DV-PV培訓課件：設計驗證和生產確認

DesignVerification

andProductionValidation設計驗證和生產確認WelcomeFordTechnicalEducation

Program福特技術培訓項目SystemsEngineeringFundamentals系統(tǒng)工程基本原理ParameterDesign參數(shù)設計ToleranceDesign公差設計FMEA失效模式后果與分析ExperimentalDesign實驗設計FTEP福特技術培訓項目Reliability可靠性AppliedConsumer

Focus應用顧客的關注DV&

PV設計驗證&生產確認Global

8D全球8DStatisticalEngineering統(tǒng)計工程學Course

Structure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VehicleLevel

DV整車級別的設計驗證System/Sub-SystemLevel

DV系統(tǒng)/子系統(tǒng)級別的設計驗證ComponentLevel

DV零部件級別的設計驗證System/Sub-SystemLevel

PV系統(tǒng)/子系統(tǒng)級別的生產確認ComponentLevel

PV零部件級別的生產確認Summary總結DesignVerification

and

ProductionValidation設計驗證和生產確認DesignVerification

andProductionValidation設計驗證和生產確認BenefittoFord

MotorCompany對福特汽車公司的益處DesignVerification

andProductionValidation設計驗證和生產確認Design

Verification:設計驗證asdesigned,aproductwillfunctioninthemannerthatthecustomer

expects.根據(jù)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,aproductfunctionsinthemannerthatthecustomerexpectsandcanbemanufacturedatrequired

volumes.根據(jù)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。DV&PVWithin

SystemsEngineering系統(tǒng)工程內的DV&PVVerificationand

SystemicThinking驗證和系統(tǒng)思想Customer

Wants顧客的需要Engineering

Targets工程目標Design

Verification設計驗證Requirements

Cascade需求逐級傳遞WorkinginaSystemsEngineering

contextsupportssystemic

thinking.系統(tǒng)工程中的工作支持系統(tǒng)的考慮OppositeofTraditionalapproachto

engineering.與傳統(tǒng)的工程方法相反Systems“V”

Model系統(tǒng)V模型DV&PVisarequirementsdriven

processDV和PV

是一個需求驅動的過程DV&PVisbestconductedinasystemsengineeringcontextthroughthesystems

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施。VehicleSystemSub-SystemComponentDefining

Requirements定義需求VehicleSystemSub-SystemComponentTherequirementscascadedowntheleft

side.需求的逐級傳遞如左側Thecascadeisaniterative

process.該逐級傳遞是一反復的過程ITERATIVEPLANNINGTop

Down由上到下Verification

Bottom-up驗證自下至上Verificationtestingisimplementedasabottom-upsequential

process.驗證試驗是按照自下至上的順序過程執(zhí)行的VerificationmayincludeacombinationofAnalyticalandphysical

tests.驗證可能包括分析試驗和物理試驗的組合。VehicleSystemSub-SystemComponentITERATIVEPLANNINGTop

Down自上至下Bottom

Up自下至上SEQUENTIALDOING反復計劃工作順序DV&PVand

PDSAPlanPlanPlanPlan計劃Do,Study,

Act 做，研究，行動Do,Study,

ActDo,Study,

ActDo,Study,

ActVehicle整車System系統(tǒng)Sub-System子系統(tǒng)Component零部件LowerLevel

Interactions較低級別的相互作用SystemsApproach

toManufacturing進行制造的系統(tǒng)方法Vehicle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機器設計制

造ngNote-S5/P5

TimiFPDS

TimingFPDS時間Vehiclelevel,Systemlevel&Sub-sys

level1DVP

Created生成整車，系統(tǒng)&子系統(tǒng)的DVPSub-syslevel

2&

ComponentDVP

Created生成子系統(tǒng)級別2&零部件DVPFullDVP

CreatedReqts&Targets

Frozen生成完整的DVP需求&目標凍結Componenttesting

complete零部件試驗完成Sub-system

andSystemtestingcomplete子系統(tǒng)和系統(tǒng)試驗完成Vehicletestingmostlycomplete:PrelimEngSign

