DV-PV培训课件：设计验证和生产确认

DesignVerification

andProductionValidation设计验证和生产确认WelcomeFordTechnicalEducation

Program福特技术培训项目SystemsEngineeringFundamentals系统工程基本原理ParameterDesign参数设计ToleranceDesign公差设计FMEA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AppliedConsumer

Focus应用顾客的关注DV&

PV设计验证&生产确认Global

8D全球8DStatisticalEngineering统计工程学Course

Structure课程结构IntroductiontoDV&

PV对设计验证及生产确认的介绍ToolsforDV&

PV设计验证及生产确认的工具VehicleLevel

DV整车级别的设计验证System/Sub-SystemLevel

DV系统/子系统级别的设计验证ComponentLevel

DV零部件级别的设计验证System/Sub-SystemLevel

PV系统/子系统级别的生产确认ComponentLevel

PV零部件级别的生产确认Summary总结DesignVerification

and

ProductionValidation设计验证和生产确认DesignVerification

andProductionValidation设计验证和生产确认BenefittoFord

MotorCompany对福特汽车公司的益处DesignVerification

andProductionValidation设计验证和生产确认Design

Verification:设计验证asdesigned,aproductwillfunctioninthemannerthatthecustomer

expects.根据设计状态，一个产品的功能要符合顾客所期望的方式。ProductionValidation:生产确认asmanufactured,aproductfunctionsinthemannerthatthecustomerexpectsandcanbemanufacturedatrequired

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&PVWithin

SystemsEngineering系统工程内的DV&PVVerificationand

SystemicThinking验证和系统思想Customer

Wants顾客的需要Engineering

Targets工程目标Design

Verification设计验证Requirements

Cascade需求逐级传递WorkinginaSystemsEngineering

contextsupportssystemic

thinking.系统工程中的工作支持系统的考虑OppositeofTraditionalapproachto

engineering.与传统的工程方法相反Systems“V”

Model系统V模型DV&PVisarequirementsdriven

processDV和PV

是一个需求驱动的过程DV&PVisbestconductedinasystemsengineeringcontextthroughthesystems

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VehicleSystemSub-SystemComponentTherequirementscascadedowntheleft

side.需求的逐级传递如左侧Thecascadeisaniterative

process.该逐级传递是一反复的过程ITERATIVEPLANNINGTop

Down由上到下Verification

Bottom-up验证自下至上Verificationtestingisimplementedasabottom-upsequential

process.验证试验是按照自下至上的顺序过程执行的VerificationmayincludeacombinationofAnalyticalandphysical

tests.验证可能包括分析试验和物理试验的组合。VehicleSystemSub-SystemComponentITERATIVEPLANNINGTop

Down自上至下Bottom

Up自下至上SEQUENTIALDOING反复计划工作顺序DV&PVand

PDSAPlanPlanPlanPlan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LowerLevel

Interactions较低级别的相互作用SystemsApproach

toManufacturing进行制造的系统方法Vehicle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ngNote-S5/P5

TimiFPDS

TimingFPDS时间Vehiclelevel,Systemlevel&Sub-sys

level1DVP

Created生成整车，系统&子系统的DVPSub-syslevel

2&

ComponentDVP

Created生成子系统级别2&零部件DVPFullDVP

CreatedReqts&Targets

Frozen生成完整的DVP需求&目标冻结Componenttesting

complete零部件试验完成Sub-system

andSystemtestingcomplete子系统和系统试验完成Vehicletestingmostlycomplete:PrelimEngSign

Off整车试验大部分完成：工程预签发Vehicle

testingcomplete:FinalEngSignOff整车试验完成：最终工程签发DVP

completeDVP完成Design“V”andFPDSTimingDV&PV设计V形图及FPDS时间的DV&PVLow低Time时间=

Design

Verification设计验证=

Production

&

ProcessValidation生产&过程确认SI SC

PA

PR

CP LR J1High高ActivityLevel活动级别DV&PVand

FPDSDV&PVarekeyrequirementsfor

signoffofavehicleprogramDV和PV对于汽车项目的签发来说是关键的需求KeySignoffmilestones

are:关键签发节点是：(CC)—

DV(LR)—

PV(LS)—

PVInputsUsedintheVerificationandValidation

Processes在验证和确认过程中使用的输入DVPlan设计验证计划SDSRequirementsSDS的需求LegalRequirements法规要求EngineeringSpecifications工程技术规范ConceptandDesignFMEAs概念和设计FMEARealWorldUsage

