模式DemonstratedResult論證的結果Inscope范圍內FDVSFDVSPreventionofMistakeReoccurrence錯誤再次發(fā)生的預防CampaignPrevent防召回LessonsLearned吸取的教訓Vigilance警惕...........干擾因素管理策略REDintheDesignProcess

設計過程39FordDesignVerificationSystem福特設計驗證系統FordDesignVerificationSyste40FordDesignVerificationSystem–FDVS

福特設計驗證系統-FDVSFDVSisacomputerbasedsystemtocreateandmanagerequirementsdrivenDVplans.FDVS是一計算機為基礎的系統，生成并管理驅動DV計劃的需求。FDVSincludesanumberofgenericrequirementsandDesignVerificationMethods(DVMs)FDVS包括許多一般需求和設計驗證方面（DVM）安全法規(guī)法人的要求技術規(guī)范設計驗證方法整車要求（項目專有）項目專有的設計驗證計劃系統要求（項目專有）DVM（項目專有）FordDesignVerificationSyste41DesignVerificationMethod

設計驗證方法WithinFDVSrequirementsareverifiedusingDesignVerificationMethods(DVMs)在FDVS內，使用設計驗證方法（DVM）驗證需求DVMscontainalltheinformationrequiredtoconducttestingandrecordresultsDVM包括所有要求試驗和記錄結果的信息ExistingandGenericDVMscanbeusedasastartingpointtodevelopprogramDMVs,buttheymustbereviewed現有的和一般的DVM能作為一個開始點用以開發(fā)項目的DMV，但是它們必須進行審核DesignVerificationMethod

設計驗42TestingMethodologies試驗方法學TestingMethodologies試驗方法學43TypesofTest

試驗的類型TherearethreegeneraltypesoftestingthatcanbeimplementedforeitherDesignVerificationorProductionValidation:有三種可以在設計驗證或生產確認中實施的一般試驗類型TestingtoBogey標準測試TestingtoFailure測試至失效TestingFunctionalDegradation測試功能退化TypesofTest

試驗的類型Therearet44TesttoBogeyMinimumAcceptableFunction最小可接受功能Function功能Time/Cycles/Miles時間/循環(huán)/里程Bogey失效柱狀圖TesttoBogeyMinimumAcceptabl45TesttoFailure測試至失效MinimumAcceptableFunction最小可接受功能Function功能Time/Cycles/Miles時間/循環(huán)/里程失效時間分布圖TesttoFailure測試至失效MinimumAc46DegradationTesting

退化測試MinimumAcceptableFunction最小可接受功能Function功能Time/Cycles/Miles時間/循環(huán)/里程BogeyCompleteDegradationHistoryDegradationTesting

退化測試Minimu47Example:FunctionalDegradation

ofThreeDesignAlternatives

范例：三種設計方案的功能退化CBAExample:FunctionalDegradatio48TestLevelComparison

測試水平比較Bogey標準Failure失效InformationQuality信息質量Cost成本Higher較高Lower較低Higher較高Lower較低Degradation退化TestLevelComparison

測試水平比較Bo49TestPrecision測試精度失效概率TestPrecision測試精度失效概率50StatisticalConfidence

統計可信度Statisticalconfidenceforagivenreliabilityestimateistheprobabilitythatthetruereliabilityofthepopulationisequaltoorgreaterthantheestimate.對于特定的可靠性預測，統計可信度是一種總體真實可靠性等于或大于預測情況的概率StatisticalConfidence

統計可信度St51EngineeringConfidenceReducesSampleSize

工程可信度減小樣本量Large

Sample大樣本ReducedSample減少的樣本Min:1sample/failuremode最小：1個樣本/失效模式Severity/Accelerationofkeynoisesintests試驗中關鍵干擾的嚴重度/加速Knowledgeofpriorperform-anceundersimilarconditions相似條件下優(yōu)先性能的知識Normal通常High高High高Low低FailureSeverity&Occurrence失效嚴重度&發(fā)生TestLevel測試水平BogeyFailureDegradationEngineeringConfidenceReduces52RealWorldUsageProfiles真正顧客使用概況RealWorldUsageProfiles真正顧客使53TypesofCustomerUsage