Off整車試驗大部分完成：工程預簽發(fā)Vehicle

testingcomplete:FinalEngSignOff整車試驗完成：最終工程簽發(fā)DVP

completeDVP完成Design“V”andFPDSTimingDV&PV設計V形圖及FPDS時間的DV&PVLow低Time時間=

Design

Verification設計驗證=

Production

&

ProcessValidation生產&過程確認SI SC

PA

PR

CP LR J1High高ActivityLevel活動級別DV&PVand

FPDSDV&PVarekeyrequirementsfor

signoffofavehicleprogramDV和PV對于汽車項目的簽發(fā)來說是關鍵的需求KeySignoffmilestones

are:關鍵簽發(fā)節(jié)點是：(CC)—

DV(LR)—

PV(LS)—

PVInputsUsedintheVerificationandValidation

Processes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FMEARealWorldUsage

Profile真正的顧客使用狀況P-DiagramP圖Existing

DVPs現(xiàn)有的DVPGeneric

DVMs一般DVMHistorical

8Ds歷史上8DKeyLife

Tests關鍵壽命試驗DV&PVasPartofthe

ProductCreation

ProcessDV

和PV作為產品創(chuàng)造過程的部分DVandPVconfirmthatComponentsandsystemrobustlymeetcustomer

requirementsDV和PV確認零部件和系統(tǒng)殷實可靠地符合顧客的需求。DV&PVtestingisnot

exploratoryDV和PV試驗不是探險Testingshouldbeagainstexpectedresultsnot

tofind

out“whathappens

if”試驗應該是針對所預測的結果而不是去發(fā)現(xiàn)“如果…會怎樣”DV&PVcomesafterthedesignphasenot

duringthe

designphaseDV

和PV

要在設計以后而不是在設計階段中進行Introductionofthe

FEADExampleFEAD舉例介紹FEAD

ExampleFEAD范例AsinglesystemtheFEAD(FrontEnd

AccessoryDrive)willbeusedtodemonstrateDV&

PV使用一個單獨的系統(tǒng)FEAD（前端附件驅動）來示范DV&PVTheFrontEndAccessoryDrive(FEAD)–HowIt

WorksFEAD-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?shù)紽EAD附件上。TheFEADtransmitsthis

energyFEAD傳輸該能量DesignVerificationatAll

Levels所有級別上的設計驗證DesignVerificationshouldoccurat

alllevelswiththeemphasisbeingatthelower

levels.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。Production

Validation生產確認Itisimportanttoverifythedesign驗證設計是重要的Itisequallyimportanttovalidatethattheproductionprocessusedtomanufacturethebeltisabletoproducebeltstothedesign

specification.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,thebeltasmanufacturedmustbeable

totransmittherequiredamountof

torque.例如，所制造的皮帶必須能轉送所要求大小的扭矩。ConfirmingRobustand

ReliableDesign–

Robustness確認殷實及可靠的設計-殷實可靠性ToolsForDV&

PVDV&PV的工具MethodsUsedinEfficientandEffective

Verification在有效且高效的驗證中使用的方法Someoftheimportantmethodsusedinefficientand

effectiveverificationandvalidationprocesses

are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RealWorldUsageProfilesandDuty

Cycles真正全球顧客使用的概況和工況Accelerated

Tests,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RobustEngineering

Design(RED)殷實的工程設計RobustTest

Plans殷實可靠的試驗計劃RobusttestplansinDV&PVincorporateNoisefactorsandtheireffectsinordertoensurethattheproductwillmeetitsdesignintentunderallconditions.Noisefactorscanbegroupedintofive

categories: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-Piece

Variation件與件間的變差ChangesOver

Time隨著時間過去的變化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NoiseFactor

Management干擾因素的管理Test/TechnologyChange試驗/技術更改RobustDesignbyParameterDesign通過參數(shù)設計的牢靠設計RobustDesignbyIncreasedStrength通過增加強度的牢靠的設計RemoveorReduce

Noise去除或減小干擾CompensationDevice補償裝置DisguisetheProblem隱蔽問題InternalEnvironment(SystemInteractions)內部環(huán)境（系統(tǒng)交互作YesYesYesSystemFMEAYesSystemFMEAExternalEnvironment(Climate/RoadConditions)外部環(huán)境（氣候/路況）YesYesYesNoPieceto

