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

1、Systems EngineeringFundamentals系統(tǒng)工程基本原理系統(tǒng)工程基本原理Parameter Design參數(shù)設(shè)計(jì)參數(shù)設(shè)計(jì)ToleranceDesign公差設(shè)計(jì)公差設(shè)計(jì)Global 8D全球全球8DFMEA失效模式后果與分析失效模式后果與分析ExperimentalDesign實(shí)驗(yàn)設(shè)計(jì)實(shí)驗(yàn)設(shè)計(jì)Reliability可靠性可靠性Applied Consumer Focus應(yīng)用顧客的關(guān)注應(yīng)用顧客的關(guān)注DV & PV設(shè)計(jì)驗(yàn)證設(shè)計(jì)驗(yàn)證&生產(chǎn)確認(rèn)生產(chǎn)確認(rèn)Statistical Engineering統(tǒng)計(jì)工程學(xué)統(tǒng)計(jì)工程學(xué)Course Structure課程結(jié)構(gòu)Intro

2、duction to DV & PV對(duì)設(shè)計(jì)驗(yàn)證及生產(chǎn)確認(rèn)的介紹Tools for DV & PV設(shè)計(jì)驗(yàn)證及生產(chǎn)確認(rèn)的工具Vehicle Level DV整車級(jí)別的設(shè)計(jì)驗(yàn)證System/Sub-System Level DV系統(tǒng)/子系統(tǒng)級(jí)別的設(shè)計(jì)驗(yàn)證Component Level DV零部件級(jí)別的設(shè)計(jì)驗(yàn)證System/Sub-System Level PV系統(tǒng)/子系統(tǒng)級(jí)別的生產(chǎn)確認(rèn)Component Level PV零部件級(jí)別的生產(chǎn)確認(rèn)Summary總結(jié)Design Verification and Production Validation設(shè)計(jì)驗(yàn)證和生產(chǎn)確認(rèn)Benefit to

3、 Ford Motor Company對(duì)福特汽車公司的益處Design Verification and Production Validation設(shè)計(jì)驗(yàn)證和生產(chǎn)確認(rèn)Design Verification: 設(shè)計(jì)驗(yàn)證as designed, a product will function in the manner that the customer expects. 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。Production Validation: 生產(chǎn)確認(rèn)as manufactured, a product functions in the manner that the c

4、ustomer expects and can be manufactured at required volumes. 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)。DV&PV Within Systems Engineering系統(tǒng)工程內(nèi)的DV&PVVerification and Systemic Thinking驗(yàn)證和系統(tǒng)思想Customer Wants顧客的需要顧客的需要Engineering Targets工程目標(biāo)工程目標(biāo)Design Verification設(shè)計(jì)驗(yàn)證設(shè)計(jì)驗(yàn)證Requirements Cascade需求逐級(jí)傳遞Wo

5、rking in a Systems Engineering context supports systemic thinking.系統(tǒng)工程中的工作支持系統(tǒng)的考慮 Opposite of Traditional approach to engineering. 與傳統(tǒng)的工程方法相反Systems “V” Model系統(tǒng)V模型DV&PV is a requirements driven processDV和PV 是一個(gè)需求驅(qū)動(dòng)的過程DV&PV is best conducted in a systems engineering context through the system

6、s V. 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-SystemComponentDefining Requirements定義需求The requirements cascade down the left side. 需求的逐級(jí)傳遞如左側(cè)The cascade is an iterative process. 該逐級(jí)傳遞是一反復(fù)的過程 VehicleSystemSub-SystemComponentITERATIVE PLANNINGTop Down由上到下由上到下Verification Bottom-up驗(yàn)證自下至上Verificatio