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8DKeyLife

Tests关键寿命试验DV&PVasPartofthe

ProductCreation

ProcessDV

和PV作为产品创造过程的部分DVandPVconfirmthatComponentsandsystemrobustlymeetcustomer

requirementsDV和PV确认零部件和系统殷实可靠地符合顾客的需求。DV&PVtestingisnot

exploratoryDV和PV试验不是探险Testingshouldbeagainstexpectedresultsnot

tofind

out“whathappens

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&PVcomesafterthedesignphasenot

duringthe

designphaseDV

和PV

要在设计以后而不是在设计阶段中进行Introductionofthe

FEADExampleFEAD举例介绍FEAD

ExampleFEAD范例AsinglesystemtheFEAD(FrontEnd

AccessoryDrive)willbeusedtodemonstrateDV&

PV使用一个单独的系统FEAD（前端附件驱动）来示范DV&PVTheFrontEndAccessoryDrive(FEAD)–HowIt

WorksFEAD-它如何工作Thesourceofpowerinthevehicleistheengine.汽车内动力的来源是发动机PartoftherotationalpoweroutputfromtheengineneedstobetransmittedtotheFEADaccessories.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。TheFEADtransmitsthis

energyFEAD传输该能量DesignVerificationatAll

Levels所有级别上的设计验证DesignVerificationshouldoccurat

alllevelswiththeemphasisbeingatthelower

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Itisimportanttoverifythedesign验证设计是重要的Itisequallyimportanttovalidatethattheproductionprocessusedtomanufacturethebeltisabletoproducebeltstothedesign

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。Forexample,thebeltasmanufacturedmustbeable

totransmittherequiredamountof

torque.例如，所制造的皮带必须能转送所要求大小的扭矩。ConfirmingRobustand

ReliableDesign–

Robustness确认殷实及可靠的设计-殷实可靠性ToolsForDV&

PVDV&PV的工具MethodsUsedinEfficientandEffective

Verification在有效且高效的验证中使用的方法Someoftheimportantmethodsusedinefficientand

effectiveverificationandvalidationprocesses

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RobustEngineeringDesignPhilosophy

(RED)殷实的工程设计基本定律FordDesignVerificationSystem

(FDVS)福特设计验证体系TestingMethodologies,试验方法学RealWorldUsageProfilesandDuty

Cycles真正全球顾客使用的概况和工况Accelerated

Tests,加速试验KeyLifeTests

(KLT),关键寿命试验ComputerAidedEngineering

(CAE)计算机辅助工程DesignofExperiment

(DoE).实验设计RobustEngineering

Design(RED)殷实的工程设计RobustTest

Plans殷实可靠的试验计划RobusttestplansinDV&PVincorporateNoisefactorsandtheireffectsinordertoensurethattheproductwillmeetitsdesignintentunderallconditions.Noisefactorscanbegroupedintofive

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ChangesOver

Time随着时间过去的变化Customer

Usage顾客的使用External

Environment外部环境System

Interactions系统间的交互作用NoiseFactor

Management干扰因素的管理Test/TechnologyChange试验/技术更改RobustDesignbyParameterDesign通过参数设计的牢靠设计RobustDesignbyIncreasedStrength通过增加强度的牢靠的设计RemoveorReduce

Noise去除或减小干扰CompensationDevice补偿装置DisguisetheProblem隐蔽问题InternalEnvironment(SystemInteractions)内部环境（系统交互作YesYesYesSystemFMEAYesSystemFMEAExternalEnvironment(Climate/RoadConditions)外部环境（气候/路况）YesYesYesNoPieceto