PieceVariation件與件間的差異YesYesYesSPCChangesOver

Time(Wear

Out)隨著時間產生的變化（磨損）YesYesMaterialsEngineeringYesSystemFMEACustomerUsage顧客使用YesYesYesNoRobustEngineering

Design殷實可靠的工程設計RobustEngineeringDesign(RED)isprimarilyadesign

tool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。REDfocusesonidentification

andmanagementofnoise

factorsRED著重于干擾因素的識別和管理RobustEngineering

Design殷實可靠的工程設計REDisinherentinthesystemsVandrunsthroughallphasesofthe

VRED是系統(tǒng)V內固有的，并且貫穿系統(tǒng)V的所有階段REDisateambased

processRED是以小組為基礎的過程REDappliesthroughoutFord(DesignandManufacturing)andat

suppliersRED應用于整個福特（設計和制造）以及供應商。Applying

RED應用REDREDallows

testingatthelowestpossiblelevelRED允許在最低可能性級別進行測試Cautionmust

beused必須使用警示RedAppliedtoVehicleLevel

TestingRed應用于整車級別的測試REDAppliedat

Sub-SystemLevelRED應用于子系統(tǒng)級別WhendevelopingDesignVerificationMethodsatthesystem/sub-systemorcomponentlevel,itisimportanttoensurethattheeffectsofSystemInteractionNoisefactorsthatarepresentinthetotalvehicleenvironmentare

included.當開發(fā)系統(tǒng)/子系統(tǒng)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(xiàn)的系統(tǒng)交互作用干擾因素的影響。REDAppliedatComponent

LevelRED應用于零部件級別Atthecomponentleveltestingismostefficentbutinteractionswithothercomponentsare

lost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Testplansmustcompensateforthislossbyreproducing

thekeystressesfromthe

interactions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Muchcomponenttestingmaybedoneat

suppliers.許多零部件試驗可能在供應商處進行。SuppliersmustapplythesameRED

methodolgies供應商必須應用相同的RED方法Tosupportthis,Fordengineersneedtocascade

noisefactorstothe

supplier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REDintheDesign

Process設計過程中 ED的RNoise

Factors干擾因素Piece

to

Piece件與件Aging/Wear老化/磨損Customer

Usage顧客使用Environment環(huán)境Subsystem

Interaction子系統(tǒng)交互作用Sourcesthatdisruptidealfunctionthatcannot

becontrolled(e.g..column

friction)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/RobustnessDemonstration

Matrix可靠性/殷實可靠性實證矩陣圖Signal信號Energyputintothesystemstomakeitwork(e.g..Steeringwheel

angle)能量進入系統(tǒng)使其工作（例如..方向盤轉角）Control

FactorsFeaturesofthedesignthatcanbecontrolled(e.g..Torsionbarrate)控制因素可以控制的設計特性（例如..扭桿比率）States 異常狀態(tài)UndesirableoutputorFailureModes(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)AvailableTests有用的試驗Failuremode

totest

traceability失效模式試驗可追查性NoiseFactorsManagement

StrategySystem(Steering

System)系統(tǒng)（轉向系統(tǒng)）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）ErrorFMEAWCR

SDSDOE(if

necessary如果有必要)WCR KLT DVP&RIn

scope范圍內FDVSFDVSPreventionofMistake

Reoccurrence錯誤再次發(fā)生的預防Campaign

Prevent防召回Lessons

Learned吸取的教訓Vigilance警惕FailureMode失效模式Test試驗CriticalNoiseFactors關鍵干擾因素DemonstratedResult論證的結果.

.. .

...

