設(shè)計(jì)驗(yàn)證和生產(chǎn)確認(rèn)福特FORD課件

WelcomeDesignVerificationandProductionValidation設(shè)計(jì)驗(yàn)證和生產(chǎn)確認(rèn)WelcomeDesignVerificationand1FordTechnicalEducationProgram福特技術(shù)培訓(xùn)項(xiàng)目Systems

EngineeringFundamentals系統(tǒng)工程基本原理Parameter

Design參數(shù)設(shè)計(jì)Tolerance

Design公差設(shè)計(jì)Global8D全球8DFMEA失效模式后果與分析Experimental

Design實(shí)驗(yàn)設(shè)計(jì)FTEP福特技術(shù)培訓(xùn)項(xiàng)目Reliability可靠性AppliedConsumerFocus應(yīng)用顧客的關(guān)注DV&PV設(shè)計(jì)驗(yàn)證&生產(chǎn)確認(rèn)StatisticalEngineering統(tǒng)計(jì)工程學(xué)FordTechnicalEducationProgr2CourseStructure

課程結(jié)構(gòu)IntroductiontoDV&PV對(duì)設(shè)計(jì)驗(yàn)證及生產(chǎn)確認(rèn)的介紹ToolsforDV&PV設(shè)計(jì)驗(yàn)證及生產(chǎn)確認(rèn)的工具VehicleLevelDV整車級(jí)別的設(shè)計(jì)驗(yàn)證System/Sub-SystemLevelDV系統(tǒng)/子系統(tǒng)級(jí)別的設(shè)計(jì)驗(yàn)證ComponentLevelDV零部件級(jí)別的設(shè)計(jì)驗(yàn)證System/Sub-SystemLevelPV系統(tǒng)/子系統(tǒng)級(jí)別的生產(chǎn)確認(rèn)ComponentLevelPV零部件級(jí)別的生產(chǎn)確認(rèn)Summary總結(jié)CourseStructure

課程結(jié)構(gòu)Introduct3DesignVerificationandProductionValidation

設(shè)計(jì)驗(yàn)證和

生產(chǎn)確認(rèn)DesignVerificationandProduc4DesignVerificationandProductionValidation

設(shè)計(jì)驗(yàn)證和生產(chǎn)確認(rèn)DesignVerificationandProduc5BenefittoFordMotorCompany

對(duì)福特汽車公司的益處BenefittoFordMotorCompany

6DesignVerificationand

ProductionValidation

設(shè)計(jì)驗(yàn)證和生產(chǎn)確認(rèn)DesignVerification:設(shè)計(jì)驗(yàn)證asdesigned,aproductwillfunctioninthemannerthatthecustomerexpects.根據(jù)設(shè)計(jì)狀態(tài)，一個(gè)產(chǎn)品的功能要符合顧客所期望的方式。ProductionValidation:生產(chǎn)確認(rèn)asmanufactured,aproductfunctionsinthemannerthatthecustomerexpectsandcanbemanufacturedatrequiredvolumes.根據(jù)制造狀態(tài)，一個(gè)產(chǎn)品的功能要符合顧客所期望的方式，而且能以所要求的產(chǎn)量進(jìn)行生產(chǎn)。DesignVerificationand

Produ7DV&PVWithinSystemsEngineering系統(tǒng)工程內(nèi)的DV&PVDV&PVWithinSystemsEngineeri8VerificationandSystemicThinking

驗(yàn)證和系統(tǒng)思想CustomerWants顧客的需要EngineeringTargets工程目標(biāo)DesignVerification設(shè)計(jì)驗(yàn)證VerificationandSystemicThin9RequirementsCascade

需求逐級(jí)傳遞WorkinginaSystemsEngineeringcontextsupportssystemicthinking.系統(tǒng)工程中的工作支持系統(tǒng)的考慮OppositeofTraditionalapproachtoengineering.與傳統(tǒng)的工程方法相反RequirementsCascade

需求逐級(jí)傳遞Wor10Systems“V”Model

系統(tǒng)V模型DV&PVisarequirementsdrivenprocessDV和PV是一個(gè)需求驅(qū)動(dòng)的過程DV&PVisbestconductedinasystemsengineeringcontextthroughthesystemsV.DV和PV在貫穿系統(tǒng)V模型的系統(tǒng)工程中得到最好的實(shí)施。

VehicleSystemSub-SystemComponentSystems“V”Model

系統(tǒng)V模型DV&PVi11DefiningRequirements

定義需求Therequirementscascadedowntheleftside.需求的逐級(jí)傳遞如左側(cè)Thecascadeisaniterativeprocess.該逐級(jí)傳遞是一反復(fù)的過程

VehicleSystemSub-SystemComponentITERATIVE

PLANNINGTopDown由上到下DefiningRequirements

定義需求The12VerificationBottom-up

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

VehicleSystemSub-SystemComponentITERATIVE

PLANNINGTopDown自上至下BottomUp自下至上SEQUENTIAL

DOING反復(fù)計(jì)劃工作順序VerificationBottom-up

驗(yàn)證自下至上V13DV&PVandPDSAPlanPlanPlan

Plan計(jì)劃Do,Study,Act做，研究，行動(dòng)

