福特公司DVPV培训教材ppt课件

1、Design Verification and Production Validation设计验证和生产确认WelcomeFord Technical Education Program福特技术培训项目Systems EngineeringFundamentals系统工程基本原理Parameter Design参数设计ToleranceDesign公差设计Global 8D全球8DFMEA失效模式后果与分析ExperimentalDesign实验设计FTEP福特技术培训项目Reliability可靠性Applied Consumer Focus应用顾客的关注DV & PV设计验证&生产确认St

2、atistical Engineering统计工程学Course Structure课程结构Introduction to DV & PV对设计验证及生产确认的介绍Tools for DV & PV设计验证及生产确认的工具Vehicle Level DV整车级别的设计验证System/Sub-System Level DV系统/子系统级别的设计验证Component Level DV零部件级别的设计验证System/Sub-System Level PV系统/子系统级别的生产确认Component Level PV零部件级别的生产确认Summary总结Design Verification a

3、nd Production Validation设计验证和生产确认Design Verification and Production Validation设计验证和生产确认Benefit to Ford Motor Company对福特汽车公司的益处Design Verification and Production Validation设计验证和生产确认Design Verification: 设计验证as designed, a product will function in the manner that the customer expects. 根据设计状态，一个产品的功能要符合

4、顾客所期望的方式。Production Validation: 生产确认as manufactured, a product functions in the manner that the customer expects and can be manufactured at required volumes. 根据制造状态，一个产品的功能要符合顾客所期望的方式，而且能以所要求的产量进行生产。DV&PV Within Systems Engineering系统工程内的DV&PVVerification and Systemic Thinking验证和系统思想Customer Wants顾客的

5、需要Engineering Targets工程目标Design Verification设计验证Requirements Cascade需求逐级传递Working in a Systems Engineering context supports systemic thinking.系统工程中的工作支持系统的考虑 Opposite of Traditional approach to engineering. 与传统的工程方法相反Systems “V” Model系统V模型DV&PV is a requirements driven processDV和PV 是一个需求驱动的过程DV&PV i

6、s best conducted in a systems engineering context through the systems V. DV和PV在贯穿系统V模型的系统工程中得到最好的实施。 VehicleSystemSub-SystemComponentDefining Requirements定义需求The requirements cascade down the left side. 需求的逐级传递如左侧The cascade is an iterative process. 该逐级传递是一反复的过程 VehicleSystemSub-SystemComponentITERA

7、TIVE PLANNINGTop Down由上到下Verification Bottom-up验证自下至上Verification testing is implemented as a bottom-up sequential process. 验证试验是按照自下至上的顺序过程执行的Verification may include a combination of Analytical and physical tests.验证可能包括分析试验和物理试验的组合。 VehicleSystemSub-SystemComponentITERATIVE PLANNINGTop Down自上至下Bot

8、tom Up自下至上SEQUENTIAL DOING反复计划工作顺序DV & PV and PDSAPlanPlanPlan Plan计划 Do, Study, Act 做，研究，行动 Do, Study, ActDo, Study, ActDo, Study, ActVehicle整车System系统Sub-System子系统Component零部件Lower Level Interactions较低级别的相互作用Systems Approach to Manufacturing进行制造的系统方法VehicleSystemSub-SystemComponentPlantAssemblyOpe

9、rationMachineVehicle整车System系统Sub-System子系统Component零部件ManufacturingDesignPlant 工厂Assembly 装配Operation 操作Machine机器设计制 造Note - S5/P5 TimingFPDS TimingFPDS时间Vehicle level,System level& Sub-sys level1DVP Created生成整车，系统&子系统的DVPSub-sys level 2& ComponentDVP Created生成子系统级别2&零部件DVPFull DVP CreatedReqts & T

10、argets Frozen生成完整的DVP需求&目标冻结Component testing complete零部件试验完成Sub-system and System testing complete子系统和系统试验完成Vehicle testing mostly complete:Prelim Eng Sign Off整车试验大部分完成：工程预签发Vehicle testing complete:Final Eng Sign Off整车试验完成：最终工程签发DVP completeDVP完成Design “V” and FPDS TimingDV&PV设计V形图及FPDS时间的DV&PVLow