. .干擾Noise 因素Factors 管干擾因素

理策略FordDesign

VerificationSystem福特設計驗證系統(tǒng)FordDesignVerificationSystem–

FDVS福特設計驗證系統(tǒng)-FDVSFDVSisacomputerbasedsystemtocreateandmanagerequirementsdrivenDV

plans.FDVS是一計算機為基礎的系統(tǒng)，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(tǒng)要求（項目專有）DVM（項目專有）DesignVerification

Method設計驗證方法WithinFDVSrequirementsareverifiedusingDesignVerificationMethods

(DVMs)在FDVS內，使用設計驗證方法（DVM）驗證需求DVMscontainalltheinformationrequiredtoconducttestingandrecord

resultsDVM包括所有要求試驗和記錄結果的信息ExistingandGenericDVMscanbeusedasastartingpointtodevelopprogramDMVs,buttheymustbe

reviewed現(xiàn)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Testing

Methodologies試驗方法學Typesof

Test試驗的類型TherearethreegeneraltypesoftestingthatcanbeimplementedforeitherDesignVerificationorProduction

Validation: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Testingto

Bogey標準測試Testingto

Failure測試至失效TestingFunctional

Degradation測試功能退化Testto

BogeyMinimum

AcceptableFunction最小可接受功能Function功能Time/Cycles/Miles時間/循環(huán)/里程BogeyFailureHistogramPassFail失效柱狀圖Test

to

Failure測試至失效FailureTimeDistributionMinimumAcceptableFunction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Degradation

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

DegradationHistoryExample:Functional

DegradationofThreeDesignAlternatives范例：三種設計方案的功能退化109876543025,00050,000125,000150,000Design

A Design

B DesignCFunction(higherthe

better)75,000 100,000MilesCBATestLevel

Comparison測試水平比較Failure失效Bogey標準Cost成本Information

Quality信息質量Higher較高Lower較低Higher較高Lower較低Degradation退化Test

Precision測試精度失效概率Statistical

Confidence統(tǒng)計可信度Statisticalconfidenceforagivenreliabilityestimateistheprobabilitythatthetruereliabilityofthepopulationisequaltoorgreaterthanthe

estimate.對于特定的可靠性預測，統(tǒng)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EngineeringConfidenceReducesSample

Size工程可信度減小樣本量Large

Sample大樣本ReducedSample減少的樣本Min:1sample/failure

mode最?。?個樣本/失效模式FailureSeverity&Occurrence失效嚴重度&發(fā)生Test

Level測試水平BogeyFailureDegradationRealWorldUsage

Profiles真正顧客使用概況TypesofCustomer

Usage顧客使用的類型Normal

use一般使用Misuse誤用Abuse

?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Instrumentation儀器Existing

Data現(xiàn)有數(shù)據(jù)Observation觀察Percentiles百分點ActualCustomer

Usage真正顧客使用5%Total95thPercentileuse95th

百分點使用CoreTargetCustomer(Marketing)核心目標顧客（市場）Example:Cooling

Fan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UsageProfileandCustomerDutyCycle使用概況及顧客工況Usage

Profile使用概況Duty

Cycle工況Howoftenthe

customeropensawindow顧客開啟窗戶的頻次如何Numberofswitchactivationsormotorrunningtimesforthewindow

motor開關的次數(shù)或窗戶電機運轉次數(shù)Climateoroutsidetemperaturerangesinwhichthevehicle

operates車輛運轉時的氣候或外界溫度的范圍Airconditioningsystemfrequencyofoperationandload空調系統(tǒng)的運轉頻次和負荷DutyCycle

Example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Accelerated

Testing加速測試Accelerated

Testing加速測試Purpose:目的:Accumulateproductstresshistoryinashortperiodoftime在短時間內累積產品應力史Shortenverificationtime&reducedevelopment

costs縮短驗證時間&減少開發(fā)成本AcceleratedTesting

Methods加速測試方法0100200300LoadFrequencyoveraSpecifiedTest

Procedure在指定的試驗規(guī)程上加大加載頻次40030%

60%

100%Percent

Frequency

of

Occurrence發(fā)生頻次的百分比Load載荷Normal

Load正常負載 IncreasedLoad加大負載portionofprocedurewithincreased

loadsDefineAcceleratedTestbasedon

this50

mph

Freeway

50

mph高速公路Climbing

hillin1st

gear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AcceleratedTesting

Cautions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(lián)Preventunrepresentativefailure