顧客使用的類型Normaluse一般使用Misuse誤用Abuse?濫用？TypesofCustomerUsage

顧客使用的類54NormalUse一般使用NormalUse一般使用55Misuse誤用Misuse誤用56Abuse濫用Abuse濫用57DataSources

數據來源Yourself自身Instrumentation儀器ExistingData現有數據Observation觀察DataSources

數據來源YourselfInstr58

Percentiles百分點ActualCustomerUsage真正顧客使用5%

Total95thPercentileuse95th

百分點使用CoreTargetCustomer(Marketing)

核心目標顧客（市場）Percentiles百分點ActualCustomer59Example:CoolingFan范例：冷卻風扇Stress受力狀態(tài)Europe歐洲SouthernEuropeanCities南歐城市NorthernEuropeanCities北歐城市Example:CoolingFanStressEuro60UsageProfileandCustomerDutyCycle

使用概況及顧客工況UsageProfile使用概況DutyCycle工況Howoftenthecustomeropensawindow顧客開啟窗戶的頻次如何Numberofswitchactivationsormotorrunningtimesforthewindowmotor開關的次數或窗戶電機運轉次數Climateoroutsidetemperaturerangesinwhichthevehicleoperates車輛運轉時的氣候或外界溫度的范圍Airconditioningsystemfrequencyofoperationandload空調系統的運轉頻次和負荷UsageProfileandCustomerDut61DutyCycleExample

工況范例同步齒形帶發(fā)動機工況綠線：一般顧客紅線：苛刻顧客注：皮帶負荷在低轉速時更苛刻DutyCycleExample

工況范例同步齒形帶發(fā)動62AcceleratedTesting加速測試AcceleratedTesting加速測試63AcceleratedTesting

加速測試Purpose:目的:Accumulateproductstresshistoryinashortperiodoftime在短時間內累積產品應力史Shortenverificationtime&reducedevelopmentcosts縮短驗證時間&減少開發(fā)成本AcceleratedTesting

加速測試Purpos64AcceleratedTestingMethods

加速測試方法LoadFrequencyoveraSpecifiedTestProcedure在指定的試驗規(guī)程上加大加載頻次010020030040030%60%100%PercentFrequencyofOccurrence發(fā)生頻次的百分比Load載荷NormalLoad正常負載IncreasedLoad加大負載DefineAcceleratedTestbasedonthisportionofprocedurewithincreasedloads50mphFreeway50mph高速公路Climbinghillin1stgear一檔爬山以加大的載荷在這部分試驗規(guī)程的基礎上定義加速測試AcceleratedTestingMethods

加速65AcceleratedTestingCautions

加速測試警示Correlateaccelerationtorealworlddeterioration使其加速形式與真正顧客使用的退化情況相關聯Preventunrepresentativefailuremodes預防不具備代表性的失效模式Notallfailuremodescanbeaccelerated不是所有的失效模式都可以加速的AcceleratedTestingCautions

加66KeyLifeTests關鍵壽命試驗KeyLifeTests關鍵壽命試驗67KeyLifeTests

關鍵壽命試驗KeyLifeTestsfocusonthekeystress(es)whichdrivelossoffunctionand/orfailuremechanismsassociatedwithrealworldusage.關鍵壽命試驗著重于會促使真正顧客使用相關的功能損失和/或失效機理的關鍵應力KeyLifeTests

關鍵壽命試驗KeyLife68KeyLifeTests

關鍵壽命試驗AKeyLifeTest:一個關鍵壽命試驗IsbasedontheRWUP是以RWUP為基礎的Providesatooltoevaluateproductreliability提供了一個工具以評估產品的可靠性Allowscomparisonofdesignswithbenchmarkedcompetitiveproductssothatthebestdesigncanbeidentified使其與競爭產品進行設計的比較，從而可以確定最佳設計Validatesmodelsandassumptionsinthedesignprocess在設計過程中確認模型和設想Validatesthedesign確認設計KeyLifeTests

