设计验证和生产确认福特FORD课件

WelcomeDesignVerificationandProductionValidation设计验证和生产确认WelcomeDesignVerificationand1FordTechnicalEducationProgram福特技术培训项目Systems

EngineeringFundamentals系统工程基本原理Parameter

Design参数设计Tolerance

Design公差设计Global8D全球8DFMEA失效模式后果与分析Experimental

Design实验设计FTEP福特技术培训项目Reliability可靠性AppliedConsumerFocus应用顾客的关注DV&PV设计验证&生产确认StatisticalEngineering统计工程学FordTechnicalEducationProgr2CourseStructure

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VehicleLevelDV整车级别的设计验证System/Sub-SystemLevelDV系统/子系统级别的设计验证ComponentLevelDV零部件级别的设计验证System/Sub-SystemLevelPV系统/子系统级别的生产确认ComponentLevelPV零部件级别的生产确认Summary总结CourseStructure

课程结构Introduct3DesignVerificationandProductionValidation

设计验证和

生产确认DesignVerificationandProduc4DesignVerificationandProductionValidation

设计验证和生产确认DesignVerificationandProduc5BenefittoFordMotorCompany

对福特汽车公司的益处BenefittoFordMotorCompany

6DesignVerificationand

ProductionValidation

设计验证和生产确认DesignVerification:设计验证asdesigned,aproductwillfunctioninthemannerthatthecustomerexpects.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,aproductfunctionsinthemannerthatthecustomerexpectsandcanbemanufacturedatrequiredvolumes.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。DesignVerificationand

Produ7DV&PVWithinSystemsEngineering系统工程内的DV&PVDV&PVWithinSystemsEngineeri8VerificationandSystemicThinking

验证和系统思想CustomerWants顾客的需要EngineeringTargets工程目标DesignVerification设计验证VerificationandSystemicThin9RequirementsCascade

需求逐级传递WorkinginaSystemsEngineeringcontextsupportssystemicthinking.系统工程中的工作支持系统的考虑OppositeofTraditionalapproachtoengineering.与传统的工程方法相反RequirementsCascade

需求逐级传递Wor10Systems“V”Model

系统V模型DV&PVisarequirementsdrivenprocessDV和PV是一个需求驱动的过程DV&PVisbestconductedinasystemsengineeringcontextthroughthesystemsV.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-SystemComponentSystems“V”Model

系统V模型DV&PVi11DefiningRequirements

定义需求Therequirementscascadedowntheleftside.需求的逐级传递如左侧Thecascadeisaniterativeprocess.该逐级传递是一反复的过程

VehicleSystemSub-SystemComponentITERATIVE

PLANNINGTopDown由上到下DefiningRequirements

定义需求The12VerificationBottom-up

验证自下至上Verificationtestingisimplementedasabottom-upsequentialprocess.验证试验是按照自下至上的顺序过程执行的VerificationmayincludeacombinationofAnalyticalandphysicaltests.验证可能包括分析试验和物理试验的组合。

VehicleSystemSub-SystemComponentITERATIVE

PLANNINGTopDown自上至下BottomUp自下至上SEQUENTIAL

DOING反复计划工作顺序VerificationBottom-up

验证自下至上V13DV&PVandPDSAPlanPlanPlan

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DV&PVandPDSAPlanPlanPlan14LowerLevelInteractions

较低级别的相互作用LowerLevelInteractions

较低级别的15SystemsApproachtoManufacturing

进行制造的系统方法VehicleSystemSub-SystemComponentPlantAssemblyOperationMachineVehicle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SystemsApproachtoManufactur16Note-S5/P5TimingFPDSTiming

FPDS时间Vehiclelevel,Systemlevel&Sub-syslevel1DVPCreated生成整车，系统&子系统的DVPSub-syslevel2&ComponentDVPCreated生成子系统级别2&零部件DVPFullDVPCreatedReqts&TargetsFrozen生成完整的DVP需求&目标冻结Componenttestingcomplete零部件试验完成Sub-systemandSystemtestingcomplete子系统和系统试验完成Vehicletestingmostlycomplete:PrelimEngSignOff整车试验大部分完成：工程预签发Vehicletestingcomplete:FinalEngSignOff整车试验完成：最终工程签发DVPcompleteDVP完成Note-S5/P5TimingFPDSTiming17Design“V”andFPDSTiming

