6-提高内燃机产品使用可靠性的捷径与对策(潍柴-胡金寿)

提高内燃机产品使用可靠性的捷径和对策THESHORTCUTANDCOUNTERMEASURESTOIMPROVETHERELIABILITYOFINTERNALCOMBUSTIONENGINE潍柴动力产品可靠性总监ProductreliabilitydirectorofWeichaiPowerHuJinshou2014年3月30日March30th,2014一、前言Introduction二、内燃机存在的主要使用可靠性问题及原因分析Majorreliabilityproblemsofcombusionengineandcauseanalysis三、提高产品使用可靠性从失效分析抓起Improveproductreliability,startfromfailureanalysis四、设计对标是快速调高内燃机设计可靠性的捷径Benchmarkingdesignisashortcuttoimproveproductreliability五、合理配套是确保内燃机使用可靠性的关键Suitablematchisthekeytoguaranteecombusionreliability六、建立产品可靠性数据库Constructproductreliabilitydatabase七、结束语Endingwords目录Contents前言INTRODUTION一、前言Introduction作为造福于人类的动力设备,内燃机已被广泛应用于工程机械、卡车、发电机组、船舶、长途客车、工程用车、城市公交车以及农机等Ashuman’sbeneficialpowerequipments,combustionshavealreadybeenusedinmanyareasofengineeringmachinery、truck、generatingunit、ships、coachbus、citybus、agriculturemachinery…etc.1内燃机成为个体用户发家致富的强有力工具,因而提高内燃机的可靠性就显得特别的紧迫

Combustionshavebeenpowerfultoolsofindividualsubscriptionstogetrich,Withtheresultthatimprovingcombustionreliabilityseemstobeparticularlyurgency.2激烈的市场竞争是质量、服务、价格的竞争，可靠性是质量的核心，良好的可靠性会使企业、客户、社会获得三赢Fiercemarketcompetitionisthequality