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

較低級(jí)別的相互作用LowerLevelInteractions

較低級(jí)別的15SystemsApproachtoManufacturing

進(jìn)行制造的系統(tǒng)方法VehicleSystemSub-SystemComponentPlantAssemblyOperationMachineVehicle整車System系統(tǒng)Sub-System子系統(tǒng)Component零部件ManufacturingDesignPlant工廠Assembly裝配Operation操作Machine機(jī)器設(shè)計(jì)制造SystemsApproachtoManufactur16Note-S5/P5TimingFPDSTiming

FPDS時(shí)間Vehiclelevel,Systemlevel&Sub-syslevel1DVPCreated生成整車，系統(tǒng)&子系統(tǒng)的DVPSub-syslevel2&ComponentDVPCreated生成子系統(tǒng)級(jí)別2&零部件DVPFullDVPCreatedReqts&TargetsFrozen生成完整的DVP需求&目標(biāo)凍結(jié)Componenttestingcomplete零部件試驗(yàn)完成Sub-systemandSystemtestingcomplete子系統(tǒng)和系統(tǒng)試驗(yàn)完成Vehicletestingmostlycomplete:PrelimEngSignOff整車試驗(yàn)大部分完成：工程預(yù)簽發(fā)Vehicletestingcomplete:FinalEngSignOff整車試驗(yàn)完成：最終工程簽發(fā)DVPcompleteDVP完成Note-S5/P5TimingFPDSTiming17Design“V”andFPDSTiming

DV&PV

設(shè)計(jì)V形圖及FPDS時(shí)間的DV&PVLow低High高ActivityLevel活動(dòng)級(jí)別Time時(shí)間=DesignVerification設(shè)計(jì)驗(yàn)證=Production&ProcessValidation生產(chǎn)&過程確認(rèn)SISCPAPRCPLRJ1Design“V”andFPDSTiming

DV&18DV&PVandFPDSDV&PVarekeyrequirementsforsignoffofavehicleprogramDV和PV對(duì)于汽車項(xiàng)目的簽發(fā)來說是關(guān)鍵的需求KeySignoffmilestonesare:關(guān)鍵簽發(fā)節(jié)點(diǎn)是：(CC)—DV(LR)—PV(LS)—PVDV&PVandFPDSDV&PVareke19InputsUsedintheVerificationandValidationProcesses

在驗(yàn)證和確認(rèn)過程中使用的輸入DVPlan設(shè)計(jì)驗(yàn)證計(jì)劃SDSRequirementsSDS的需求LegalRequirements法規(guī)要求EngineeringSpecifications工程技術(shù)規(guī)范ConceptandDesignFMEAs概念和設(shè)計(jì)FMEARealWorldUsageProfile真正的顧客使用狀況P-DiagramP圖ExistingDVPs現(xiàn)有的DVPGenericDVMs一般DVMHistorical8Ds歷史上8DKeyLifeTests關(guān)鍵壽命試驗(yàn)InputsUsedintheVerificatio20DV&PVasPartoftheProductCreationProcess

DV和PV作為產(chǎn)品創(chuàng)造過程的部分DVandPVconfirmthatComponentsandsystemrobustlymeetcustomerrequirementsDV和PV確認(rèn)零部件和系統(tǒng)殷實(shí)可靠地符合顧客的需求。DV&PVtestingisnotexploratoryDV和PV試驗(yàn)不是探險(xiǎn)Testingshouldbeagainstexpectedresultsnottofindout“whathappensif”試驗(yàn)應(yīng)該是針對(duì)所預(yù)測(cè)的結(jié)果而不是去發(fā)現(xiàn)“如果…會(huì)怎樣”DV&PVcomesafterthedesignphasenotduringthedesignphaseDV和PV要在設(shè)計(jì)以后而不是在設(shè)計(jì)階段中進(jìn)行DV&PVasPartoftheProductC21IntroductionoftheFEADExampleFEAD舉例介紹IntroductionoftheFEADExamp22FEADExample

FEAD范例AsinglesystemtheFEAD(FrontEndAccessoryDrive)willbeusedtodemonstrateDV&PV使用一個(gè)單獨(dú)的系統(tǒng)FEAD（前端附件驅(qū)動(dòng)）來示范DV&PVFEADExample

FEAD范例Asinglesy23TheFrontEndAccessoryDrive(FEAD)–HowItWorks

FEAD-它如何工作Thesourceofpowerinthevehicleistheengine.汽車內(nèi)動(dòng)力的來源是發(fā)動(dòng)機(jī)PartoftherotationalpoweroutputfromtheengineneedstobetransmittedtotheFEADaccessories.來自發(fā)動(dòng)機(jī)轉(zhuǎn)動(dòng)動(dòng)力輸出的一部分需要被傳輸?shù)紽EAD附件上。TheFEADtransmitsthisenergyFEAD傳輸該能量TheFrontEndAccessoryDrive24DesignVerificationatAllLevels

所有級(jí)別上的設(shè)計(jì)驗(yàn)證DesignVerificationshouldoccuratalllevelswiththeemphasisbeingatthelowerlevels.設(shè)計(jì)驗(yàn)證應(yīng)該重點(diǎn)放在較低級(jí)別的情況下在所有級(jí)別上進(jìn)行。DesignVerificationatAllLev25ProductionValidation