PieceVariation件与件间的差异YesYesYesSPCChangesOver

Time(Wear

Out)随着时间产生的变化（磨损）YesYesMaterialsEngineeringYesSystemFMEACustomerUsage顾客使用YesYesYesNoRobustEngineering

Design殷实可靠的工程设计RobustEngineeringDesign(RED)isprimarilyadesign

tool殷实的工程设计主要是一种设计工具REDmustbeconsideredinDV&PVasREDwilldrivethetypeofDV&PVteststhatneedtobeundertaken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。REDfocusesonidentification

andmanagementofnoise

factorsRED着重于干扰因素的识别和管理RobustEngineering

Design殷实可靠的工程设计REDisinherentinthesystemsVandrunsthroughallphasesofthe

VRED是系统V内固有的，并且贯穿系统V的所有阶段REDisateambased

processRED是以小组为基础的过程REDappliesthroughoutFord(DesignandManufacturing)andat

suppliersRED应用于整个福特（设计和制造）以及供应商。Applying

RED应用REDREDallows

testingatthelowestpossiblelevelRED允许在最低可能性级别进行测试Cautionmust

beused必须使用警示RedAppliedtoVehicleLevel

TestingRed应用于整车级别的测试REDAppliedat

Sub-SystemLevelRED应用于子系统级别WhendevelopingDesignVerificationMethodsatthesystem/sub-systemorcomponentlevel,itisimportanttoensurethattheeffectsofSystemInteractionNoisefactorsthatarepresentinthetotalvehicleenvironmentare

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。REDAppliedatComponent

LevelRED应用于零部件级别Atthecomponentleveltestingismostefficentbutinteractionswithothercomponentsare

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Testplansmustcompensateforthislossbyreproducing

thekeystressesfromthe

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Muchcomponenttestingmaybedoneat

suppliers.许多零部件试验可能在供应商处进行。SuppliersmustapplythesameRED

methodolgies供应商必须应用相同的RED方法Tosupportthis,Fordengineersneedtocascade

noisefactorstothe

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REDintheDesign

Process设计过程中 ED的RNoise

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Sourcesthatdisruptidealfunctionthatcannot

becontrolled(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-DiagramReliabilityChecklist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Energyputintothesystemstomakeitwork(e.g..Steeringwheel

angle)能量进入系统使其工作（例如..方向盘转角）Control

FactorsFeaturesofthedesignthatcanbecontrolled(e.g..Torsionbarrate)控制因素可以控制的设计特性（例如..扭杆比率）States 异常状态UndesirableoutputorFailureModes(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AvailableTests有用的试验Failuremode

totest

traceability失效模式试验可追查性NoiseFactorsManagement

StrategySystem(Steering

System)系统（转向系统）IdealFunction理想功能Primaryintendedfunctionofthedesign设计的主要意图功能(e.g.Lateralaccelerationofvehicle)（例如..车辆的横向加速度）ErrorFMEAWCR

SDSDOE(if

necessary如果有必要)WCR KLT DVP&RIn

scope范围内FDVSFDVSPreventionofMistake

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FailureMode失效模式Test试验CriticalNoiseFactors关键干扰因素DemonstratedResult论证的结果.

.. .

...

. .干扰Noise 因素Factors 管干扰因素

理策略FordDesign

VerificationSystem福特设计验证系统FordDesignVerificationSystem–

FDVS福特设计验证系统-FDVSFDVSisacomputerbasedsystemtocreateandmanagerequirementsdrivenDV

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。FDVSincludesanumberofgenericrequirementsandDesignVerificationMethods

(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）DesignVerification

Method设计验证方法WithinFDVSrequirementsareverifiedusingDesignVerificationMethods

(DVMs)在FDVS内，使用设计验证方法（DVM）验证需求DVMscontainalltheinformationrequiredtoconducttestingandrecord

resultsDVM包括所有要求试验和记录结果的信息ExistingandGenericDVMscanbeusedasastartingpointtodevelopprogramDMVs,buttheymustbe