11、低High高ActivityLevel活动级别Time时间= Design Verification设计验证= Production & Process Validation生产&过程确认SISCPAPRCPLRJ1DV & PV and FPDSDV & PV are key requirements for sign off of a vehicle programDV和PV对于汽车项目的签发来说是关键的需求Key Sign off milestones are:关键签发节点是：(CC) DV(LR) PV(LS) PVInputs Used in the Verification and

12、 Validation Processes在验证和确认过程中使用的输入DV Plan设计验证计划SDS RequirementsSDS的需求LegalRequirements法规要求EngineeringSpecifications工程技术规范Concept and Design FMEAs概念和设计FMEAReal World Usage Profile真正的顾客使用状况P-DiagramP图Existing DVPs现有的DVPGeneric DVMs一般DVMHistorical 8Ds历史上8DKey Life Tests关键寿命试验DV&PV as Part of the Produ

13、ct Creation Process DV 和PV作为产品创造过程的部分DV and PV confirm that Components and system robustly meet customer requirementsDV和PV确认零部件和系统殷实可靠地符合顾客的需求。DV & PV testing is not exploratoryDV和PV试验不是探险Testing should be against expected results not to find out “what happens if”试验应该是针对所预测的结果而不是去发现“如果会怎样”DV&PV come

14、s after the design phase not during the design phaseDV 和PV 要在设计以后而不是在设计阶段中进行Introduction of the FEAD ExampleFEAD举例介绍FEAD ExampleFEAD范例A single system the FEAD (Front End Accessory Drive) will be used to demonstrate DV & PV使用一个单独的系统FEAD（前端附件驱动）来示范DV&PVThe Front End Accessory Drive (FEAD) How It Works

15、FEAD-它如何工作The source of power in the vehicle is the engine. 汽车内动力的来源是发动机Part of the rotational power output from the engine needs to be transmitted to the FEAD accessories. 来自发动机转动动力输出的一部分需要被传输到FEAD附件上。The FEAD transmits this energyFEAD传输该能量Design Verification at All Levels所有级别上的设计验证Design Verificat

16、ion should occur at all levels with the emphasis being at the lower levels. 设计验证应该重点放在较低级别的情况下在所有级别上进行。Production Validation生产确认It is important to verify the design 验证设计是重要的It is equally important to validate that the production process used to manufacture the belt is able to produce belts to the de

17、sign specification. 确认制造皮带所使用的生产过程能够生产出符合设计规范的皮带同等地重要。For example, the belt as manufactured must be able to transmit the required amount of torque.例如，所制造的皮带必须能转送所要求大小的扭矩。Confirming Robust and Reliable Design Robustness确认殷实及可靠的设计-殷实可靠性Tools For DV & PVDV&PV的工具Methods Used in Efficient and Effective V

18、erification在有效且高效的验证中使用的方法Some of the important methods used in efficient and effective verification and validation processes are 在有效且高效的验证和确认过程中所使用的一些重要方法是Robust Engineering Design Philosophy (RED)殷实的工程设计基本定律Ford Design Verification System (FDVS)福特设计验证体系Testing Methodologies,试验方法学Real World Usage P

19、rofiles and Duty Cycles真正全球顾客使用的概况和工况Accelerated Tests, 加速试验Key Life Tests (KLT), 关键寿命试验Computer Aided Engineering (CAE)计算机辅助工程Design of Experiment (DoE).实验设计Robust Engineering Design(RED)殷实的工程设计Robust Test Plans殷实可靠的试验计划Robust test plans in DV&PV incorporate Noise factors and their effects in order

20、 to ensure that the product will meet its design intent under all conditions. Noise factors can be grouped into five categories: 为了确保该产品在所有条件下都符合其设计意图，DV和PV中殷实的试验计划合并了干扰因素及其他们的影响。干扰因素可以分成5类：Piece-to-Piece Variation 件与件间的变差Changes Over Time 随着时间过去的变化Customer Usage 顾客的使用External Environment 外部环境System