生產(chǎn)確認(rèn)Itisimportanttoverifythedesign驗(yàn)證設(shè)計(jì)是重要的Itisequallyimportanttovalidatethattheproductionprocessusedtomanufacturethebeltisabletoproducebeltstothedesignspecification.確認(rèn)制造皮帶所使用的生產(chǎn)過程能夠生產(chǎn)出符合設(shè)計(jì)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(zhuǎn)送所要求大小的扭矩。ProductionValidation

生產(chǎn)確認(rèn)Iti26ConfirmingRobustandReliableDesign–Robustness

確認(rèn)殷實(shí)及可靠的設(shè)計(jì)-殷實(shí)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(yàn)證中使用的方法Someoftheimportantmethodsusedinefficientandeffectiveverificationandvalidationprocessesare在有效且高效的驗(yàn)證和確認(rèn)過程中所使用的一些重要方法是RobustEngineeringDesignPhilosophy(RED)殷實(shí)的工程設(shè)計(jì)基本定律FordDesignVerificationSystem(FDVS)福特設(shè)計(jì)驗(yàn)證體系TestingMethodologies,試驗(yàn)方法學(xué)RealWorldUsageProfilesandDutyCycles真正全球顧客使用的概況和工況AcceleratedTests,加速試驗(yàn)KeyLifeTests(KLT),關(guān)鍵壽命試驗(yàn)ComputerAidedEngineering(CAE)計(jì)算機(jī)輔助工程DesignofExperiment(DoE).實(shí)驗(yàn)設(shè)計(jì)MethodsUsedinEfficientand29RobustEngineeringDesign

(RED)殷實(shí)的工程設(shè)計(jì)RobustEngineeringDesign

(RED30RobustTestPlans

殷實(shí)可靠的試驗(yàn)計(jì)劃RobusttestplansinDV&PVincorporateNoisefactorsandtheireffectsinordertoensurethattheproductwillmeetitsdesignintentunderallconditions.Noisefactorscanbegroupedintofivecategories:為了確保該產(chǎn)品在所有條件下都符合其設(shè)計(jì)意圖，DV和PV中殷實(shí)的試驗(yàn)計(jì)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(shí)間過去的變化CustomerUsage顧客的使用ExternalEnvironment外部環(huán)境SystemInteractions系統(tǒng)間的交互作用RobustTestPlans

殷實(shí)可靠的試驗(yàn)計(jì)劃Rob31NoiseFactorManagement

干擾因素的管理NoiseFactorManagement

干擾因素的管32RobustEngineeringDesign

殷實(shí)可靠的工程設(shè)計(jì)RobustEngineeringDesign(RED)isprimarilyadesigntool殷實(shí)的工程設(shè)計(jì)主要是一種設(shè)計(jì)工具REDmustbeconsideredinDV&PVasREDwilldrivethetypeofDV&PVteststhatneedtobeundertaken在DV和PV中必須考慮到RED，因?yàn)镽ED將決定需要采取的DV&PV試驗(yàn)的類型。REDfocusesonidentificationandmanagementofnoisefactorsRED著重于干擾因素的識(shí)別和管理RobustEngineeringDesign

殷實(shí)可靠33RobustEngineeringDesign

殷實(shí)可靠的工程設(shè)計(jì)REDisinherentinthesystemsVandrunsthroughallphasesoftheVRED是系統(tǒng)V內(nèi)固有的，并且貫穿系統(tǒng)V的所有階段REDisateambasedprocessRED是以小組為基礎(chǔ)的過程REDappliesthroughoutFord(DesignandManufacturing)andatsuppliersRED應(yīng)用于整個(gè)福特（設(shè)計(jì)和制造）以及供應(yīng)商。RobustEngineeringDesign

殷實(shí)可靠34ApplyingRED

應(yīng)用REDREDallowstestingatthelowestpossiblelevelRED允許在最低可能性級(jí)別進(jìn)行測(cè)試Cautionmustbeused必須使用警示ApplyingRED

應(yīng)用REDREDallowst35RedAppliedtoVehicleLevelTesting

Red應(yīng)用于整車級(jí)別的測(cè)試RedAppliedtoVehicleLevelT36REDAppliedatSub-SystemLevel

RED應(yīng)用于子系統(tǒng)級(jí)別WhendevelopingDesignVerificationMethodsatthesystem/sub-systemorcomponentlevel,itisimportanttoensurethattheeffectsofSystemInteractionNoisefactorsthatarepresentinthetotalvehicleenvironmentareincluded.當(dāng)開發(fā)系統(tǒng)/子系統(tǒng)或零部件級(jí)別的設(shè)計(jì)驗(yàn)證方法時(shí)，重要的是確保要包括整個(gè)汽車環(huán)境中出現(xiàn)的系統(tǒng)交互作用干擾因素的影響。REDAppliedatSub-SystemLeve37REDAppliedatComponentLevel