7、n testing is implemented as a bottom-up sequential process. 驗(yàn)證試驗(yàn)是按照自下至上的順序過程執(zhí)行的Verification may include a combination of Analytical and physical tests.驗(yàn)證可能包括分析試驗(yàn)和物理試驗(yàn)的組合。 VehicleSystemSub-SystemComponentITERATIVE PLANNINGTop Down自上至下自上至下Bottom Up自下至上自下至上SEQUENTIAL DOING反復(fù)計(jì)劃工作順序DV & PV and PDSAPl

8、anPlanPlan Plan計(jì)劃計(jì)劃 Do, Study, Act 做，研究，行動(dòng)做，研究，行動(dòng) Do, Study, ActDo, Study, ActDo, Study, ActVehicle整車整車System系統(tǒng)系統(tǒng)Sub-System子系統(tǒng)子系統(tǒng)Component零部件零部件Lower Level Interactions較低級(jí)別的相互作用Systems Approach to Manufacturing進(jìn)行制造的系統(tǒng)方法VehicleSystemSub-SystemComponentPlantAssemblyOperationMachineVehicle整車整車System系統(tǒng)系

9、統(tǒng)Sub-System子系統(tǒng)子系統(tǒng)Component零部件零部件ManufacturingDesignPlant 工廠工廠Assembly 裝配裝配Operation 操作操作Machine機(jī)器機(jī)器設(shè)計(jì)設(shè)計(jì)制制 造造Note - S5/P5 TimingFPDS TimingFPDS時(shí)間Vehicle level,System level& Sub-sys level1DVP Created生成整車，系統(tǒng)&子系統(tǒng)的DVPSub-sys level 2& ComponentDVP Created生成子系統(tǒng)級(jí)別2&零部件DVPFull DVP CreatedReqt

10、s & Targets Frozen生成完整的生成完整的DVP需求需求&目標(biāo)凍結(jié)目標(biāo)凍結(jié)Component testing complete零部件試驗(yàn)完成Sub-system and System testing complete子系統(tǒng)和系統(tǒng)試驗(yàn)完成Vehicle testing mostly complete:Prelim Eng Sign Off整車試驗(yàn)大部分完成：工程預(yù)簽發(fā)Vehicle testing complete:Final Eng Sign Off整車試驗(yàn)完成：最整車試驗(yàn)完成：最終工程簽發(fā)終工程簽發(fā)DVP completeDVP完成完成Design “V” an

11、d FPDS TimingDV&PV設(shè)計(jì)V形圖及FPDS時(shí)間的DV&PVLow低低High高高ActivityLevel活動(dòng)級(jí)別活動(dòng)級(jí)別Time時(shí)間時(shí)間= Design Verification設(shè)計(jì)驗(yàn)證設(shè)計(jì)驗(yàn)證= Production & Process Validation生產(chǎn)生產(chǎn)&過程確認(rèn)過程確認(rèn)SISCPAPRCPLRJ1DV & PV and FPDSDV & PV are key requirements for sign off of a vehicle programDV和PV對(duì)于汽車項(xiàng)目的簽發(fā)來說是關(guān)鍵的需求Key Sign of

12、f milestones are:關(guān)鍵簽發(fā)節(jié)點(diǎn)是：(CC) DV(LR) PV(LS) PVInputs Used in the Verification and Validation Processes在驗(yàn)證和確認(rèn)過程中使用的輸入DV Plan設(shè)計(jì)驗(yàn)證設(shè)計(jì)驗(yàn)證計(jì)劃計(jì)劃SDS RequirementsSDS的需求的需求LegalRequirements法規(guī)要求法規(guī)要求EngineeringSpecifications工程技術(shù)規(guī)范工程技術(shù)規(guī)范Concept and Design FMEAs概念和設(shè)計(jì)概念和設(shè)計(jì)FMEAReal World Usage Profile真正的顧客使用狀況真正的顧客使用

13、狀況P-DiagramP圖圖Existing DVPs現(xiàn)有的現(xiàn)有的DVPGeneric DVMs一般一般DVMHistorical 8Ds歷史上歷史上8DKey Life Tests關(guān)鍵壽命試驗(yàn)關(guān)鍵壽命試驗(yàn)DV&PV as Part of the Product Creation Process DV 和PV作為產(chǎn)品創(chuàng)造過程的部分DV and PV confirm that Components and system robustly meet customer requirementsDV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 & PV testing is n