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Typesof

Test试验的类型TherearethreegeneraltypesoftestingthatcanbeimplementedforeitherDesignVerificationorProduction

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Testingto

Bogey标准测试Testingto

Failure测试至失效TestingFunctional

Degradation测试功能退化Testto

BogeyMinimum

AcceptableFunction最小可接受功能Function功能Time/Cycles/Miles时间/循环/里程BogeyFailureHistogramPassFail失效柱状图Test

to

Failure测试至失效FailureTimeDistributionMinimumAcceptableFunction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MinimumAcceptableFunction最小可接受功能Function功能BogeyTime/Cycles/Miles时间/循环/里程Complete

DegradationHistoryExample:Functional

DegradationofThreeDesignAlternatives范例：三种设计方案的功能退化109876543025,00050,000125,000150,000Design

A Design

B DesignCFunction(higherthe

better)75,000 100,000MilesCBATestLevel

Comparison测试水平比较Failure失效Bogey标准Cost成本Information

Quality信息质量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Statisticalconfidenceforagivenreliabilityestimateistheprobabilitythatthetruereliabilityofthepopulationisequaltoorgreaterthanthe

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EngineeringConfidenceReducesSample

Size工程可信度减小样本量Large

Sample大样本ReducedSample减少的样本Min:1sample/failure

mode最小：1个样本/失效模式FailureSeverity&Occurrence失效严重度&发生Test

Level测试水平BogeyFailureDegradationRealWorldUsage

Profiles真正顾客使用概况TypesofCustomer

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Observation观察Percentiles百分点ActualCustomer

Usage真正顾客使用5%Total95thPercentileuse95th

百分点使用CoreTargetCustomer(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UsageProfileandCustomerDutyCycle使用概况及顾客工况Usage

Profile使用概况Duty

Cycle工况Howoftenthe

customeropensawindow顾客开启窗户的频次如何Numberofswitchactivationsormotorrunningtimesforthewindow

motor开关的次数或窗户电机运转次数Climateoroutsidetemperaturerangesinwhichthevehicle

operates车辆运转时的气候或外界温度的范围Airconditioningsystemfrequencyofoperationandload空调系统的运转频次和负荷DutyCycle

Example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:Accumulateproductstresshistoryinashortperiodoftime在短时间内累积产品应力史Shortenverificationtime&reducedevelopment

costs缩短验证时间&减少开发成本AcceleratedTesting

Methods加速测试方法0100200300LoadFrequencyoveraSpecifiedTest

Procedure在指定的试验规程上加大加载频次40030%

60%

100%Percent

Frequency

of

Occurrence发生频次的百分比Load载荷Normal

Load正常负载 IncreasedLoad加大负载portionofprocedurewithincreased

loadsDefineAcceleratedTestbasedon

this50

mph

Freeway

50

mph高速公路Climbing

hillin1st

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AcceleratedTesting

Cautions加速测试警示Correlateaccelerationtorealworlddeterioration使其加速形式与真正顾客使用的退化情况相关联Preventunrepresentativefailure

modes预防不具备代表性的失效模式Notallfailuremodescanbe

accelerated不是所有的失效模式都可以加速的KeyLife

Tests关键寿命试验KeyLife

Tests关键寿命试验KeyLifeTestsfocusonthekeystress(es)whichdrivelossoffunctionand/orfailuremechanisms

associatedwithrealworld

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KeyLife

Tests关键寿命试验AKeyLife

Test:一个关键寿命试验Isbasedonthe

RWUP是以RWUP为基础的Providesatooltoevaluateproduct

reliability提供了一个工具以评估产品的可靠性Allowscomparisonofdesignswithbenchmarked

competitiveproductssothatthebestdesigncanbe

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Validatesmodelsandassumptionsinthedesign

process在设计过程中确认模型和设想Validatesthe

design确认设计KeyLife

Tests关键寿命试验IS是IS

Not否Reliabilityand

RobustnessDemonstration

Matrix可靠性和殷实可靠性实证矩阵图Reliability

and

RobustnessDemonstration

Matrix可靠性和殷实可靠性实证矩阵图ReliabilityandRobustnessDemonstrationMatrix(RRDM)capturesanddisplaysthekeyverificationmethodsandallCriticalNoise