service

pricecompetition,andreliabilityisthecoreofquality.Betterreliabilitywillleadenterprises、customers、societytobeallthewinners.3要提高内燃机的使用可靠性，必须要从设计、工艺、制造、物流、储存、主机配套以及用户使用全过程来提高可靠性Toimprovetheusingreliabilityofcombustion,peoplemustworkfromthewholeprocessofdesigningcraftmanufacturetransportstorematchingandallcustomers’operation.4要使内燃机可靠性不断增长，必须要有最大限度满足用户需要的理念，除了千方百计提高零部件本身的可靠性外，还要充分考虑用户实际使用和保养的情况，尽可能地消除用户使用和保养过程中可能要产生的问题，只有真正树立“用户第一”的思想，才能确保内燃机可靠性的不断增长Tokeepcombustionreliabilityimprovingconstantly,wemustunderstandtheconceptofcustomers’maximumsatisfaction.Notonlydoeverythingpossibletoimprovethereliabilityofcomponentitself,butalsoconsidersituationsofcustomers’actualuseandmaintenancesufficiently,eliminatepossiblyproblemsintheprocessofuseandmaintenance.Onlyifsetupuserfirstideologycouldweensurecombustionreliabilityimprovingconstantly.5一、前言Introduction内燃机存在的主要使用可靠性问题及原因分析Majorreliabilityproblemsofcombustionengineandcauseanalysis二、内燃机存在的主要使用可靠性问题及原因分析Majorreliabilityproblemsofcombustionengineandcauseanalysis主要可靠性可分为两大类Twomajorkindsofreliabilityproblems性能performance零部件故障（失效）Componetsfailure性能可靠性问题Performancereliabilityproblems空气质量Airquality相关零部件如配气机构和四配套工作表面的耗损Relevantcomponentssurfaceweared(suchasvalvemechanismandpistoncomponent)油品、天然气气源Fuel\oilquality使用保养Useandmaintenance二、内燃机存在的主要使用可靠性问题及原因分析Majorreliabilityproblemsofcombusionengineandcauseanalysis零部件可靠性问题-故障（失效）Componentreliability-broken(failure)用户使用保养正确性Correctuseandmaintenance物流储存可靠性Transportandstorereliability本身设计可靠性Designreliability油品环境适应性Fuelenvironmentadaptability工艺制作可靠性Processreliability与主机配套合理性Suitablematching二、内燃机存在的主要使用可靠性问题及原因分析Majorreliabilityproblemsofcombustionengineandcauseanalysis提高产品使用可靠性从故障（失效）分析抓起Productusereliabilityimproving,failureanalysiscomesfirst成功失败常言道：失败乃成功之母！三、提高产品使用可靠性从故障（失效）分析抓起Productusereliabilityimproving,failureanalysiscomesfirst要提高内燃机使用可靠性首先要提高易发生故障（失效）零部件的使用可靠性Toimprovecombustionusereliability,weshouldimprovefailureeasilycomponentsusereliabilityfirst要提高易发生故障（失效）零部件的使用可靠性必须要弄清楚零部件故障（失效）的根本原因Toimprovefailureeasilycomponentsusereliability,wemustfigureouttherootcause要找出根本原因应对故障（失效）件、故障（失效）模式进行分析，即从故障（失效）分析抓起Tofigureouttherootcause,weshouldanalysisfailurepartsandfailuremode,namelyfailureanalysiscomesfirst可靠性的核心任务是与故障（失效）作斗争Thecoretaskofreliabilityisfailurefighting!与故障作斗争积累出经验和教训Fightfailure,accumulateexperienceandlesson应用这些经验和教训设计极为有效It’squiteefficienttoconsummatedesignwiththeseexperienceandlesson三、提高产品使用可靠性从故障（失效）分析抓起Productusereliabilityimproving,failureanalysiscomesfirst设计可靠性案例—推杆弯曲Designreliabilitycase─pushrodbent1三、提高产品使用可靠性从故障（失效）分析抓起Productusereliabilityimproving,failureanalysiscomesfirst三、提高产品使用可靠性从故障（失效）分析抓起Productusereliabilityimproving,failureanalysiscomesfirst设计可靠性案例—继电器易损坏Designreliabilitycase─relaybrokeneasily2三、提高产品使用可靠性从故障（失效）分析抓起Productusereliabilityimproving,failureanalysiscomesfirst3制造可靠性案例--曲轴连杆烧坏Manufacturereliabilitycase─connectingrodburned制作可靠性案例--增压器断轴Manufacturereliabilitycase─superchargershaftcut4三、提高产品使用可靠性从故障（失效）分析抓起Productusereliabilityimproving,failureanalysiscomesfirst三、提高产品使用可靠性从故障（失效）分析抓起Productusereliabilityimproving,failureanalysiscomesfirst制作可靠性案例--机油泵故障Manufacturereliabilitycase─oilpumpbroken5三、提高产品使用可靠性从故障（失效）分析抓起Productusereliabilityimproving,failureanalysiscomesfirst储运可靠性案例--风扇叶片裂Storagereliabilitycase─fanbladebroken6三、提高产品使用可靠性从故障（失效）分析抓起Productusereliabilityimproving,failureanalysiscomesfirst储运可靠性案例—吊装不当砸坏机器Storagereliabilitycase─wronghoisting7三、提高产品使用可靠性从故障（失效）分析抓起Productusereliabilityimproving,failureanalysiscomesfirst与主机配套合理性—飞轮壳拉裂Suitablematch─flywheelcoverpulledcrack8三、提高产品使用可靠性从故障（失效）分析抓起Productusereliabilityimproving,failureanalysiscomesfirst与主机配套合理性—离合器分离力过大Suitablematch─clutchseparatingoverforced9三、提高产品使用可靠性从故障（失效）分析抓起Productusereliabilityimproving,failureanalysiscomesfirst与主机配套合理性—离合器选配不当Suitablematch─unsuitableclutch10油品环境适应性—不良油品导致连杆化瓦Oilenvironmentadaptation─bearingmilledcausebybadoil11三、提高产品使用可靠性从故障（失效）分析抓起Productusereliabilityimproving,failureanalysiscomesfirst三、提高产品使用可靠性从故障（失效）分析抓起Productusereliabilityimproving,failureanalysiscomesfirst油品环境适应性—空气脏引起空压泵窜油Oilenvironmentadaptation─badaircausecompressedairpumpoilexpelling12某矿用车在送车途中发生重大事故，车辆下坡途中突然听到咔咔声，停车后发现飞轮壳开裂，起动机掉地，取力器、变速器、排气筒、传动轴等损坏司机在空档溜坡时误操作误将变速器挂入低档三、提高产品使用可靠性从故障（失效）分析抓起Productusereliabilityimproving,failureanalysiscomesfirst用户使用可靠性—下坡溜车挂错挡Customerusereliability─downslopewrongshift13三、提高产品使用可靠性从故障（失效）分析抓起Productusereliabilityimproving,failureanalysiscomesfirst用户使用可靠性—下坡溜车挂错挡Customerusereliability─downslopewrongshift13某客车公司一批新气体机汽车停车场停置30天后，司机在驾驶时猛加油、急加速引起爆震，冲坏缸垫。

Inonebuscompany,abatchofnewgasenginebusesstopinparkinglotfor30days.Driversspeedupheavilyduringdriving,causedetonation,headgasketrushed.LNG发动机，在气罐中，甲烷位于上层，而丙烷、丁烷下沉，位于下层。位于气罐下部的出气管使下层的丙烷、丁烷进入燃烧室燃烧，易造成爆震