14、ot exploratoryDV和PV試驗(yàn)不是探險(xiǎn)Testing should be against expected results not to find out “what happens if”試驗(yàn)應(yīng)該是針對(duì)所預(yù)測的結(jié)果而不是去發(fā)現(xiàn)“如果會(huì)怎樣”DV&PV comes after the design phase not during the design phaseDV 和PV 要在設(shè)計(jì)以后而不是在設(shè)計(jì)階段中進(jìn)行Introduction of the FEAD ExampleFEAD舉例介紹FEAD ExampleFEAD范例A single system the FEAD

15、(Front End Accessory Drive) will be used to demonstrate DV & 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&PVThe Front End Accessory Drive (FEAD) How It WorksFEAD-它如何工作The source of power in the vehicle is the engine. 汽車內(nèi)動(dòng)力的來源是發(fā)動(dòng)機(jī)Part of the rotational power output from the engine needs to be transmitted to

16、the FEAD accessories. 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。The FEAD transmits this energyFEAD傳輸該能量Design Verification at All Levels所有級(jí)別上的設(shè)計(jì)驗(yàn)證Design Verification should occur at all levels with the emphasis being at the lower levels. 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。Production Validation生產(chǎn)確認(rèn)It is important to veri

17、fy the design 驗(yàn)證設(shè)計(jì)是重要的It is equally important to validate that the production process used to manufacture the belt is able to produce belts to the design specification. 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。For example, the belt as manufactured must be able to transmit the required amount of torque.例如，所

18、制造的皮帶必須能轉(zhuǎn)送所要求大小的扭矩。Confirming Robust and Reliable Design Robustness確認(rèn)殷實(shí)及可靠的設(shè)計(jì)-殷實(shí)可靠性Methods Used in Efficient and Effective Verification在有效且高效的驗(yàn)證中使用的方法Some of the important methods used in efficient and effective verification and validation processes are 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Robust Engineering D

19、esign Philosophy (RED)殷實(shí)的工程設(shè)計(jì)基本定律Ford Design Verification System (FDVS)福特設(shè)計(jì)驗(yàn)證體系Testing Methodologies,試驗(yàn)方法學(xué)Real World Usage Profiles and Duty Cycles真正全球顧客使用的概況和工況Accelerated Tests, 加速試驗(yàn)Key Life Tests (KLT), 關(guān)鍵壽命試驗(yàn)Computer Aided Engineering (CAE)計(jì)算機(jī)輔助工程Design of Experiment (DoE).實(shí)驗(yàn)設(shè)計(jì)Robust Engineering

20、 Design(RED)殷實(shí)的工程設(shè)計(jì)Robust Test Plans殷實(shí)可靠的試驗(yàn)計(jì)劃Robust test plans in DV&PV incorporate Noise factors and their effects in order to ensure that the product will meet its design intent under all conditions. Noise factors can be grouped into five categories: 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

21、其他們的影響。干擾因素可以分成5類：Piece-to-Piece Variation 件與件間的變差Changes Over Time 隨著時(shí)間過去的變化Customer Usage 顧客的使用External Environment 外部環(huán)境System Interactions 系統(tǒng)間的交互作用Noise Factor Management干擾因素的管理Test/TechnologyChange試驗(yàn)/技術(shù)更改Robust Designby ParameterDesign通過參數(shù)設(shè)計(jì)的牢靠設(shè)計(jì)Robust Designby IncreasedStrength通過增加強(qiáng)度的牢靠的設(shè)計(jì)Remov