RED應(yīng)用于零部件級(jí)別Atthecomponentleveltestingismostefficentbutinteractionswithothercomponentsarelost零部件級(jí)別的試驗(yàn)是最有效的，但失去了與其他零件的交互作用Testplansmustcompensateforthislossbyreproducingthekeystressesfromtheinteractions試驗(yàn)計(jì)劃必須通過再制造來自交互作用的關(guān)鍵應(yīng)力彌補(bǔ)這一損失Muchcomponenttestingmaybedoneatsuppliers.許多零部件試驗(yàn)可能在供應(yīng)商處進(jìn)行。SuppliersmustapplythesameREDmethodolgies供應(yīng)商必須應(yīng)用相同的RED方法Tosupportthis,Fordengineersneedtocascadenoisefactorstothesupplier為了支持這個(gè)，福特工程師需要逐層傳遞干擾因素直到供應(yīng)商REDAppliedatComponentLevel38REDintheDesignProcess

設(shè)計(jì)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(tǒng)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(zhuǎn)向柱磨擦）P-DiagramReliabilityChecklist

可靠性檢查清單Reliability/RobustnessDemonstrationMatrix可靠性/殷實(shí)可靠性實(shí)證矩陣圖Signal信號(hào)Energyputintothesystemstomakeitwork(e.g..Steeringwheelangle)能量進(jìn)入系統(tǒng)使其工作（例如..方向盤轉(zhuǎn)角）ControlFactorsFeaturesofthedesignthatcanbecontrolled(e.g..Torsionbarrate)控制因素可以控制的設(shè)計(jì)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(yàn)DVP&RTest試驗(yàn)CriticalNoiseFactors關(guān)鍵干擾因素Failuremodetotesttraceability失效模式試驗(yàn)可追查性

NoiseFactorsManagementStrategySystem(SteeringSystem)系統(tǒng)（轉(zhuǎn)向系統(tǒng)）IdealFunction理想功能Primaryintendedfunctionofthedesign設(shè)計(jì)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(jié)果Inscope范圍內(nèi)FDVSFDVSPreventionofMistakeReoccurrence錯(cuò)誤再次發(fā)生的預(yù)防CampaignPrevent防召回LessonsLearned吸取的教訓(xùn)Vigilance警惕...........干擾因素管理策略REDintheDesignProcess

設(shè)計(jì)過程39FordDesignVerificationSystem福特設(shè)計(jì)驗(yàn)證系統(tǒng)FordDesignVerificationSyste40FordDesignVerificationSystem–FDVS

福特設(shè)計(jì)驗(yàn)證系統(tǒng)-FDVSFDVSisacomputerbasedsystemtocreateandmanagerequirementsdrivenDVplans.FDVS是一計(jì)算機(jī)為基礎(chǔ)的系統(tǒng)，生成并管理驅(qū)動(dòng)DV計(jì)劃的需求。FDVSincludesanumberofgenericrequirementsandDesignVerificationMethods(DVMs)FDVS包括許多一般需求和設(shè)計(jì)驗(yàn)證方面（DVM）安全法規(guī)法人的要求技術(shù)規(guī)范設(shè)計(jì)驗(yàn)證方法整車要求（項(xiàng)目專有）項(xiàng)目專有的設(shè)計(jì)驗(yàn)證計(jì)劃系統(tǒng)要求（項(xiàng)目專有）DVM（項(xiàng)目專有）FordDesignVerificationSyste41DesignVerificationMethod

設(shè)計(jì)驗(yàn)證方法WithinFDVSrequirementsareverifiedusingDesignVerificationMethods(DVMs)在FDVS內(nèi)，使用設(shè)計(jì)驗(yàn)證方法（DVM）驗(yàn)證需求DVMscontainalltheinformationrequiredtoconducttestingandrecordresultsDVM包括所有要求試驗(yàn)和記錄結(jié)果的信息ExistingandGenericDVMscanbeusedasastartingpointtodevelopprogramDMVs,buttheymustbereviewed現(xiàn)有的和一般的DVM能作為一個(gè)開始點(diǎn)用以開發(fā)項(xiàng)目的DMV，但是它們必須進(jìn)行審核DesignVerificationMethod

設(shè)計(jì)驗(yàn)42TestingMethodologies試驗(yàn)方法學(xué)TestingMethodologies試驗(yàn)方法學(xué)43TypesofTest

試驗(yàn)的類型TherearethreegeneraltypesoftestingthatcanbeimplementedforeitherDesignVerificationorProductionValidation:有三種可以在設(shè)計(jì)驗(yàn)證或生產(chǎn)確認(rèn)中實(shí)施的一般試驗(yàn)類型TestingtoBogey標(biāo)準(zhǔn)測(cè)試TestingtoFailure測(cè)試至失效TestingFunctionalDegradation測(cè)試功能退化TypesofTest

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

退化測(cè)試MinimumAcceptableFunction最小可接受功能Function功能Time/Cycles/Miles時(shí)間/循環(huán)/里程BogeyCompleteDegradationHistoryDegradationTesting

退化測(cè)試Minimu47Example:FunctionalDegradation

ofThreeDesignAlternatives

范例：三種設(shè)計(jì)方案的功能退化CBAExample:FunctionalDegradatio48TestLevelComparison

測(cè)試水平比較Bogey標(biāo)準(zhǔn)Failure失效InformationQuality信息質(zhì)量Cost成本Higher較高Lower較低Higher較高Lower較低Degradation退化TestLevelComparison