21、 Interactions 系统间的交互作用Noise Factor Management干扰因素的管理Robust Engineering Design殷实可靠的工程设计Robust Engineering Design (RED) is primarily a design tool殷实的工程设计主要是一种设计工具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中必须考虑到RED，因为RED将决定需要采取的DV&PV试验的类型

22、。RED focuses on identification and management of noise factorsRED着重于干扰因素的识别和管理Robust Engineering Design殷实可靠的工程设计RED is inherent in the systems V and runs through all phases of the VRED是系统V内固有的，并且贯穿系统V的所有阶段RED is a team based processRED是以小组为基础的过程RED applies throughout Ford (Design and Manufacturing)

23、and at suppliersRED应用于整个福特（设计和制造）以及供应商。Applying RED应用REDRED allows testing at the lowest possible levelRED允许在最低可能性级别进行测试Caution must be used必须使用警示Red Applied to Vehicle Level Testing Red应用于整车级别的测试RED Applied at Sub-System LevelRED应用于子系统级别When developing Design Verification Methods at the system/sub-

24、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.当开发系统/子系统或零部件级别的设计验证方法时，重要的是确保要包括整个汽车环境中出现的系统交互作用干扰因素的影响。RED Applied at Component LevelRED应用于零部件级别At the component level testing is

25、 most efficent but interactions with other components are lost零部件级别的试验是最有效的，但失去了与其他零件的交互作用Test plans must compensate for this loss by reproducing the key stresses from the interactions试验计划必须通过再制造来自交互作用的关键应力弥补这一损失Much component testing may be done at suppliers.许多零部件试验可能在供应商处进行。Suppliers must apply th

26、e same RED methodolgies供应商必须应用相同的RED方法To support this, Ford engineers need to cascade noise factors to the supplier为了支持这个，福特工程师需要逐层传递干扰因素直到供应商RED in the Design Process设计过程中的RED Noise Factors干扰因素Piece to Piece件与件Aging/Wear老化/磨损Customer Usage顾客使用Environment环境Subsystem Interaction子系统交互作用Sources that di

27、srupt idealfunction that can not be controlled (e.g. column friction)不可控制的，破坏理想功能的来源（例如.转向柱磨擦）P-DiagramReliability Checklist 可靠性检查清单Reliability/RobustnessDemonstration Matrix 可靠性/殷实可靠性实证矩阵图Signal信号Energy put intothe systems tomake it work(e.g. Steeringwheel angle)能量进入系统使其工作（例如.方向盘转角）Control FactorsF

28、eatures of the designthat can be controlled(e.g. Torsion bar rate)控制因素可以控制的设计特性（例如.扭杆比率）ErrorStates异常状态Undesirable outputor Failure Modes(e.g. Tire slip)不需要的输出或失效模式（例如.轮胎打滑）Error States异常状态 NoiseFactors干扰因素 AvailableTests有用的试验DVP&RTest试验CriticalNoiseFactors关键干扰因素Failure mode totest traceability失效模式试

29、验可追查性 Noise FactorsManagement StrategySystem(Steering System)系统（转向系统）IdealFunction理想功能Primary intendedfunction of the design设计的主要意图功能(e.g. Lateral accelerationof vehicle)（例如.车辆的横向加速度）FMEASDSWCRDOE(if necessary如果有必要)KLTWCRFailureMode失效模式DemonstratedResult论证的结果In scope范围内FDVSFDVSPrevention of Mistake

30、Reoccurrence错误再次发生的预防Campaign Prevent 防召回Lessons Learned 吸取的教训Vigilance 警惕. . .干扰因素管理策略Ford Design Verification System福特设计验证系统Ford Design Verification System FDVS福特设计验证系统-FDVSFDVS is a computer based system to create and manage requirements driven DV plans.FDVS是一计算机为基础的系统，生成并管理驱动DV计划的需求。FDVS include