關鍵壽命試驗AKeyLif69KeyLifeTests

關鍵壽命試驗IS是ISNot否

KeyLifeTests

關鍵壽命試驗IS是ISNot70ReliabilityandRobustnessDemonstrationMatrix可靠性和殷實可靠性實證矩陣圖ReliabilityandRobustnessDem71ReliabilityandRobustnessDemonstrationMatrix

可靠性和殷實可靠性實證矩陣圖

ReliabilityandRobustnessDemonstrationMatrix(RRDM)

capturesanddisplaysthekeyverificationmethodsandallCriticalNoisefactors.RRDM吸取并顯示了關鍵驗證方法以及所有的關鍵干擾因素。ReliabilityandRobustnessDem72SelfAssessment自我評估SelfAssessment自我評估73VehicleLevelDV&PV

整車級別的DV&PVVehicleLevelDV&PV

整車級別的DV&74VehicleLevelDV&PV

整車級別的DV&PVVerificationandValidationofVehiclelevelrequirements整車級別的驗證和確認的要求Illustratedwithanexamplearoundarealworldproblem–TransitFEAD穿插了一個真實問題的范例—TransitFEADVehicleLevelDV&PV

整車級別的DV&75Problem

問題Customerswereexperiencingproblemsafterwashingtheirvehiclesordrivingthroughwater顧客在洗車或開車涉水后出現問題Problem

問題Customerswereexper76Global8D

全球8DAGlobal8Dwasconductedonthevanjetspraywashingproblemthatwaslookedatearlierandtherootcausewasidentifiedasbeltslip.采取了全球8D方式來處理剛才看到的噴霧式洗車的問題，確定根本原因為皮帶打滑。Global8D

全球8DAGlobal8Dwas77ApplyingRED

應用REDHavingdevelopedafixfortheproblemtheteamneededtoverifythechange針對問題制定出解決方案，該小組需要驗證其更改Verificationisakeypartofthe8Dprocess,justasitisforthePDP驗證是8D過程中的一個關鍵部分，就象其相對于PDP一樣。TodothistheyneedtoapplyREDprinciplestotheverification為了進行該工作，他們需要把RED的原理應用到驗證上。ApplyingRED

應用REDHavingdevel78VerifyingRobustness

驗證殷實可靠性Existingverificationmethodsusedasastartingpoint使用現有的驗證方法作為起點Fromstudyingthedata,theteamnewthattheexistingDVM’swereinsufficient通過研究該數據，小組發(fā)現現有的DVM還不充分NewDVMsmustincludeREDconsiderations新的DVM必須包括RED需要考慮的事項VerifyingRobustness

驗證殷實可靠性Ex79RevisedDVM

修正的DVMTheDVMswerethenmodified.于是對DVM進行修改FEAD子系統設計驗證方法目標：驗證FEAD系統存有水時性能的殷實可靠性試驗描述：在10kph至50kph之間每次增加5kph的車速，開車通過25，50，75以及100mm深的水洼可測量的/觀察：曲軸皮帶輪和附件皮帶輪之間的差速驗收標準：差速小于5%需要的資源及試驗設備：水洼，在已知的曲軸/發(fā)動機轉速下對附件皮帶輪轉速的整車評估RevisedDVM

修正的DVMTheDVMswer80PlanningandImplementingVerificationandValidation

計劃并實施驗證和確認PlanningoccursdowntheV–planthevehiclelevelfirst沿著V形方式向下作計劃—首先計劃整車級別VerificationandValidationoccursuptheV–VerifyandValidatethevehiclelast沿著V形方式向上進行驗證和確認—最后驗證和確認整車PlanningandImplementingVeri81Global8DandDV&PV