DV&PV

设计V形图及FPDS时间的DV&PVLow低High高ActivityLevel活动级别Time时间=DesignVerification设计验证=Production&ProcessValidation生产&过程确认SISCPAPRCPLRJ1Design“V”andFPDSTiming

DV&18DV&PVandFPDSDV&PVarekeyrequirementsforsignoffofavehicleprogramDV和PV对于汽车项目的签发来说是关键的需求KeySignoffmilestonesare:关键签发节点是：(CC)—DV(LR)—PV(LS)—PVDV&PVandFPDSDV&PVareke19InputsUsedintheVerificationandValidationProcesses

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FMEARealWorldUsageProfile真正的顾客使用状况P-DiagramP图ExistingDVPs现有的DVPGenericDVMs一般DVMHistorical8Ds历史上8DKeyLifeTests关键寿命试验InputsUsedintheVerificatio20DV&PVasPartoftheProductCreationProcess

DV和PV作为产品创造过程的部分DVandPVconfirmthatComponentsandsystemrobustlymeetcustomerrequirementsDV和PV确认零部件和系统殷实可靠地符合顾客的需求。DV&PVtestingisnotexploratoryDV和PV试验不是探险Testingshouldbeagainstexpectedresultsnottofindout“whathappensif”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&PVcomesafterthedesignphasenotduringthedesignphaseDV和PV要在设计以后而不是在设计阶段中进行DV&PVasPartoftheProductC21IntroductionoftheFEADExampleFEAD举例介绍IntroductionoftheFEADExamp22FEADExample

FEAD范例AsinglesystemtheFEAD(FrontEndAccessoryDrive)willbeusedtodemonstrateDV&PV使用一个单独的系统FEAD（前端附件驱动）来示范DV&PVFEADExample

FEAD范例Asinglesy23TheFrontEndAccessoryDrive(FEAD)–HowItWorks

FEAD-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。TheFEADtransmitsthisenergyFEAD传输该能量TheFrontEndAccessoryDrive24DesignVerificationatAllLevels

所有级别上的设计验证DesignVerificationshouldoccuratalllevelswiththeemphasisbeingatthelowerlevels.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。DesignVerificationatAllLev25ProductionValidation

生产确认Itisimportanttoverifythedesign验证设计是重要的Itisequallyimportanttovalidatethattheproductionprocessusedtomanufacturethebeltisabletoproducebeltstothedesignspecification.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,thebeltasmanufacturedmustbeabletotransmittherequiredamountoftorque.例如，所制造的皮带必须能转送所要求大小的扭矩。ProductionValidation

生产确认Iti26ConfirmingRobustandReliableDesign–Robustness

确认殷实及可靠的设计-殷实可靠性ConfirmingRobustandReliable27ToolsForDV&PV

DV&PV的工具ToolsForDV&PV

DV&PV的工具28MethodsUsedinEfficientandEffectiveVerification

在有效且高效的验证中使用的方法Someoftheimportantmethodsusedinefficientandeffectiveverificationandvalidationprocessesare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RealWorldUsageProfilesandDutyCycles真正全球顾客使用的概况和工况AcceleratedTests,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MethodsUsedinEfficientand29RobustEngineeringDesign

(RED)殷实的工程设计RobustEngineeringDesign

(RED30RobustTestPlans

殷实可靠的试验计划RobusttestplansinDV&PVincorporateNoisefactorsandtheireffectsinordertoensurethattheproductwillmeetitsdesignintentunderallconditions.Noisefactorscanbegroupedintofivecategories: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-PieceVariation件与件间的变差ChangesOverTime随着时间过去的变化CustomerUsage顾客的使用ExternalEnvironment外部环境SystemInteractions系统间的交互作用RobustTestPlans

殷实可靠的试验计划Rob31NoiseFactorManagement

干扰因素的管理NoiseFactorManagement

干扰因素的管32RobustEngineeringDesign

殷实可靠的工程设计RobustEngineeringDesign(RED)isprimarilyadesigntool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。REDfocusesonidentificationandmanagementofnoisefactorsRED着重于干扰因素的识别和管理RobustEngineeringDesign

殷实可靠33RobustEngineeringDesign

殷实可靠的工程设计REDisinherentinthesystemsVandrunsthroughallphasesoftheVRED是系统V内固有的，并且贯穿系统V的所有阶段REDisateambasedprocessRED是以小组为基础的过程REDappliesthroughoutFord(DesignandManufacturing)andatsuppliersRED应用于整个福特（设计和制造）以及供应商。RobustEngineeringDesign