22、e orReduce Noise去除或減小干擾CompensationDevice補(bǔ)償裝置Disguise theProblem隱蔽問題InternalEnvironment(SystemInteractions)內(nèi)部環(huán)境（系統(tǒng)交互作YesYesYesSystemFMEAYesSystemFMEAExternalEnvironment(Climate/RoadConditions)外部環(huán)境（氣候/路況）YesYesYesNoPiece to PieceVariation件與件間的差異YesYesYesSPCChanges Over Time(Wear Out)隨著時(shí)間產(chǎn)生的變化（磨損）YesY

23、esMaterialsEngineeringYesSystemFMEACustomer Usage顧客使用YesYesYesNoRobust Engineering Design殷實(shí)可靠的工程設(shè)計(jì)Robust Engineering Design (RED) is primarily a design tool殷實(shí)的工程設(shè)計(jì)主要是一種設(shè)計(jì)工具RED must be considered in DV&PV as RED will drive the type of DV&PV tests that need to be undertaken 在DV和PV中必須考慮到RED，因?yàn)镽

24、ED將決定需要采取的DV&PV試驗(yàn)的類型。RED focuses on identification and management of noise factorsRED著重于干擾因素的識(shí)別和管理Robust Engineering Design殷實(shí)可靠的工程設(shè)計(jì)RED is inherent in the systems V and runs through all phases of the VRED是系統(tǒng)V內(nèi)固有的，并且貫穿系統(tǒng)V的所有階段RED is a team based processRED是以小組為基礎(chǔ)的過程RED applies throughout Ford (De

25、sign and Manufacturing) and at suppliersRED應(yīng)用于整個(gè)福特（設(shè)計(jì)和制造）以及供應(yīng)商。Applying RED應(yīng)用REDRED allows testing at the lowest possible levelRED允許在最低可能性級(jí)別進(jìn)行測試Caution must be used必須使用警示Red Applied to Vehicle Level Testing Red應(yīng)用于整車級(jí)別的測試RED Applied at Sub-System LevelRED應(yīng)用于子系統(tǒng)級(jí)別When developing Design Verification Me

26、thods at the system/sub-system or component level, it is important to ensure that the effects of System Interaction Noise factors that are present in the total vehicle environment are included.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。RED Applied at Component LevelRED應(yīng)用于零部件級(jí)別At the co

27、mponent level testing is most efficent but interactions with other components are lost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Test plans must compensate for this loss by reproducing the key stresses from the interactions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Much component testing may be done at suppliers.許多零部件試驗(yàn)可能在供應(yīng)商處進(jìn)行

28、。Suppliers must apply the same RED methodolgies供應(yīng)商必須應(yīng)用相同的RED方法To support this, Ford engineers need to cascade noise factors to the supplier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RED in the Design Process設(shè)計(jì)過程中的RED Noise Factors干擾因素Piece to Piece件與件件與件Aging/Wear老化老化/磨損磨損Customer Usage顧客使用顧客使用Environment環(huán)境環(huán)境Subsys

29、tem Interaction子系統(tǒng)交互作用子系統(tǒng)交互作用Sources that disrupt idealfunction that can not be controlled (e.g. column friction)不可控制的，破壞理想功能的來源（例如.轉(zhuǎn)向柱磨擦）P-DiagramReliability Checklist 可靠性檢查清單Reliability/RobustnessDemonstration Matrix 可靠性/殷實(shí)可靠性實(shí)證矩陣圖Signal信號(hào)Energy put intothe systems tomake it work(e.g. Steeringwhee

30、l angle)能量進(jìn)入系統(tǒng)使其工作（例如.方向盤轉(zhuǎn)角）Control FactorsFeatures of the designthat can be controlled(e.g. Torsion bar rate)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)Undesirable outputor Failure Modes(e.g. Tire slip)不需要的輸出或失效模式（例如.輪胎打滑）Error States異常狀態(tài) NoiseFactors干擾因素 AvailableTests有用的試驗(yàn)DVP&RTest試驗(yàn)CriticalNoiseFa