全球8D和DV&PVGlobal8Dstudiesonprevioussimilarproductsorprocesseshelpidentifypotentialerrorstates對以前相似產品或過程的全球8D研究幫助識別潛在的異常狀態(tài)Thisisanimportantinputtothedesignofverificationmethodsforanewproductormanufacturingprocess.對于一個新產品或制造過程，這是驗證方法設計中的一個重要的輸入Verificationmethodsmustdemonstratethattheseerrorstatesdonotrecurinthenewproductorprocess.驗證方法必須證明這些異常狀態(tài)不會在新的產品和過程中再次發(fā)生。Global8DandDV&PV

全球8D和DV&PV82SelfAssessment自評SelfAssessment自評83System/Sub-SystemLevelDV

系統/子系統級別DVSystem/Sub-SystemLevelDV

系統/84FEADSub-System

FEAD子系統AFEADsystemistobedevelopedforanewvehicleprogram為一新車項目開發(fā)一個FEAD系統FEADSub-System

FEAD子系統AFEAD85Sub-SystemLevelDesignVerification

子系統級別設計驗證Formacrossfunctionalteam:組成一個交叉功能的小組Design設計Testing試驗Manufacturing制造Supplier供應商CAEQuality質量Reliability可靠性AimtoverifyatthelowestpossiblelevelontheV瞄準V模形最低可能級別上進行驗證Sub-SystemLevelDesignVerifi86FEADDesignVerificationPlan

FEAD設計驗證計劃DVPlanDV計劃SDSRequirementsSDS要求LegalRequirements法規(guī)要求EngineeringSpecifications工程技術規(guī)范ConceptandDesignFMEAs概念和設計FMEARealWorldUsageProfile真實顧客使用概況P-DiagramP圖ExistingDVPs現有DVPGenericDVMs一般DVMHistorical8Ds歷史上的8DKeyLifeTests關鍵壽命試驗FEADDesignVerificationPlan

87FEADFunctionandOperation

FEAD功能和運行IdealfunctionoftheFEADistotransfertorquetotheaccessoriesFEAD的理想功能是把扭矩傳遞給附件Irregularityinrotationisakeynoise旋轉不規(guī)則是一個關鍵的干擾Thetensionercompensatesforthenoise張緊輪對該干擾進行補償ThecorrectfunctioningofthetensionerisapriorityfortheFEADteam張緊輪的正確機能對于前端驅動附件組是最首要的。FEADFunctionandOperation

FE88CustomerRequirements

顧客需求FEADSDSRequirementFEADSDS要求Beltspanvibrationdoesnotexceed10%ofbeltspanandmeetssystemclearancerequirementstoothercomponents.Maximumtensioneramplitudeleaves10%oftotaltravelcleartoendstopinbothdirections.相帶寬度振動不超過相帶寬度的10%，要符合與其它零部件間的系統間隙要求。最大張緊輪振幅要與兩端止點留有總行程10%的間隙余量。ADVMisrequiredtoverifythisrequirement需要DVM來驗證這一要求CustomerRequirements

顧客需求FEAD89ExistingDVTest

現有的DV試驗ThereisanexistingDVMfortherequirement對該要求有一現有的DVMTheteamneedtoassessifthisDVMisappropriate小組需要評估該DVM是否合適ExistingDVTest

現有的DV試驗There90REDinSub-SystemDV

子系統DV中的REDSystemandSub-SystemlevelDVMsmustincludeconsiderationofnoises系統和子系統級別的DVM必須包括干擾需要考慮的事項IntheFEADexampleexcessivebeltvibrationwasidentifiedasacriticalerrorstate.在FEAD的范例中，過多的皮帶振動被認為是一個關鍵的異常狀態(tài)TheDVMwasassessedtobeinadequateforthisfailuremodeinthepresenceofnoise評定該DVM在有干擾存在時對這個失效模式來說是不充分的REDinSub-SystemDV