modes預防不具備代表性的失效模式Notallfailuremodescanbe

accelerated不是所有的失效模式都可以加速的KeyLife

Tests關鍵壽命試驗KeyLife

Tests關鍵壽命試驗KeyLifeTestsfocusonthekeystress(es)whichdrivelossoffunctionand/orfailuremechanisms

associatedwithrealworld

usage.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KeyLife

Tests關鍵壽命試驗AKeyLife

Test:一個關鍵壽命試驗Isbasedonthe

RWUP是以RWUP為基礎的Providesatooltoevaluateproduct

reliability提供了一個工具以評估產品的可靠性Allowscomparisonofdesignswithbenchmarked

competitiveproductssothatthebestdesigncanbe

identified使其與競爭產品進行設計的比較，從而可以確定最佳設計Validatesmodelsandassumptionsinthedesign

process在設計過程中確認模型和設想Validatesthe

design確認設計KeyLife

Tests關鍵壽命試驗IS是IS

Not否Reliabilityand

RobustnessDemonstration

Matrix可靠性和殷實可靠性實證矩陣圖Reliability

and

RobustnessDemonstration

Matrix可靠性和殷實可靠性實證矩陣圖ReliabilityandRobustnessDemonstrationMatrix(RRDM)capturesanddisplaysthekeyverificationmethodsandallCriticalNoise

factors.RRDM吸取并顯示了關鍵驗證方法以及所有的關鍵干擾因素。Self

Assessment自我評估VehicleLevelDV&

PV整車級別的DV&PVVehicleLevelDV&

PV整車級別的DV&PVVerificationandValidationofVehiclelevel

requirements整車級別的驗證和確認的要求Illustratedwithanexamplearound

arealworldproblem–Transit

FEAD穿插了一個真實問題的范例—TransitFEADProblem問題Customerswereexperiencing

problemsafterwashingtheirvehiclesordrivingthrough

water顧客在洗車或開車涉水后出現(xiàn)問題Global

8D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。Applying

RED應用REDHavingdevelopedafixfortheproblem

theteamneededtoverifythe

change針對問題制定出解決方案，該小組需要驗證其更改Verificationisakeypartofthe8D

process,justasitisforthe

PDP驗證是8D過程中的一個關鍵部分，就象其相對于PDP一樣。TodothistheyneedtoapplyREDprinciplestothe

verification為了進行該工作，他們需要把RED的原理應用到驗證上。Verifying

Robustness驗證殷實可靠性Existingverificationmethodsusedasastarting

point使用現(xiàn)有的驗證方法作為起點Fromstudyingthedata,theteamnewthattheexistingDVM’swere

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NewDVMsmustincludeRED

considerations新的DVM必須包括RED需要考慮的事項Revised

DVM修正的DVMTheDVMswerethen

modified.于是對DVM進行修改FEAD子系統(tǒng)設計驗證方法目標：驗證FEAD系統(tǒng)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Planningand

ImplementingVerificationandValidation計劃并實施驗證和確認PlanningoccursdowntheV–planthevehiclelevel

first沿著V形方式向下作計劃—首先計劃整車級別VerificationandValidationoccursuptheV–Verify

andValidatethevehicle

last沿著V形方式向上進行驗證和確認—最后驗證和確認整車Global8Dand

DV&PV全球8D和DV&PVGlobal8Dstudiesonprevioussimilarproducts

orprocesseshelpidentifypotentialerror

states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)Thisisanimportantinputtothedesignof

verificationmethodsforanewproductormanufacturing

process.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。Self

Assessment自

評System/Sub-System

LevelDV系統(tǒng)/子系統(tǒng)級別DVFEAD

Sub-SystemFEAD子系統(tǒng)AFEADsystemistobedevelopedfor

anewvehicle

program為一新車項目開發(fā)一個FEAD系統(tǒng)Sub-SystemLevel

DesignVerification子系統(tǒng)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Aimtoverifyatthelowestpossiblelevelonthe