31、ctors關(guān)鍵干擾因素Failure mode totest traceability失效模式試驗(yàn)可追查性 Noise FactorsManagement StrategySystem(Steering System)系統(tǒng)（轉(zhuǎn)向系統(tǒng)）IdealFunction理想功能Primary intendedfunction of the design設(shè)計(jì)的主要意圖功能(e.g. Lateral accelerationof vehicle)（例如.車輛的橫向加速度）FMEASDSWCRDOE(if necessary如果有必要)KLTWCRFailureMode失效模式DemonstratedResu

32、lt論證的結(jié)果In scope范圍內(nèi)FDVSFDVSPrevention of Mistake Reoccurrence錯(cuò)誤再次發(fā)生的預(yù)防Campaign Prevent 防召回Lessons Learned 吸取的教訓(xùn)Vigilance 警惕. . .干擾因素管理策略Ford Design Verification System福特設(shè)計(jì)驗(yàn)證系統(tǒng)Ford Design Verification System FDVS福特設(shè)計(jì)驗(yàn)證系統(tǒng)-FDVSFDVS is a computer based system to create and manage requirements driven DV p

33、lans.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。FDVS includes a number of generic requirements and Design Verification Methods (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)安全法規(guī)法人的要求法人的要求技術(shù)規(guī)范技術(shù)規(guī)范設(shè)計(jì)驗(yàn)證方法設(shè)計(jì)驗(yàn)證方法整車要求整車要求（項(xiàng)目專有）（項(xiàng)目專有）項(xiàng)目專有的設(shè)項(xiàng)目專有的設(shè)計(jì)驗(yàn)證計(jì)劃計(jì)驗(yàn)證計(jì)劃系統(tǒng)要求系統(tǒng)要求（項(xiàng)目專有）（項(xiàng)目專有）DVM（項(xiàng)目專有）項(xiàng)目專有）Design Verification Method設(shè)計(jì)驗(yàn)證方法Within FD

34、VS requirements are verified using Design Verification Methods (DVMs)在FDVS內(nèi)，使用設(shè)計(jì)驗(yàn)證方法（DVM）驗(yàn)證需求DVMs contain all the information required to conduct testing and record resultsDVM包括所有要求試驗(yàn)和記錄結(jié)果的信息Existing and Generic DVMs can be used as a starting point to develop program DMVs, but they must be reviewed現(xiàn)

35、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Testing Methodologies試驗(yàn)方法學(xué)Types of Test試驗(yàn)的類型There are three general types of testing that can be implemented for either Design Verification or Production Validation: 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Testing to Bogey 標(biāo)準(zhǔn)測試Testing to Failure 測試至失效Testing Functional Degrada

36、tion 測試功能退化Test to BogeyMinimum Acceptable Function最小可接受功能最小可接受功能Function功能功能Time/Cycles/Miles時(shí)間時(shí)間/循環(huán)循環(huán)/里程里程Bogey失效柱狀圖失效柱狀圖Test to Failure測試至失效Failure Time DistributionMinimum Acceptable Function最小可接受功能最小可接受功能Function功能功能Time/Cycles/Miles時(shí)間時(shí)間/循環(huán)循環(huán)/里程里程失效時(shí)間分布圖失效時(shí)間分布圖Degradation Testing退化測試Minimum Acc

37、eptable Function最小可接受功能最小可接受功能Function功能功能Time/Cycles/Miles時(shí)間時(shí)間/循環(huán)循環(huán)/里程里程BogeyComplete DegradationHistoryExample: Functional Degradation of Three Design Alternatives范例：三種設(shè)計(jì)方案的功能退化CBATest Level Comparison測試水平比較Bogey標(biāo)準(zhǔn)Failure 失效Information Quality信息質(zhì)量信息質(zhì)量Cost成本成本Higher較高較高Lower較低較低Higher較高較高Lower較低較低D