子系統DV中的RE91FEADAcceptanceCriteria

FEAD驗收標準TheacceptancecriteriawasassessedbytheteamandfoundtocovertheSDSrequirement,butneededminorimprovement.小組評估該驗收標準，發(fā)現涵蓋了SDS的要求，但仍需要小的改進。FEADAcceptanceCriteria

FEAD驗92ApplicationofRED

RED的應用Theteamneedstoconsiderallkeynoisefactors小組需要考慮所有關鍵干擾因素Thekeynoisefactorswereidentifiedas:確認關鍵噪聲為：Carryovertensionerinanewenvironment在新的環(huán)境中借用張緊輪裝置Accessoryloading附加載荷TheseNoisefactorswerenottakenintoaccountinthepreviousDVM.在以前的DVM中沒有考慮這些干擾因素ApplicationofRED

RED的應用Thet93PreviousRobustnessStudies

之前的殷實可靠性研究Previousrobustnessstudiesareakeysourceofinformation之前的殷實可靠性研究是信息的關鍵來源Theteamcanusethisinformationfortheirdesignandtesting小組可以把這一信息用于設計和測試Thistypeofinformationcancomefromsimilarordifferentvehicles這種類型的信息可以來自相似或不同的車輛Thesestrategieswereincorporatedintothenewdesign.這些策略可以并入新的設計中PreviousRobustnessStudies

之前94CheckofDVMObjective

DVM目標的檢查ThedesignteamdidnotthinkthattheobjectiveintheexistingDVMcoveredrobustness設計小組不認為現有DVM中的目標涵蓋了殷實可靠性DVMObjectiverevisedtoincluderobustness修正DVM目標，使其包括殷實可靠性CheckofDVMObjective

DVM目標的檢95DVMTestMethod

DVM試驗方法Theteamthenturneditsattentiontothetestmethod然后小組把注意力轉向試驗方法Thismethodhadbeenusedonpreviousprogramsbuttheseprogramshadexperiencedfailures

這個方法在原來的項目中曾被使用過，但是這些項目已經出現過失效DVMTestMethod

DVM試驗方法Thetea96ApplyingRED

應用REDAREDapproach,wasusedtomodifytheDVM.采用RED的方法修改DVMAG8Dstudyhadbeenconductedtoresolvethebeltsquealproblemonthepreviousvehicle.采用了全球8D的研究來解決原來車輛上皮帶尖叫的問題TheG8DiskeyinformationforRED全球8D對于RED是關鍵的信息ApplyingRED

應用REDAREDapproa97Global8DSummaryReport

全球8D總結報告Global8DSummaryReport

全球8D總98Global8DSummaryFindings

全球8D總結調查結果5：選擇永久糾正措施：采用參數設計實驗以增加在附加載荷的干擾因素存在時FEAD系統的殷實可靠性驗證：從產品開發(fā)實驗的確認來確定FEAD的殷實可靠性增加了%效果100%Global8DSummaryFindings

全球899ConfirmingRobustness

確定殷實可靠性ThesuccessfulimprovementoftheFEADrobustnesstodifferentaccessoryloadingconditionsmeantthatoneoftheteam'sprioritieswastoensurethatthisrobustnesswouldbeconfirmedbytherevisedDVM.對不同附加載荷的條件下FEAD殷實可靠性的成功改進意味著小組優(yōu)先考慮的事項之一是確保該殷實可靠性會通過修正的DVM來確認。ConfirmingRobustness

確定殷實可靠性T100DesignFMEAReview

計劃FMEA評審項目功能潛在失效模式潛在失效后果潛在原因/失效機理保持皮帶張緊力張緊力降低過多的相帶寬度振動。指定阻尼帶的不適當的材料特性。阻尼帶材料特性的退化DesignFMEAReview

計劃FMEA評審項目潛101P-DiagramasSourceofInformation

P圖作為信息來源輸入信號理想功能出錯狀態(tài)控制噪聲干擾因素P圖系統P-DiagramasSourceofInforma102FMEAtoP-DiagramCrossCheck