測(cè)試水平比較Bo49TestPrecision測(cè)試精度失效概率TestPrecision測(cè)試精度失效概率50StatisticalConfidence

統(tǒng)計(jì)可信度Statisticalconfidenceforagivenreliabilityestimateistheprobabilitythatthetruereliabilityofthepopulationisequaltoorgreaterthantheestimate.對(duì)于特定的可靠性預(yù)測(cè)，統(tǒng)計(jì)可信度是一種總體真實(shí)可靠性等于或大于預(yù)測(cè)情況的概率StatisticalConfidence

統(tǒng)計(jì)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?。?個(gè)樣本/失效模式Severity/Accelerationofkeynoisesintests試驗(yàn)中關(guān)鍵干擾的嚴(yán)重度/加速Knowledgeofpriorperform-anceundersimilarconditions相似條件下優(yōu)先性能的知識(shí)Normal通常High高High高Low低FailureSeverity&Occurrence失效嚴(yán)重度&發(fā)生TestLevel測(cè)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(shù)據(jù)來源Yourself自身Instrumentation儀器ExistingData現(xiàn)有數(shù)據(jù)Observation觀察DataSources

數(shù)據(jù)來源YourselfInstr58

Percentiles百分點(diǎn)ActualCustomerUsage真正顧客使用5%

Total95thPercentileuse95th

百分點(diǎn)使用CoreTargetCustomer(Marketing)

核心目標(biāo)顧客（市場(chǎng)）Percentiles百分點(diǎn)ActualCustomer59Example:CoolingFan范例：冷卻風(fēng)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(guān)的次數(shù)或窗戶電機(jī)運(yùn)轉(zhuǎn)次數(shù)Climateoroutsidetemperaturerangesinwhichthevehicleoperates車輛運(yùn)轉(zhuǎn)時(shí)的氣候或外界溫度的范圍Airconditioningsystemfrequencyofoperationandload空調(diào)系統(tǒng)的運(yùn)轉(zhuǎn)頻次和負(fù)荷UsageProfileandCustomerDut61DutyCycleExample

工況范例同步齒形帶發(fā)動(dòng)機(jī)工況綠線：一般顧客紅線：苛刻顧客注：皮帶負(fù)荷在低轉(zhuǎn)速時(shí)更苛刻DutyCycleExample

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

加速測(cè)試Purpose:目的:Accumulateproductstresshistoryinashortperiodoftime在短時(shí)間內(nèi)累積產(chǎn)品應(yīng)力史Shortenverificationtime&reducedevelopmentcosts縮短驗(yàn)證時(shí)間&減少開發(fā)成本AcceleratedTesting

加速測(cè)試Purpos64AcceleratedTestingMethods

加速測(cè)試方法LoadFrequencyoveraSpecifiedTestProcedure在指定的試驗(yàn)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(fù)載IncreasedLoad加大負(fù)載DefineAcceleratedTestbasedonthisportionofprocedurewithincreasedloads50mphFreeway50mph高速公路Climbinghillin1stgear一檔爬山以加大的載荷在這部分試驗(yàn)規(guī)程的基礎(chǔ)上定義加速測(cè)試AcceleratedTestingMethods

加速65AcceleratedTestingCautions

加速測(cè)試警示Correlateaccelerationtorealworlddeterioration使其加速形式與真正顧客使用的退化情況相關(guān)聯(lián)Preventunrepresentativefailuremodes預(yù)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(guān)鍵壽命試驗(yàn)KeyLifeTests關(guān)鍵壽命試驗(yàn)67KeyLifeTests

關(guān)鍵壽命試驗(yàn)KeyLifeTestsfocusonthekeystress(es)whichdrivelossoffunctionand/orfailuremechanismsassociatedwithrealworldusage.關(guān)鍵壽命試驗(yàn)著重于會(huì)促使真正顧客使用相關(guān)的功能損失和/或失效機(jī)理的關(guān)鍵應(yīng)力KeyLifeTests

關(guān)鍵壽命試驗(yàn)KeyLife68KeyLifeTests

關(guān)鍵壽命試驗(yàn)AKeyLifeTest:一個(gè)關(guān)鍵壽命試驗(yàn)IsbasedontheRWUP是以RWUP為基礎(chǔ)的Providesatooltoevaluateproductreliability提供了一個(gè)工具以評(píng)估產(chǎn)品的可靠性Allowscomparisonofdesignswithbenchmarkedcompetitiveproductssothatthebestdesigncanbeidentified使其與競(jìng)爭(zhēng)產(chǎn)品進(jìn)行設(shè)計(jì)的比較，從而可以確定最佳設(shè)計(jì)Validatesmodelsandassumptionsinthedesignprocess在設(shè)計(jì)過程中確認(rèn)模型和設(shè)想Validatesthedesign確認(rèn)設(shè)計(jì)KeyLifeTests

關(guān)鍵壽命試驗(yàn)AKeyLif69KeyLifeTests

關(guān)鍵壽命試驗(yàn)IS是ISNot否

KeyLifeTests

關(guān)鍵壽命試驗(yàn)IS是ISNot70ReliabilityandRobustnessDemonstrationMatrix可靠性和殷實(shí)可靠性實(shí)證矩陣圖ReliabilityandRobustnessDem71ReliabilityandRobustnessDemonstrationMatrix