38、egradation 退化Test Precision測試精度失效概率失效概率Statistical confidence for a given reliability estimate is the probability that the true reliability of the population is equal to or greater than the estimate.對(duì)于特定的可靠性預(yù)測，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)測情況的概率Large Sample大樣本大樣本Reduced Sample減少的樣本減少的樣本Min: 1 sample/failure

39、 mode最小：1個(gè)樣本/失效模式Severity/Acceleration of key noises in tests試驗(yàn)中關(guān)鍵干擾的嚴(yán)重度試驗(yàn)中關(guān)鍵干擾的嚴(yán)重度/加速加速Knowledge of prior perform-ance under similar conditions相似條件下優(yōu)先性相似條件下優(yōu)先性能的知識(shí)能的知識(shí)Normal通常通常High高高High高高Low低低FailureSeverity & Occurrence失效嚴(yán)重度失效嚴(yán)重度&發(fā)生發(fā)生Test Level測試水平測試水平BogeyFailureDegradationReal World Us

40、age Profiles真正顧客使用概況Types of Customer Usage顧客使用的類型Normal use一般使用Misuse誤用Abuse ?濫用？濫用？Normal Use一般使用Misuse誤用Abuse濫用Data Sources數(shù)據(jù)來源Yourself自身自身Instrumentation儀器儀器Existing Data現(xiàn)有數(shù)據(jù)現(xiàn)有數(shù)據(jù)Observation觀察觀察Actual Customer Usage真正顧客使用5% Total95th Percentile use95th 百分點(diǎn)使用 Core Target Customer(Marketing) 核心目標(biāo)顧客

41、（市場）Stress受力狀態(tài)受力狀態(tài)Europe歐洲歐洲Usage Profile and Customer Duty Cycle使用概況及顧客工況Usage Profile使用概況使用概況Duty Cycle工況工況How often the customer opens a window顧客開啟窗戶的頻次如何Number of switch activations or motor running times for the window motor 開關(guān)的次數(shù)或窗戶電機(jī)運(yùn)轉(zhuǎn)次數(shù)Climate or outside temperature ranges in which the vehic

42、le operates車輛運(yùn)轉(zhuǎn)時(shí)的氣候或外界溫度的范圍Air conditioning system frequency of operation and load空調(diào)系統(tǒng)的運(yùn)轉(zhuǎn)頻次和負(fù)荷Duty Cycle Example工況范例同步齒形帶發(fā)動(dòng)機(jī)工況同步齒形帶發(fā)動(dòng)機(jī)工況綠線：一般顧客綠線：一般顧客紅線：苛刻顧客紅線：苛刻顧客注：皮帶負(fù)荷在低轉(zhuǎn)注：皮帶負(fù)荷在低轉(zhuǎn) 速時(shí)更苛刻速時(shí)更苛刻Accelerated Testing加速測試Accelerated Testing加速測試Purpose:目的:Accumulate product stress history in a short perio

43、d of time 在短時(shí)間內(nèi)累積產(chǎn)品應(yīng)力史Shorten verification time & reduce development costs縮短驗(yàn)證時(shí)間&減少開發(fā)成本Accelerated Testing Methods加速測試方法Load Frequency over a Specified Test Procedure 在指定的試驗(yàn)規(guī)程上加大加載頻次在指定的試驗(yàn)規(guī)程上加大加載頻次010020030040030%60%100%Percent Frequency of Occurrence發(fā)生頻次的百分比發(fā)生頻次的百分比Load載荷載荷Normal Load正常負(fù)載正常

44、負(fù)載Increased Load加大負(fù)載加大負(fù)載Define Accelerated Test based on this portion of procedure with increased loads50 mph Freeway 50 mph高速公路高速公路Climbing hill in 1st gear一檔爬山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)上定義加速測試義加速測試Accelerated Testing Cautions加速測試警示Correlate acceleration to real world deterioration使其加