LNGengine:thegas-holderinterior,methaneuptothetoplayer,propane

andbutanesinktobottom.outletpipebelowthegas-holderconveypropane

andbutanetocombustor,causingknockeasily.三、提高产品使用可靠性从故障（失效）分析抓起Productusereliabilityimproving,failureanalysiscomesfirst用户使用可靠性—猛加速引起爆震，冲坏缸垫Customerusereliability─heavilyspeedingupcausedetonation,rushingheadgasket14三、提高产品使用可靠性从故障（失效）分析抓起Productusereliabilityimproving,failureanalysiscomesfirst用户使用可靠性—猛加速引起爆震，冲坏缸垫Customerusereliability─heavilyspeedingupcausedetonation,rushingheadgasket14设计对标是快速提高内燃机设计可靠性的捷径Benchmarkingdesignisashortcuttoimproveproductreliability一个正确的设计不能凭空产生，他是前人经验的积累和继承。一个成熟的部件也会由于环境和使用工况的变动而失效，产品结构设计的持续改进是一个永恒的话题。Arightdesignationdoesn’tgenerategroundless.Itdependsonpredecessors’accumulatedexperience.Amaturepartalsoloseefficacybythechangingenvironmentandusingsituation.Sustainedimprovingofproductstructuredesignationwillbeaforevertopic.

提高产品的使用可靠性最关键的是要提高产品的设计可靠性，而要提高产品的设计可靠性最快捷的方法是“设计对标”。

Thekeytoimproveproductusereliabilityistoimproveproductdesignreliability,andtheshotcutwaytoimproveproductdesignreliabilityis“benchmarkingdesign”.综述overview四、设计对标是快速提高内燃机设计可靠性的捷径Benchmarkingdesignisashortcuttoimproveproductreliability“设计对标”就是与其它系列的产品进行结构设计对比，从结构设计的角度找出产品使用中发生故障的真正原因，参照其它产品成熟的设计来改善自己的产品。“Benchmarkingdesign”isthecomparisontootherseriesproductofstructuredesign.Findoutrealfailurecausethroughproductusingfromtheangleofstructuredesign.Consultothermaturedesigntoimproveourselves.“设计对标”不仅改进速度快，而且风险极小，能以最短的时间迅速提高产品的使用可靠性。“Benchmarkingdesign”,notonlyimprovefast,butalsosafety,couldspeedilyimproveproductusereliabilitywithintheshortesttime.综述四、设计对标是快速提高内燃机设计可靠性的捷径Benchmarkingdesignisashortcuttoimproveproductreliability飞轮壳裂纹问题flywheelcrackle1对标四、设计对标是快速提高内燃机设计可靠性的捷径Benchmarkingdesignisashortcuttoimproveproductreliability传动皮带易开裂问题transmissionbeltcracking

2对标四、设计对标是快速提高内燃机设计可靠性的捷径Benchmarkingdesignisashortcuttoimproveproductreliability增压器止推片异常磨损superchargerthrustplateabnormalwear3四、设计对标是快速提高内燃机设计可靠性的捷径Benchmarkingdesignisashortcuttoimproveproductreliability风扇托架失效问题fanbracketfailure

4四、设计对标是快速提高内燃机设计可靠性的捷径Benchmarkingdesignisashortcuttoimproveproductreliability对标合理配套是确保内燃机使用可靠性的关键Suitablematchisthekeytoguaranteecombustionreliability为了确保内燃机的使用可靠性，内燃机与主机的配套合理性极为关键Toguaranteecombustionusereliability,asuitablematchisquiteimportant合理性问题过去以主机厂研究为主，现在是买方市场，应主动与主机配套好SuitablematchmainlyrelyonOEM’sresearchinthepast,nowitsbuyers’market,weshouldmatchinitiatively.

配套不良造成的零部件机械故障。如水箱与风扇之间的距离安装不合适引起柴油机水温不正常，外接排气总管没有支撑易引起增压器损坏以及空气滤清器选用不当引起柴油机早期磨损等

Componentmechanicalfailurecausedbyunsuitablematch.suchasunsuitabledistancebetweenwatertankandfancauseabnormalwatertemperature,externalexhaustmanifoldwithoutsupportcausesuperchargerbrokenandunsuitableairfiltercausedieselengineprematurewear…etc.五、合理配套是确保内燃机使用可靠性的关键Suitablematchisthekeytoguaranteecombustionreliability五、合理配套是确保内燃机使用可靠性的关键Suitablematchisthekeytoguaranteecombustionreliability要进行配套合理性评定必须要有一个评定的规范Astandardmustbesettoevaluatematchsuitability.规范编写的依据有两点：一是将常规的要求编进去;二是把过去失败的经验总结编进去

therearetwopointstowritestandard:oneistowriteconventionalrequest,anotheristowritefailureexperienceinthepast.把过去发生过的各种失效模式和解决方法进行总结变成评定的规范summarizeallkindsoffailuremodeandsolutionsinthepastandmakethemtobeevaluatestandard.派有经验的人员按规范的要求并结合自己的实践经验对配套合理性进行评定

Accordingtostandardrequirementdispatchexperiencestaffandcombineyourownexperiencetoevaluatematchsuitability.系列柴油机首次与整车配套安装评定检查表

seriesdieselenginefirstmatchingevaluatechecklist五、合理配套是确保内燃机使用可靠性的关键Suitablematchisthekeytoguaranteecombustionreliability建立产品可靠性数据库Constructproductreliabilitydatabase六、建立产品可靠性数