FMEA對P圖的交叉檢查FMEAtoP-DiagramCrossCheck

103FMEAContents

FMEA內容PotentialCause(s)/Mechanism(s)ofFailure潛在原因/失效機理FEADBeltDesginFMEAFEAD皮帶設計FMEABeltmoduluschangeduetofluidcontamination(beltmaterialnotrobusttofluidcontamination)由于流動污染（皮帶材料對流動污染不殷實可靠），皮帶模數更改(P-diagramNoisefactor)ExternalEnvironment（P圖干擾噪聲因素）外部環(huán)境Drivingterrain行駛地形Temperature溫度Humidity濕度Water水Contamination污染PotentialCause(s)/Mechanism(s)ofFailure潛在原因/失效機理FEADSub-SystemDesignFMEAFEAD子系統設計FMEABeltspanVibrationdueto:Insufficientsystemdampingduetocrankshaftcyclicirregularitygreaterthansystemdesignassumptions相帶寬度振動由于：由于曲軸循環(huán)不規(guī)則性要比系統設計設想的大而造成系統阻尼不足SystemInteractions:系統交互作用Enginecalibration發(fā)動機標定Crankshaftirregularity曲軸不規(guī)則Accessoryloadrequirements附加載荷的要求Numberandtypeofaccessories附件的數量及類型Routing(with/withoutAC)路由（帶/不帶空調）Accessorywear附件磨損Torsionalvibration扭轉振動Wrapanglevariation包角振動FMEAContents

FMEA內容Potential104P-Diagram/FMEAInputsintoDVM

P圖/FMEA輸入到DVMOriginalDVM原始DVMP-Diagram/FMEAInputsintoDVM105UsingCAEasPartofVerification

使用CAE作為驗證的一部分TheDesignTeam’sCAErepresentativehashighlightedtotheteamthataCAEmodeloftheFEADisavailable設計小組的CAE代表向小組強調FEAD的CAE模型已經具備TheCAEmodelneedstobecalibratedCAE模型需要進行校準Thecalibrationwillallowthemodeltohaveongoingusefulness標定將使得模型具有正在進行的有效性UsingCAEasPartofVerificat106ModificationofDVMTestDescription

DVM試驗描述的更改PreviousTestDescription以前的試驗描述Usingavideocameraand,ifnecessary,astrobelight,recordtheFEADsystemwhiletheengineisonadynosubjecttoload.ScalesmaybeplacedalongsidethebeltandtensionersothataroughestimatecanbemadeofAmplitudeofmovement.Sweeptheenginefromidletomaximumspeed.使用攝影機，如果有必要則加上閃光燈，當發(fā)動機機在臺架上承載時錄下FEAD系統?？梢苑胖帽壤咴谄Ш蛷埦o輪側邊從而對其運動振幅做大致的估測。從發(fā)動機怠速開始直到最大轉速。ModifiedTestDescription更改后的試驗描述CAEsimulation:Modelbasedonparameterdesignexperimentandincludetheeffectofcyclicirregularityatthecrankpulleyonbeltandtensionervibration.TheeffectofthefollowingtobeincludedasNoisefactors:CAE模擬：參數設計試驗基礎上的模型包括曲軸皮帶輪循環(huán)不規(guī)則性對皮帶和張緊輪振動的影響。作為干擾因素，下列影響要包括在內：(Differentlevelsof)accessoryloading(includingworstcase)附件載荷（的不同級別）（包括最糟糕的情況）Beltrouting皮帶的路由Variationofbeltelasticproperties皮帶彈性特性的變差Temperature溫度Aging/durabilityofFEADcomponentsFEAD零件的老化/耐久性ManufacturingPiece-to-PieceVariation件與件間的制造變差ModificationofDVMTestDescr107ModificationofMeasurables/ObservablesandAcceptanceCriteria

測量/觀察和驗收標準的更改AcceptanceCriteria標準Amplitudeversusfrequencydistributionw