可靠性和殷實(shí)可靠性實(shí)證矩陣圖

ReliabilityandRobustnessDemonstrationMatrix(RRDM)

capturesanddisplaysthekeyverificationmethodsandallCriticalNoisefactors.RRDM吸取并顯示了關(guān)鍵驗(yàn)證方法以及所有的關(guān)鍵干擾因素。ReliabilityandRobustnessDem72SelfAssessment自我評(píng)估SelfAssessment自我評(píng)估73VehicleLevelDV&PV

整車級(jí)別的DV&PVVehicleLevelDV&PV

整車級(jí)別的DV&74VehicleLevelDV&PV

整車級(jí)別的DV&PVVerificationandValidationofVehiclelevelrequirements整車級(jí)別的驗(yàn)證和確認(rèn)的要求Illustratedwithanexamplearoundarealworldproblem–TransitFEAD穿插了一個(gè)真實(shí)問題的范例—TransitFEADVehicleLevelDV&PV

整車級(jí)別的DV&75Problem

問題Customerswereexperiencingproblemsafterwashingtheirvehiclesordrivingthroughwater顧客在洗車或開車涉水后出現(xiàn)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?yàn)槠Т蚧?。Global8D

全球8DAGlobal8Dwas77ApplyingRED

應(yīng)用REDHavingdevelopedafixfortheproblemtheteamneededtoverifythechange針對(duì)問題制定出解決方案，該小組需要驗(yàn)證其更改Verificationisakeypartofthe8Dprocess,justasitisforthePDP驗(yàn)證是8D過程中的一個(gè)關(guān)鍵部分，就象其相對(duì)于PDP一樣。TodothistheyneedtoapplyREDprinciplestotheverification為了進(jìn)行該工作，他們需要把RED的原理應(yīng)用到驗(yàn)證上。ApplyingRED

應(yīng)用REDHavingdevel78VerifyingRobustness

驗(yàn)證殷實(shí)可靠性Existingverificationmethodsusedasastartingpoint使用現(xiàn)有的驗(yàn)證方法作為起點(diǎn)Fromstudyingthedata,theteamnewthattheexistingDVM’swereinsufficient通過研究該數(shù)據(jù)，小組發(fā)現(xiàn)現(xiàn)有的DVM還不充分NewDVMsmustincludeREDconsiderations新的DVM必須包括RED需要考慮的事項(xiàng)VerifyingRobustness

驗(yàn)證殷實(shí)可靠性Ex79RevisedDVM

修正的DVMTheDVMswerethenmodified.于是對(duì)DVM進(jìn)行修改FEAD子系統(tǒng)設(shè)計(jì)驗(yàn)證方法目標(biāo)：驗(yàn)證FEAD系統(tǒng)存有水時(shí)性能的殷實(shí)可靠性試驗(yàn)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(cè)量的/觀察：曲軸皮帶輪和附件皮帶輪之間的差速驗(yàn)收標(biāo)準(zhǔn)：差速小于5%需要的資源及試驗(yàn)設(shè)備：水洼，在已知的曲軸/發(fā)動(dòng)機(jī)轉(zhuǎn)速下對(duì)附件皮帶輪轉(zhuǎn)速的整車評(píng)估RevisedDVM

修正的DVMTheDVMswer80PlanningandImplementingVerificationandValidation

計(jì)劃并實(shí)施驗(yàn)證和確認(rèn)PlanningoccursdowntheV–planthevehiclelevelfirst沿著V形方式向下作計(jì)劃—首先計(jì)劃整車級(jí)別VerificationandValidationoccursuptheV–VerifyandValidatethevehiclelast沿著V形方式向上進(jìn)行驗(yàn)證和確認(rèn)—最后驗(yàn)證和確認(rèn)整車PlanningandImplementingVeri81Global8DandDV&PV

全球8D和DV&PVGlobal8Dstudiesonprevioussimilarproductsorprocesseshelpidentifypotentialerrorstates對(duì)以前相似產(chǎn)品或過程的全球8D研究幫助識(shí)別潛在的異常狀態(tài)Thisisanimportantinputtothedesignofverificationmethodsforanewproductormanufacturingprocess.對(duì)于一個(gè)新產(chǎn)品或制造過程，這是驗(yàn)證方法設(shè)計(jì)中的一個(gè)重要的輸入Verificationmethodsmustdemonstratethattheseerrorstatesdonotrecurinthenewproductorprocess.驗(yàn)證方法必須證明這些異常狀態(tài)不會(huì)在新的產(chǎn)品和過程中再次發(fā)生。Global8DandDV&PV

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

系統(tǒng)/子系統(tǒng)級(jí)別DVSystem/Sub-SystemLevelDV

系統(tǒng)/84FEADSub-System

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

FEAD子系統(tǒng)AFEAD85Sub-SystemLevelDesignVerification

子系統(tǒng)級(jí)別設(shè)計(jì)驗(yàn)證Formacrossfunctionalteam:組成一個(gè)交叉功能的小組Design設(shè)計(jì)Testing試驗(yàn)Manufacturing制造Supplier供應(yīng)商CAEQuality質(zhì)量Reliability可靠性AimtoverifyatthelowestpossiblelevelontheV瞄準(zhǔn)V模形最低可能級(jí)別上進(jìn)行驗(yàn)證Sub-SystemLevelDesignVerifi86FEADDesignVerificationPlan