45、速形式與真正顧客使用的退化情況相關(guān)聯(lián)Prevent unrepresentative failure modes預(yù)防不具備代表性的失效模式Not all failure modes can be accelerated不是所有的失效模式都可以加速的Key Life Tests關(guān)鍵壽命試驗(yàn)Key Life Tests關(guān)鍵壽命試驗(yàn)Key Life Tests focus on the key stress(es) which drive loss of function and/or failure mechanisms associated with real world usage.關(guān)鍵壽命試

46、驗(yàn)著重于會(huì)促使真正顧客使用相關(guān)的功能損失關(guān)鍵壽命試驗(yàn)著重于會(huì)促使真正顧客使用相關(guān)的功能損失和和/或失效機(jī)理的關(guān)鍵應(yīng)力或失效機(jī)理的關(guān)鍵應(yīng)力Key Life Tests關(guān)鍵壽命試驗(yàn)A Key Life Test: 一個(gè)關(guān)鍵壽命試驗(yàn)Is based on the RWUP 是以RWUP為基礎(chǔ)的Provides a tool to evaluate product reliability 提供了一個(gè)工具以評(píng)估產(chǎn)品的可靠性Allows comparison of designs with benchmarked competitive products so that the best design c

47、an be identified 使其與競爭產(chǎn)品進(jìn)行設(shè)計(jì)的比較，從而可以確定最佳設(shè)計(jì)Validates models and assumptions in the design process 在設(shè)計(jì)過程中確認(rèn)模型和設(shè)想Validates the design 確認(rèn)設(shè)計(jì)Key Life Tests關(guān)鍵壽命試驗(yàn)IS是是IS Not否否Reliability and Robustness Demonstration Matrix可靠性和殷實(shí)可靠性實(shí)證矩陣圖Reliability and Robustness Demonstration Matrix可靠性和殷實(shí)可靠性實(shí)證矩陣圖Reliability

48、 and Robustness Demonstration Matrix (RRDM) captures and displays the key verification methods and all Critical Noise factors. 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。Self Assessment自我評(píng)估Vehicle Level DV & PV整車級(jí)別的DV&PVVerification and Validation of Vehicle level requirements整車級(jí)別的驗(yàn)證和確認(rèn)的要求Illustrated with

49、an example around a real world problem Transit FEAD穿插了一個(gè)真實(shí)問題的范例Transit FEADProblem問題Customers were experiencing problems after washing their vehicles or driving through water顧客在洗車或開車涉水后出現(xiàn)問題Global 8D全球8DA Global 8D was conducted on the van jet spray washing problem that was looked at earlier and the

50、root cause was identified as belt slip. 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?。Applying RED應(yīng)用REDHaving developed a fix for the problem the team needed to verify the change針對(duì)問題制定出解決方案，該小組需要驗(yàn)證其更改Verification is a key part of the 8D process, just as it is for the PDP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。To do thi

51、s they need to apply RED principles to the verification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。Verifying Robustness驗(yàn)證殷實(shí)可靠性Existing verification methods used as a starting point使用現(xiàn)有的驗(yàn)證方法作為起點(diǎn)From studying the data, the team new that the existing DVMs were insufficient通過研究該數(shù)據(jù)，小組發(fā)現(xiàn)現(xiàn)有的DVM還不充分New DVMs must include RED

52、considerations新的DVM必須包括RED需要考慮的事項(xiàng)Revised DVM修正的DVMThe DVMs were then modified. 于是對(duì)DVM進(jìn)行修改FEAD子系統(tǒng)設(shè)計(jì)驗(yàn)證方法子系統(tǒng)設(shè)計(jì)驗(yàn)證方法目標(biāo)：目標(biāo)：驗(yàn)證驗(yàn)證FEAD系統(tǒng)存有水時(shí)性能的殷實(shí)可靠性系統(tǒng)存有水時(shí)性能的殷實(shí)可靠性試驗(yàn)描述：在試驗(yàn)描述：在10kph至至50kph之間每次增加之間每次增加5kph的車速，開車通過的車速，開車通過25，50，75以及以及100mm深的水洼深的水洼可測量的可測量的/觀察：曲軸皮帶輪和附件皮帶輪之觀察：曲軸皮帶輪和附件皮帶輪之間的差速間的差速驗(yàn)收標(biāo)準(zhǔn)：差速小于驗(yàn)收標(biāo)準(zhǔn)：差速小于5