V瞄準V模形最低可能級別上進行驗證FEADDesignVerification

PlanFEAD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Concept

andDesign

FMEAs概念和設計FMEARealWorldUsage

Profile真實顧客使用概況P-DiagramP

圖Existing

DVPs現(xiàn)有DVPGeneric

DVMs一般DVMHistorical

8Ds歷史上的8DKeyLife

Tests關鍵壽命試驗FEADFunctionand

OperationFEAD功能和運行IdealfunctionoftheFEADistotransfertorque

tothe

accessoriesFEAD的理想功能是把扭矩傳遞給附件Irregularityinrotationisakey

noise旋轉不規(guī)則是一個關鍵的干擾Thetensionercompensatesforthe

noise張緊輪對該干擾進行補償Thecorrectfunctioningofthetensioneris

apriorityfortheFEAD

team張緊輪的正確機能對于前端驅動附件組是最首要的。Customer

Requirements顧客需求FEADSDSRequirementFEAD

SDS

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(tǒng)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。ADVMisrequiredtoverifythis

requirement需要DVM來驗證這一要求ExistingDV

Test現(xiàn)有的DV試驗ThereisanexistingDVMfor

therequirement對該要求有一現(xiàn)有的DVMTheteamneedtoassessifthisDVM

isappropriate小組需要評估該DVM是否合適REDinSub-System

DV子系統(tǒng)DV中的REDSystemandSub-SystemlevelDVMs

mustincludeconsiderationofnoises系統(tǒng)和子系統(tǒng)級別的DVM必須包括干擾需要考慮的事項IntheFEADexampleexcessivebeltvibrationwasidentifiedasacriticalerror

state.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)TheDVMwasassessedtobeinadequateforthisfailuremodeinthepresenceof

noise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FEADAcceptance

CriteriaFEAD驗收標準Theacceptancecriteriawasassessedbytheteamandfoundtocoverthe

SDSrequirement,butneededminorimprovement.小組評估該驗收標準，發(fā)現(xiàn)涵蓋了SDS的要求，但仍需要小的改進。Applicationof

REDRED的應用Theteamneedstoconsiderallkeynoise

factors小組需要考慮所有關鍵干擾因素Thekeynoisefactorswereidentified

as:確認關鍵噪聲為：Carryovertensionerinanew

environment在新的環(huán)境中借用張緊輪裝置Accessory

loading附加載荷TheseNoisefactorswerenottakenintoaccountintheprevious

DVM.在以前的DVM中沒有考慮這些干擾因素PreviousRobustness

Studies之前的殷實可靠性研究Previousrobustnessstudiesareakeysource

ofinformation之前的殷實可靠性研究是信息的關鍵來源Theteamcanusethisinformationfor

theirdesignand

testing小組可以把這一信息用于設計和測試Thistypeofinformationcancomefrom

similarordifferentvehicles這種類型的信息可以來自相似或不同的車輛Thesestrategieswereincorporatedintothe

newdesign.這些策略可以并入新的設計中CheckofDVMObjectiveDVM目標的檢查ThedesignteamdidnotthinkthattheobjectiveintheexistingDVMcovered

robustness設計小組不認為現(xiàn)有DVM中的目標涵蓋了殷實可靠性DVMObjectiverevisedtoinclude

robustness修正DVM目標，使其包括殷實可靠性DVMTest

MethodDVM試驗方法Theteamthenturneditsattentiontothetestmethod然后小組把注意力轉向試驗方法Thismethodhadbeenusedonpreviousprogramsbuttheseprogramshadexperienced

failures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(xiàn)過失效Applying

RED應用REDAREDapproach,wasusedtomodify

theDVM.采用RED的方法修改DVMAG8Dstudyhadbeenconductedto

resolvethebeltsquealproblemonthepreviousvehicle.采用了全球8D的研究來解決原來車輛上皮帶尖叫的問題TheG8Diskeyinformationfor

RED全球8D對于RED是關鍵的信息Global8DSummary

Report全球8D總結報告Global8DSummary

Findings全球8D總結調查結果5：選擇永久糾正措施：采用參數(shù)設計實驗以增加在附加載荷的干擾因素存在時FEAD系統(tǒng)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%Confirming