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VehicleLevelDV&

PV整车级别的DV&PVVehicleLevelDV&

PV整车级别的DV&PVVerificationandValidationofVehiclelevel

requirements整车级别的验证和确认的要求Illustratedwithanexamplearound

arealworldproblem–Transit

FEAD穿插了一个真实问题的范例—TransitFEADProblem问题Customerswereexperiencing

problemsafterwashingtheirvehiclesordrivingthrough

water顾客在洗车或开车涉水后出现问题Global

8D全球8DAGlobal8Dwasconductedonthevanjetspraywashingproblemthatwaslookedatearlierandtherootcausewasidentifiedasbeltslip.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REDHavingdevelopedafixfortheproblem

theteamneededtoverifythe

change针对问题制定出解决方案，该小组需要验证其更改Verificationisakeypartofthe8D

process,justasitisforthe

PDP验证是8D过程中的一个关键部分，就象其相对于PDP一样。TodothistheyneedtoapplyREDprinciplestothe

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Existingverificationmethodsusedasastarting

point使用现有的验证方法作为起点Fromstudyingthedata,theteamnewthattheexistingDVM’swere

insufficient通过研究该数据，小组发现现有的DVM还不充分NewDVMsmustincludeRED

considerations新的DVM必须包括RED需要考虑的事项Revised

DVM修正的DVMTheDVMswerethen

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/发动机转速下对附件皮带轮转速的整车评估Planningand

ImplementingVerificationandValidation计划并实施验证和确认PlanningoccursdowntheV–planthevehiclelevel

first沿着V形方式向下作计划—首先计划整车级别VerificationandValidationoccursuptheV–Verify

andValidatethevehicle

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Global8Dand

DV&PV全球8D和DV&PVGlobal8Dstudiesonprevioussimilarproducts

orprocesseshelpidentifypotentialerror

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Thisisanimportantinputtothedesignof

verificationmethodsforanewproductormanufacturing

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Verificationmethodsmustdemonstratethattheseerrorstatesdonotrecurinthenewproductorprocess.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

LevelDV系统/子系统级别DVFEAD

Sub-SystemFEAD子系统AFEADsystemistobedevelopedfor

anewvehicle

program为一新车项目开发一个FEAD系统Sub-SystemLevel

DesignVerification子系统级别设计验证Formacrossfunctionalteam: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Aimtoverifyatthelowestpossiblelevelonthe

V瞄准V模形最低可能级别上进行验证FEADDesignVerification

PlanFEAD设计验证计划DVPlanDV计划SDSRequirementsSDS要求LegalRequirements法规要求EngineeringSpecifications工程技术规范Concept

andDesign

FMEAs概念和设计FMEARealWorldUsage

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8DKeyLife

Tests关键寿命试验FEADFunctionand

OperationFEAD功能和运行IdealfunctionoftheFEADistotransfertorque

tothe

accessoriesFEAD的理想功能是把扭矩传递给附件Irregularityinrotationisakey

noise旋转不规则是一个关键的干扰Thetensionercompensatesforthe

noise张紧轮对该干扰进行补偿Thecorrectfunctioningofthetensioneris

apriorityfortheFEAD

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FEADSDSRequirementFEAD

SDS

要求–Beltspanvibrationdoesnotexceed10%ofbeltspanandmeetssystemclearancerequirementstoothercomponents.Maximumtensioneramplitudeleaves10%oftotaltravelcleartoendstopinbothdirections.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。ADVMisrequiredtoverifythis

requirement需要DVM来验证这一要求ExistingDV

Test现有的DV试验ThereisanexistingDVMfor

therequirement对该要求有一现有的DVMTheteamneedtoassessifthisDVM

isappropriate小组需要评估该DVM是否合适REDinSub-System

DV子系统DV中的REDSystemandSub-SystemlevelDVMs

mustincludeconsiderationofnoises系统和子系统级别的DVM必须包括干扰需要考虑的事项IntheFEADexampleexcessivebeltvibrationwasidentifiedasacriticalerror

state.在FEAD的范例中，过多的皮带振动被认为是一个关键的异常状态TheDVMwasassessedtobeinadequateforthisfailuremodeinthepresenceof