53、%需要的資源及試驗(yàn)設(shè)備：水洼，在已知的曲軸需要的資源及試驗(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Planning and Implementing Verification and Validation計(jì)劃并實(shí)施驗(yàn)證和確認(rèn)Planning occurs down the V plan the vehicle level first沿著V形方式向下作計(jì)劃首先計(jì)劃整車級(jí)別Verification and Validation occurs up the V Verify and Validate the vehicle last沿著V

54、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Global 8D and DV&PV全球8D和DV&PVGlobal 8D studies on previous similar products or processes help identify potential error states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)This is an important input to the design of verification methods for a new product or manufacturing process. 對(duì)于一個(gè)新產(chǎn)品或制

55、造過程，這是驗(yàn)證方法設(shè)計(jì)中的一個(gè)重要的輸入Verification methods must demonstrate that these error states do not recur in the new product or process. 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。Self Assessment自 評(píng)FEAD Sub-SystemFEAD子系統(tǒng)A FEAD system is to be developed for a new vehicle program 為一新車項(xiàng)目開發(fā)一個(gè)FEAD系統(tǒng)Sub-System Level Design Veri

56、fication子系統(tǒng)級(jí)別設(shè)計(jì)驗(yàn)證Form a cross functional team: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Aim to verify at the lowest possible level on the V瞄準(zhǔn)V模形最低可能級(jí)別上進(jìn)行驗(yàn)證FEAD Design Verification PlanFEAD設(shè)計(jì)驗(yàn)證計(jì)劃DV PlanDV計(jì)劃計(jì)劃SDS RequirementsSDS要求要求LegalRequirements法規(guī)要求法規(guī)要求Enginee

57、ringSpecifications工程技術(shù)規(guī)范工程技術(shù)規(guī)范Concept and Design FMEAs概念和設(shè)計(jì)概念和設(shè)計(jì)FMEAReal World Usage Profile真實(shí)顧客使用概況真實(shí)顧客使用概況P-DiagramP 圖圖Existing DVPs現(xiàn)有現(xiàn)有DVPGeneric DVMs一般一般DVMHistorical 8Ds歷史上的歷史上的8DKey Life Tests關(guān)鍵壽命試驗(yàn)關(guān)鍵壽命試驗(yàn)FEAD Function and OperationFEAD功能和運(yùn)行Ideal function of the FEAD is to transfer torque to th

58、e accessoriesFEAD的理想功能是把扭矩傳遞給附件Irregularity in rotation is a key noise旋轉(zhuǎn)不規(guī)則是一個(gè)關(guān)鍵的干擾The tensioner compensates for the noise張緊輪對(duì)該干擾進(jìn)行補(bǔ)償The correct functioning of the tensioner is a priority for the FEAD team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。Customer Requirements顧客需求FEAD SDS Requirement FEAD SDS 要求Belt span vibra

59、tion does not exceed 10% of belt span and meets system clearance requirements to other components. Maximum tensioner amplitude leaves 10% of total travel clear to end stop in both directions. 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。A DVM is required to verify this requirement

60、需要DVM來驗(yàn)證這一要求Existing DV Test現(xiàn)有的DV試驗(yàn)There is an existing DVM for the requirement對(duì)該要求有一現(xiàn)有的DVMThe team need to assess if this DVM is appropriate小組需要評(píng)估該DVM是否合適RED in Sub-System DV子系統(tǒng)DV中的REDSystem and Sub-System level DVMs must include consideration of noises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)In the FEAD example excessive belt vibration was identified as a critical error state.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)The DVM was assessed to be inadequate for this