Robustness確定殷實可靠性ThesuccessfulimprovementoftheFEADrobustnesstodifferentaccessoryloadingconditionsmeantthatoneof

theteam'sprioritieswastoensurethatthisrobustnesswouldbeconfirmedbytherevised

DVM.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。DesignFMEA

Review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?shù)牟牧咸匦?。阻尼帶材料特性的退化P-DiagramasSourceofInformationP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(tǒng)FMEAtoP-DiagramCross

CheckFMEA對P圖的交叉檢查FMEA

ContentsFMEA內容Potential

Cause(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(shù)更改(P-diagramNoise

factor)External

Environment（P圖干擾噪聲因素）外部環(huán)境Driving

terrain行駛地形Temperature

溫度Humidity

濕度Water

水Contamination

污染Potential

Cause(s)/Mechanism(s)

of

Failure潛在原因/失效機理FEAD

Sub-SystemDesign

FMEAFEAD子系統(tǒng)設計FMEABeltspanVibrationdue

to:Insufficientsystemdampingduetocrankshaftcyclicirregularitygreaterthansystemdesign

assumptionsSystem

Interactions:系統(tǒng)交互作用Engine

calibration發(fā)動機標定Crankshaft

irregularity曲軸不規(guī)則Accessoryload

requirements相帶寬度振動由于：由于曲軸循環(huán)不規(guī)則性要比系統(tǒng)設計設想的大而造成系統(tǒng)阻尼不足附加載荷的要求Numberandtypeof

accessories附件的數(shù)量及類型Routing(with/without

AC)路由（帶/不帶空調）Accessory

wear附件磨損Torsional

vibration扭轉振動Wrapangle

variation包角振動P-Diagram/FMEAInputsinto

DVMP圖/FMEA

輸入到DVMOriginal

DVM原始DVMUsingCAEasPartofVerification使用CAE作為驗證的一部分TheDesignTeam’sCAErepresentativehashighlightedtotheteamthataCAEmodeloftheFEADis

available設計小組的CAE代表向小組強調FEAD的CAE模型已經具備TheCAEmodelneedstobe

calibratedCAE模型需要進行校準Thecalibrationwillallowthemodeltohaveongoing

usefulness標定將使得模型具有正在進行的有效性ModificationofDVMTest

DescriptionDVM試驗描述的更改Previous

TestDescription以前的試驗描述Usingavideocameraand,ifnecessary,astrobelight,recordtheFEADsystemwhiletheengineisonadynosubjectto

load.ScalesmaybeplacedalongsidethebeltandtensionersothataroughestimatecanbemadeofAmplitudeof

movement.Sweeptheenginefromidletomaximum

speed.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(tǒng)?？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。Modified

TestDescription更改后的試驗描述CAEsimulation:Modelbasedonparameterdesignexperimentandincludetheeffectofcyclicirregularityatthecrankpulleyonbeltandtensionervibration.TheeffectofthefollowingtobeincludedasNoise

factors:CAE模擬：參數(shù)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(includingworst

case)附件載荷（的不同級別）（包括最糟糕的情況）Belt

routing皮帶的路由Variationofbeltelastic

properties皮帶彈性特性的變差Temperature溫度Aging/durabilityofFEAD

componentsFEAD零件的老化/耐久性ManufacturingPiece-to-Piece

Variation件與件間的制造變差ModificationofMeasurables/ObservablesandAcceptance

Criteria測量/觀察和驗收標準的更改Measurables/Observations測量/觀察AmplitudeofbeltspanvibrationandTensionerarmmovementas

afunctionof

frequency.作為頻數(shù)的作用，測量/觀察相帶寬度振動的振幅和張緊輪臂的運動AcceptanceCriteria標準Amplitudeversusfrequencydistributionwithinaccepted

limit.振幅相對頻率的分布要在可接受的限度內。Maximumtensioneramplitudeleaves10%oftotaltravelcleartoend

stop.最大張緊輪振幅要與端頭止點留有總行程10%的間隙余量。Beltspanvibrationamplitudedoesnotexceed10%ofbeltspanandmeetssystemclearancerequirementstoothercomponents.相帶寬度振動振幅不超過相帶寬度的10%，要符合與其它零部件間的系統(tǒng)間隙要求。ModificationofResourceand