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FEADAcceptance

CriteriaFEAD验收标准Theacceptancecriteriawasassessedbytheteamandfoundtocoverthe

SDSrequirement,butneededminorimprovement.小组评估该验收标准，发现涵盖了SDS的要求，但仍需要小的改进。Applicationof

REDRED的应用Theteamneedstoconsiderallkeynoise

factors小组需要考虑所有关键干扰因素Thekeynoisefactorswereidentified

as:确认关键噪声为：Carryovertensionerinanew

environment在新的环境中借用张紧轮装置Accessory

loading附加载荷TheseNoisefactorswerenottakenintoaccountintheprevious

DVM.在以前的DVM中没有考虑这些干扰因素PreviousRobustness

Studies之前的殷实可靠性研究Previousrobustnessstudiesareakeysource

ofinformation之前的殷实可靠性研究是信息的关键来源Theteamcanusethisinformationfor

theirdesignand

testing小组可以把这一信息用于设计和测试Thistypeofinformationcancomefrom

similarordifferentvehicles这种类型的信息可以来自相似或不同的车辆Thesestrategieswereincorporatedintothe

newdesign.这些策略可以并入新的设计中CheckofDVMObjectiveDVM目标的检查ThedesignteamdidnotthinkthattheobjectiveintheexistingDVMcovered

robustness设计小组不认为现有DVM中的目标涵盖了殷实可靠性DVMObjectiverevisedtoinclude

robustness修正DVM目标，使其包括殷实可靠性DVMTest

MethodDVM试验方法Theteamthenturneditsattentiontothetestmethod然后小组把注意力转向试验方法Thismethodhadbeenusedonpreviousprogramsbuttheseprogramshadexperienced

failures这个方法在原来的项目中曾被使用过，但是这些项目已经出现过失效Applying

RED应用REDAREDapproach,wasusedtomodify

theDVM.采用RED的方法修改DVMAG8Dstudyhadbeenconductedto

resolvethebeltsquealproblemonthepreviousvehicle.采用了全球8D的研究来解决原来车辆上皮带尖叫的问题TheG8Diskeyinformationfor

RED全球8D对于RED是关键的信息Global8DSummary

Report全球8D总结报告Global8DSummary

Findings全球8D总结调查结果5：选择永久纠正措施：采用参数设计实验以增加在附加载荷的干扰因素存在时FEAD系统的殷实可靠性验证：从产品开发实验的确认来确定FEAD的殷实可靠性增加了%效果100%Confirming

Robustness确定殷实可靠性ThesuccessfulimprovementoftheFEADrobustnesstodifferentaccessoryloadingconditionsmeantthatoneof

theteam'sprioritieswastoensurethatthisrobustnesswouldbeconfirmedbytherevised

DVM.对不同附加载荷的条件下FEAD殷实可靠性的成功改进意味着小组优先考虑的事项之一是确保该殷实可靠性会通过修正的DVM来确认。DesignFMEA

Review计划FMEA评审项目功能潜在失效模式潜在失效后果潜在原因/失效机理保持皮带张紧力张紧力降低过多的相带宽度振动。指定阻尼带的不适当的材料特性。阻尼带材料特性的退化P-DiagramasSourceofInformationP图作为信息来源输入信号理想功能出错状态控制噪声干扰因素P图系统FMEAtoP-DiagramCross