FEAD設(shè)計(jì)驗(yàn)證計(jì)劃DVPlanDV計(jì)劃SDSRequirementsSDS要求LegalRequirements法規(guī)要求EngineeringSpecifications工程技術(shù)規(guī)范ConceptandDesignFMEAs概念和設(shè)計(jì)FMEARealWorldUsageProfile真實(shí)顧客使用概況P-DiagramP圖ExistingDVPs現(xiàn)有DVPGenericDVMs一般DVMHistorical8Ds歷史上的8DKeyLifeTests關(guān)鍵壽命試驗(yàn)FEADDesignVerificationPlan

87FEADFunctionandOperation

FEAD功能和運(yùn)行IdealfunctionoftheFEADistotransfertorquetotheaccessoriesFEAD的理想功能是把扭矩傳遞給附件Irregularityinrotationisakeynoise旋轉(zhuǎn)不規(guī)則是一個(gè)關(guān)鍵的干擾Thetensionercompensatesforthenoise張緊輪對(duì)該干擾進(jìn)行補(bǔ)償ThecorrectfunctioningofthetensionerisapriorityfortheFEADteam張緊輪的正確機(jī)能對(duì)于前端驅(qū)動(dòng)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(dòng)不超過相帶寬度的10%，要符合與其它零部件間的系統(tǒng)間隙要求。最大張緊輪振幅要與兩端止點(diǎn)留有總行程10%的間隙余量。ADVMisrequiredtoverifythisrequirement需要DVM來驗(yàn)證這一要求CustomerRequirements

顧客需求FEAD89ExistingDVTest

現(xiàn)有的DV試驗(yàn)ThereisanexistingDVMfortherequirement對(duì)該要求有一現(xiàn)有的DVMTheteamneedtoassessifthisDVMisappropriate小組需要評(píng)估該DVM是否合適ExistingDVTest

現(xiàn)有的DV試驗(yàn)There90REDinSub-SystemDV

子系統(tǒng)DV中的REDSystemandSub-SystemlevelDVMsmustincludeconsiderationofnoises系統(tǒng)和子系統(tǒng)級(jí)別的DVM必須包括干擾需要考慮的事項(xiàng)IntheFEADexampleexcessivebeltvibrationwasidentifiedasacriticalerrorstate.在FEAD的范例中，過多的皮帶振動(dòng)被認(rèn)為是一個(gè)關(guān)鍵的異常狀態(tài)TheDVMwasassessedtobeinadequateforthisfailuremodeinthepresenceofnoise評(píng)定該DVM在有干擾存在時(shí)對(duì)這個(gè)失效模式來說是不充分的REDinSub-SystemDV

子系統(tǒng)DV中的RE91FEADAcceptanceCriteria

FEAD驗(yàn)收標(biāo)準(zhǔn)TheacceptancecriteriawasassessedbytheteamandfoundtocovertheSDSrequirement,butneededminorimprovement.小組評(píng)估該驗(yàn)收標(biāo)準(zhǔn)，發(fā)現(xiàn)涵蓋了SDS的要求，但仍需要小的改進(jìn)。FEADAcceptanceCriteria

FEAD驗(yàn)92ApplicationofRED

RED的應(yīng)用Theteamneedstoconsiderallkeynoisefactors小組需要考慮所有關(guān)鍵干擾因素Thekeynoisefactorswereidentifiedas:確認(rèn)關(guān)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(yīng)用Thet93PreviousRobustnessStudies

之前的殷實(shí)可靠性研究Previousrobustnessstudiesareakeysourceofinformation之前的殷實(shí)可靠性研究是信息的關(guān)鍵來源Theteamcanusethisinformationfortheirdesignandtesting小組可以把這一信息用于設(shè)計(jì)和測(cè)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(shè)計(jì)中PreviousRobustnessStudies

之前94CheckofDVMObjective

DVM目標(biāo)的檢查ThedesignteamdidnotthinkthattheobjectiveintheexistingDVMcoveredrobustness設(shè)計(jì)小組不認(rèn)為現(xiàn)有DVM中的目標(biāo)涵蓋了殷實(shí)可靠性DVMObjectiverevisedtoincluderobustness修正DVM目標(biāo)，使其包括殷實(shí)可靠性CheckofDVMObjective

DVM目標(biāo)的檢95DVMTestMethod

DVM試驗(yàn)方法Theteamthenturneditsattentiontothetestmethod然后小組把注意力轉(zhuǎn)向試驗(yàn)方法Thismethodhadbeenusedonpreviousprogramsbuttheseprogramshadexperiencedfailures

這個(gè)方法在原來的項(xiàng)目中曾被使用過，但是這些項(xiàng)目已經(jīng)出現(xiàn)過失效DVMTestMethod

DVM試驗(yàn)方法Thetea96ApplyingRED

應(yīng)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(duì)于RED是關(guān)鍵的信息ApplyingRED