31、s a number of generic requirements and Design Verification Methods (DVMs)FDVS包括许多一般需求和设计验证方面（DVM）安全法规法人的要求技术规范设计验证方法整车要求（项目专有）项目专有的设计验证计划系统要求（项目专有）DVM（项目专有）Design Verification Method设计验证方法Within FDVS requirements are verified using Design Verification Methods (DVMs)在FDVS内，使用设计验证方法（DVM）验证需求DVMs conta

32、in all the information required to conduct testing and record resultsDVM包括所有要求试验和记录结果的信息Existing and Generic DVMs can be used as a starting point to develop program DMVs, but they must be reviewed现有的和一般的DVM能作为一个开始点用以开发项目的DMV，但是它们必须进行审核Testing Methodologies试验方法学Types of Test试验的类型There are three gener

33、al types of testing that can be implemented for either Design Verification or Production Validation: 有三种可以在设计验证或生产确认中实施的一般试验类型Testing to Bogey 标准测试Testing to Failure 测试至失效Testing Functional Degradation 测试功能退化Test to BogeyMinimum Acceptable Function最小可接受功能Function功能Time/Cycles/Miles时间/循环/里程Bogey失效柱状图

34、Test to Failure测试至失效Minimum Acceptable Function最小可接受功能Function功能Time/Cycles/Miles时间/循环/里程失效时间分布图Degradation Testing退化测试Minimum Acceptable Function最小可接受功能Function功能Time/Cycles/Miles时间/循环/里程BogeyComplete DegradationHistoryExample: Functional Degradation of Three Design Alternatives范例：三种设计方案的功能退化CBATes

35、t Level Comparison测试水平比较Bogey标准Failure 失效Information Quality信息质量Cost成本Higher较高Lower较低Higher较高Lower较低Degradation 退化Test Precision测试精度失效概率Statistical Confidence统计可信度Statistical confidence for a given reliability estimate is the probability that the true reliability of the population is equal to or gre

36、ater than the estimate.对于特定的可靠性预测，统计可信度是一种总体真实可靠性等于或大于预测情况的概率Engineering Confidence Reduces Sample Size工程可信度减小样本量Large Sample大样本Reduced Sample减少的样本Min: 1 sample/failure mode最小：1个样本/失效模式Severity/Acceleration of key noises in tests试验中关键干扰的严重度/加速Knowledge of prior perform-ance under similar conditions相

37、似条件下优先性能的知识Normal通常High高High高Low低FailureSeverity & Occurrence失效严重度&发生Test Level测试水平BogeyFailureDegradationReal World Usage Profiles真正顾客使用概况Types of Customer Usage顾客使用的类型Normal use一般使用Misuse误用Abuse ?滥用？Normal Use一般使用Misuse误用Abuse滥用Data Sources数据来源Yourself自身Instrumentation仪器Existing Data现有数据Observatio

38、n观察 Percentiles百分点Actual Customer Usage真正顾客使用5% Total95th Percentile use95th 百分点使用 Core Target Customer(Marketing) 核心目标顾客（市场）Example: Cooling Fan范例：冷却风扇Stress受力状态Europe欧洲SouthernEuropeanCities南欧城市NorthernEuropeanCities北欧城市Usage Profile and Customer Duty Cycle使用概况及顾客工况Usage Profile使用概况Duty Cycle工况How

39、 often the customer opens a window顾客开启窗户的频次如何Number of switch activations or motor running times for the window motor 开关的次数或窗户电机运转次数Climate or outside temperature ranges in which the vehicle operates车辆运转时的气候或外界温度的范围Air conditioning system frequency of operation and load空调系统的运转频次和负荷Duty Cycle Example

40、工况范例同步齿形带发动机工况绿线：一般顾客红线：苛刻顾客注：皮带负荷在低转 速时更苛刻Accelerated Testing加速测试Accelerated Testing加速测试Purpose:目的:Accumulate product stress history in a short period of time 在短时间内累积产品应力史Shorten verification time & reduce development costs缩短验证时间&减少开发成本Accelerated Testing Methods加速测试方法Load Frequency over a Specifie