CheckFMEA对P图的交叉检查FMEA

ContentsFMEA内容Potential

Cause(s)/Mechanism(s)

ofFailure潜在原因/失效机理FEADBeltDesginFMEAFEAD皮带设计FMEABeltmoduluschangeduetofluidcontamination(beltmaterialnotrobusttofluidcontamination)由于流动污染（皮带材料对流动污染不殷实可靠），皮带模数更改(P-diagramNoise

factor)External

Environment（P图干扰噪声因素）外部环境Driving

terrain行驶地形Temperature

温度Humidity

湿度Water

水Contamination

污染Potential

Cause(s)/Mechanism(s)

of

Failure潜在原因/失效机理FEAD

Sub-SystemDesign

FMEAFEAD子系统设计FMEABeltspanVibrationdue

to:Insufficientsystemdampingduetocrankshaftcyclicirregularitygreaterthansystemdesign

assumptionsSystem

Interactions:系统交互作用Engine

calibration发动机标定Crankshaft

irregularity曲轴不规则Accessoryload

requirements相带宽度振动由于：由于曲轴循环不规则性要比系统设计设想的大而造成系统阻尼不足附加载荷的要求Numberandtypeof

accessories附件的数量及类型Routing(with/without

AC)路由（带/不带空调）Accessory

wear附件磨损Torsional

vibration扭转振动Wrapangle

variation包角振动P-Diagram/FMEAInputsinto

DVMP图/FMEA

输入到DVMOriginal

DVM原始DVMUsingCAEasPartofVerification使用CAE作为验证的一部分TheDesignTeam’sCAErepresentativehashighlightedtotheteamthataCAEmodeloftheFEADis

available设计小组的CAE代表向小组强调FEAD的CAE模型已经具备TheCAEmodelneedstobe

calibratedCAE模型需要进行校准Thecalibrationwillallowthemodeltohaveongoing

usefulness标定将使得模型具有正在进行的有效性ModificationofDVMTest

DescriptionDVM试验描述的更改Previous

TestDescription以前的试验描述Usingavideocameraand,ifnecessary,astrobelight,recordtheFEADsystemwhiletheengineisonadynosubjectto

load.ScalesmaybeplacedalongsidethebeltandtensionersothataroughestimatecanbemadeofAmplitudeof

movement.Sweeptheenginefromidletomaximum

speed.使用摄影机，如果有必要则加上闪光灯，当发动机机在台架上承载时录下FEAD系统。可以放置比例尺在皮带和张紧轮侧边从而对其运动振幅做大致的估测。从发动机怠速开始直到最大转速。Modified

TestDescription更改后的试验描述CAEsimulation:Modelbasedonparameterdesignexperimentandincludetheeffectofcyclicirregularityatthecrankpulleyonbeltandtensionervibration.TheeffectofthefollowingtobeincludedasNoise

factors:CAE模拟：参数设计试验基础上的模型

包括曲轴皮带轮循环不规则性对皮带和张紧轮振动的影响。作为干扰因素，下列影响要包括在内：(Differentlevelsof)accessoryloading(includingworst

case)附件载荷（的不同级别）（包括最糟糕的情况）Belt

routing皮带的路由Variationofbeltelastic

properties皮带弹性特性的变差Temperature温度Aging/durabilityofFEAD

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

Variation件与件间的制造变差ModificationofMeasurables/ObservablesandAcceptance

Criteria测量/观察和验收标准的更改Measurables/Observations测量/观察AmplitudeofbeltspanvibrationandTensionerarmmovementas

afunctionof

frequency.作为频数的作用，测量/观察相带宽度振动的振幅和张紧轮臂的运动AcceptanceCriteria标准Amplitudeversusfrequencydistributionwithinaccepted

limit.振幅相对频率的分布要在可接受的限度内。Maximumtensioneramplitudeleaves10%oftotaltravelcleartoend

stop.最大张紧轮振幅要与端头止点留有总行程10%的间隙余量。Beltspanvibrationamplitudedoesnotexceed10%ofbeltspanandmeetssystemclearancerequirementstoothercomponents.相带宽度振动振幅不超过相带宽度的10%，要符合与其它零部件间的系统间隙要求。ModificationofResourceand