應(yīng)用REDAREDapproa97Global8DSummaryReport

全球8D總結(jié)報(bào)告Global8DSummaryReport

全球8D總98Global8DSummaryFindings

全球8D總結(jié)調(diào)查結(jié)果5：選擇永久糾正措施：采用參數(shù)設(shè)計(jì)實(shí)驗(yàn)以增加在附加載荷的干擾因素存在時(shí)FEAD系統(tǒng)的殷實(shí)可靠性驗(yàn)證：從產(chǎn)品開發(fā)實(shí)驗(yàn)的確認(rèn)來確定FEAD的殷實(shí)可靠性增加了%效果100%Global8DSummaryFindings

全球899ConfirmingRobustness

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

確定殷實(shí)可靠性T100DesignFMEAReview

計(jì)劃FMEA評(píng)審項(xiàng)目功能潛在失效模式潛在失效后果潛在原因/失效機(jī)理保持皮帶張緊力張緊力降低過多的相帶寬度振動(dòng)。指定阻尼帶的不適當(dāng)?shù)牟牧咸匦?。阻尼帶材料特性的退化DesignFMEAReview

計(jì)劃FMEA評(píng)審項(xiàng)目潛101P-DiagramasSourceofInformation

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

FMEA對(duì)P圖的交叉檢查FMEAtoP-DiagramCrossCheck

103FMEAContents

FMEA內(nèi)容PotentialCause(s)/Mechanism(s)ofFailure潛在原因/失效機(jī)理FEADBeltDesginFMEAFEAD皮帶設(shè)計(jì)FMEABeltmoduluschangeduetofluidcontamination(beltmaterialnotrobusttofluidcontamination)由于流動(dòng)污染（皮帶材料對(duì)流動(dòng)污染不殷實(shí)可靠），皮帶模數(shù)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(jī)理FEADSub-SystemDesignFMEAFEAD子系統(tǒng)設(shè)計(jì)FMEABeltspanVibrationdueto:Insufficientsystemdampingduetocrankshaftcyclicirregularitygreaterthansystemdesignassumptions相帶寬度振動(dòng)由于：由于曲軸循環(huán)不規(guī)則性要比系統(tǒng)設(shè)計(jì)設(shè)想的大而造成系統(tǒng)阻尼不足SystemInteractions:系統(tǒng)交互作用Enginecalibration發(fā)動(dòng)機(jī)標(biāo)定Crankshaftirregularity曲軸不規(guī)則Accessoryloadrequirements附加載荷的要求Numberandtypeofaccessories附件的數(shù)量及類型Routing(with/withoutAC)路由（帶/不帶空調(diào)）Accessorywear附件磨損Torsionalvibration扭轉(zhuǎn)振動(dòng)Wrapanglevariation包角振動(dòng)FMEAContents

FMEA內(nèi)容Potential104P-Diagram/FMEAInputsintoDVM

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

使用CAE作為驗(yàn)證的一部分TheDesignTeam’sCAErepresentativehashighlightedtotheteamthataCAEmodeloftheFEADisavailable設(shè)計(jì)小組的CAE代表向小組強(qiáng)調(diào)FEAD的CAE模型已經(jīng)具備TheCAEmodelneedstobecalibratedCAE模型需要進(jìn)行校準(zhǔn)Thecalibrationwillallowthemodeltohaveongoingusefulness標(biāo)定將使得模型具有正在進(jìn)行的有效性UsingCAEasPartofVerificat106ModificationofDVMTestDescription

DVM試驗(yàn)描述的更改PreviousTestDescription以前的試驗(yàn)描述Usingavideocameraand,ifnecessary,astrobelight,recordtheFEADsystemwhiletheengineisonadynosubjecttoload.ScalesmaybeplacedalongsidethebeltandtensionersothataroughestimatecanbemadeofAmplitudeofmovement.Sweeptheenginefromidletomaximumspeed.使用攝影機(jī)，如果有必要?jiǎng)t加上閃光燈，當(dāng)發(fā)動(dòng)機(jī)機(jī)在臺(tái)架上承載時(shí)錄下FEAD系統(tǒng)?？梢苑胖帽壤咴谄Ш蛷埦o輪側(cè)邊從而對(duì)其運(yùn)動(dòng)振幅做大致的估測(cè)。從發(fā)動(dòng)機(jī)怠速開始直到最大轉(zhuǎn)速。ModifiedTestDescription更改后的試驗(yàn)描述CAEsimulation:Modelbasedonparameterdesignexperimentandincludetheeffectofcyclicirregularityatthecrankpulleyonbeltandtensionervibration.TheeffectofthefollowingtobeincludedasNoisefactors:CAE模擬：參數(shù)設(shè)計(jì)試驗(yàn)基礎(chǔ)上的模型包括曲軸皮帶輪循環(huán)不規(guī)則性對(duì)皮帶和張緊輪振動(dòng)的影響。作為干擾因素，下列影響要包括在內(nèi)：(Differentlevelsof)accessoryloading(includingworstcase)附件載荷（的不同級(jí)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(cè)量/觀察和驗(yàn)收標(biāo)準(zhǔn)的更改AcceptanceCriteria標(biāo)準(zhǔn)Amplitudeversusfrequencydistributionw