41、d Test Procedure 在指定的试验规程上加大加载频次010020030040030%60%100%Percent Frequency of Occurrence发生频次的百分比Load载荷Normal Load正常负载Increased Load加大负载Define Accelerated Test based on this portion of procedure with increased loads50 mph Freeway 50 mph高速公路Climbing hill in 1st gear一档爬山以加大的载荷在这部分试验规程的基础上定义加速测试Accelerate

42、d Testing Cautions加速测试警示Correlate acceleration to real world deterioration使其加速形式与真正顾客使用的退化情况相关联Prevent unrepresentative failure modes预防不具备代表性的失效模式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关键寿命试验Key Life Tests关键寿命试验Key Life Tests focus on the key stress(es) which drive loss

43、 of function and/or failure mechanisms associated with real world usage.关键寿命试验着重于会促使真正顾客使用相关的功能损失和/或失效机理的关键应力Key Life Tests关键寿命试验A Key Life Test: 一个关键寿命试验Is based on the RWUP 是以RWUP为基础的Provides a tool to evaluate product reliability 提供了一个工具以评估产品的可靠性Allows comparison of designs with benchmarked compe

44、titive products so that the best design can be identified 使其与竞争产品进行设计的比较，从而可以确定最佳设计Validates models and assumptions in the design process 在设计过程中确认模型和设想Validates the design 确认设计Key Life Tests关键寿命试验IS是IS Not否Reliability and Robustness Demonstration Matrix可靠性和殷实可靠性实证矩阵图Reliability and Robustness Demons

45、tration Matrix可靠性和殷实可靠性实证矩阵图Reliability and Robustness Demonstration Matrix (RRDM) captures and displays the key verification methods and all Critical Noise factors. RRDM吸取并显示了关键验证方法以及所有的关键干扰因素。Self Assessment自我评估Vehicle Level DV & PV整车级别的DV&PVVehicle Level DV & PV整车级别的DV&PVVerification and Validati

46、on of Vehicle level requirements整车级别的验证和确认的要求Illustrated with an example around a real world problem Transit FEAD穿插了一个真实问题的范例Transit FEADProblem问题Customers were experiencing problems after washing their vehicles or driving through water顾客在洗车或开车涉水后出现问题Global 8D全球8DA Global 8D was conducted on the van

47、 jet spray washing problem that was looked at earlier and the root cause was identified as belt slip. 采取了全球8D方式来处理刚才看到的喷雾式洗车的问题，确定根本原因为皮带打滑。Applying RED应用REDHaving developed a fix for the problem the team needed to verify the change针对问题制定出解决方案，该小组需要验证其更改Verification is a key part of the 8D process,

48、just as it is for the PDP验证是8D过程中的一个关键部分，就象其相对于PDP一样。To do this they need to apply RED principles to the verification为了进行该工作，他们需要把RED的原理应用到验证上。Verifying Robustness验证殷实可靠性Existing verification methods used as a starting point使用现有的验证方法作为起点From studying the data, the team new that the existing DVMs wer

49、e insufficient通过研究该数据，小组发现现有的DVM还不充分New DVMs must include RED considerations新的DVM必须包括RED需要考虑的事项Revised DVM修正的DVMThe DVMs were then modified. 于是对DVM进行修改FEAD子系统设计验证方法目标：验证FEAD系统存有水时性能的殷实可靠性试验描述：在10kph至50kph之间每次增加5kph的车速，开车通过25，50，75以及100mm深的水洼可测量的/观察：曲轴皮带轮和附件皮带轮之间的差速验收标准：差速小于5%需要的资源及试验设备：水洼，在已知的曲轴/发动机

50、转速下对附件皮带轮转速的整车评估Planning and Implementing Verification and Validation计划并实施验证和确认Planning occurs down the V plan the vehicle level first沿着V形方式向下作计划首先计划整车级别Verification and Validation occurs up the V Verify and Validate the vehicle last沿着V形方式向上进行验证和确认最后验证和确认整车Global 8D and DV&PV全球8D和DV&PVGlobal 8D stud

51、ies on previous similar products or processes help identify potential error states对以前相似产品或过程的全球8D研究帮助识别潜在的异常状态This is an important input to the design of verification methods for a new product or manufacturing process. 对于一个新产品或制造过程，这是验证方法设计中的一个重要的输入Verification methods must demonstrate that these er

52、ror states do not recur in the new product or process. 验证方法必须证明这些异常状态不会在新的产品和过程中再次发生。Self Assessment自 评System/Sub-System Level DV系统/子系统级别DVFEAD Sub-SystemFEAD子系统A FEAD system is to be developed for a new vehicle program 为一新车项目开发一个FEAD系统Sub-System Level Design Verification子系统级别设计验证Form a cross functi

53、onal team:组成一个交叉功能的小组Design设计Testing试验Manufacturing制造Supplier供应商CAEQuality质量Reliability可靠性Aim to verify at the lowest possible level on the V瞄准V模形最低可能级别上进行验证FEAD Design Verification PlanFEAD设计验证计划DV PlanDV计划SDS RequirementsSDS要求LegalRequirements法规要求EngineeringSpecifications工程技术规范Concept and Design F

54、MEAs概念和设计FMEAReal World Usage Profile真实顾客使用概况P-DiagramP 图Existing DVPs现有DVPGeneric DVMs一般DVMHistorical 8Ds历史上的8DKey Life Tests关键寿命试验FEAD Function and OperationFEAD功能和运行Ideal function of the FEAD is to transfer torque to the accessoriesFEAD的理想功能是把扭矩传递给附件Irregularity in rotation is a key noise旋转不规则是一个

55、关键的干扰The tensioner compensates for the noise张紧轮对该干扰进行补偿The correct functioning of the tensioner is a priority for the FEAD team张紧轮的正确机能对于前端驱动附件组是最首要的。Customer Requirements顾客需求FEAD SDS Requirement FEAD SDS 要求Belt span vibration does not exceed 10% of belt span and meets system clearance requirements

56、to other components. Maximum tensioner amplitude leaves 10% of total travel clear to end stop in both directions. 相带宽度振动不超过相带宽度的10%，要符合与其它零部件间的系统间隙要求。最大张紧轮振幅要与两端止点留有总行程10%的间隙余量。A DVM is required to verify this requirement 需要DVM来验证这一要求Existing DV Test现有的DV试验There is an existing DVM for the requiremen

57、t对该要求有一现有的DVMThe team need to assess if this DVM is appropriate小组需要评估该DVM是否合适RED in Sub-System DV子系统DV中的REDSystem and Sub-System level DVMs must include consideration of noises系统和子系统级别的DVM必须包括干扰需要考虑的事项In the FEAD example excessive belt vibration was identified as a critical error state.在FEAD的范例中，过多的

58、皮带振动被认为是一个关键的异常状态The DVM was assessed to be inadequate for this failure mode in the presence of noise评定该DVM在有干扰存在时对这个失效模式来说是不充分的FEAD Acceptance CriteriaFEAD验收标准The acceptance criteria was assessed by the team and found to cover the SDS requirement, but needed minor improvement.小组评估该验收标准，发现涵盖了SDS的要求，

59、但仍需要小的改进。Application of REDRED的应用The team needs to consider all key noise factors小组需要考虑所有关键干扰因素The key noise factors were identified as:确认关键噪声为：Carryover tensioner in a new environment在新的环境中借用张紧轮装置Accessory loading附加载荷These Noise factors were not taken into account in the previous DVM.在以前的DVM中没有考虑这些

60、干扰因素Previous Robustness Studies之前的殷实可靠性研究Previous robustness studies are a key source of information之前的殷实可靠性研究是信息的关键来源The team can use this information for their design and testing小组可以把这一信息用于设计和测试This type of information can come from similar or different vehicles这种类型的信息可以来自相似或不同的车辆These strategies