殷实可靠34ApplyingRED

应用REDREDallowstestingatthelowestpossiblelevelRED允许在最低可能性级别进行测试Cautionmustbeused必须使用警示ApplyingRED

应用REDREDallowst35RedAppliedtoVehicleLevelTesting

Red应用于整车级别的测试RedAppliedtoVehicleLevelT36REDAppliedatSub-SystemLevel

RED应用于子系统级别WhendevelopingDesignVerificationMethodsatthesystem/sub-systemorcomponentlevel,itisimportanttoensurethattheeffectsofSystemInteractionNoisefactorsthatarepresentinthetotalvehicleenvironmentareincluded.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。REDAppliedatSub-SystemLeve37REDAppliedatComponentLevel

RED应用于零部件级别Atthecomponentleveltestingismostefficentbutinteractionswithothercomponentsarelost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Testplansmustcompensateforthislossbyreproducingthekeystressesfromtheinteractions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Muchcomponenttestingmaybedoneatsuppliers.许多零部件试验可能在供应商处进行。SuppliersmustapplythesameREDmethodolgies供应商必须应用相同的RED方法Tosupportthis,Fordengineersneedtocascadenoisefactorstothesupplier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REDAppliedatComponentLevel38REDintheDesignProcess

设计过程中的RED

NoiseFactors干扰因素PiecetoPiece件与件Aging/Wear老化/磨损CustomerUsage顾客使用Environment环境SubsystemInteraction子系统交互作用Sourcesthatdisruptidealfunctionthatcannotbecontrolled(e.g..columnfriction)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/RobustnessDemonstrationMatrix可靠性/殷实可靠性实证矩阵图Signal信号Energyputintothesystemstomakeitwork(e.g..Steeringwheelangle)能量进入系统使其工作（例如..方向盘转角）ControlFactorsFeaturesofthedesignthatcanbecontrolled(e.g..Torsionbarrate)控制因素可以控制的设计特性（例如..扭杆比率）ErrorStates异常状态UndesirableoutputorFailureModes(e.g..Tireslip)不需要的输出或失效模式（例如..轮胎打滑）ErrorStates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Failuremodetotesttraceability失效模式试验可追查性

NoiseFactorsManagementStrategySystem(SteeringSystem)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）FMEASDSWCRDOE(ifnecessary如果有必要)KLTWCRFailureMode失效模式DemonstratedResult论证的结果Inscope范围内FDVSFDVSPreventionofMistakeReoccurrence错误再次发生的预防CampaignPrevent防召回LessonsLearned吸取的教训Vigilance警惕...........干扰因素管理策略REDintheDesignProcess

设计过程39FordDesignVerificationSystem福特设计验证系统FordDesignVerificationSyste40FordDesignVerificationSystem–FDVS

福特设计验证系统-FDVSFDVSisacomputerbasedsystemtocreateandmanagerequirementsdrivenDVplans.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）FordDesignVerificationSyste41DesignVerificationMethod

设计验证方法WithinFDVSrequirementsareverifiedusingDesignVerificationMethods(DVMs)在FDVS内，使用设计验证方法（DVM）验证需求DVMscontainalltheinformationrequiredtoconducttestingandrecordresultsDVM包括所有要求试验和记录结果的信息ExistingandGenericDVMscanbeusedasastartingpointtodevelopprogramDMVs,buttheymustbereviewed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DesignVerificationMethod

设计验42TestingMethodologies试验方法学TestingMethodologies试验方法学43TypesofTest

试验的类型TherearethreegeneraltypesoftestingthatcanbeimplementedforeitherDesignVerificationorProductionValidation: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TestingtoBogey标准测试TestingtoFailure测试至失效TestingFunctionalDegradation测试功能退化TypesofTest

试验的类型Therearet44TesttoBogeyMinimumAcceptableFunction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TesttoBogeyMinimumAcceptabl45TesttoFailure测试至失效MinimumAcceptableFunction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TesttoFailure测试至失效MinimumAc46DegradationTesting

退化测试MinimumAcceptableFunction最小可接受功能Function功能Time/Cycles/Miles时间/循环/里程BogeyCompleteDegradationHistoryDegradationTesting

退化测试Minimu47Example:FunctionalDegradation

ofThreeDesignAlternatives

范例：三种设计方案的功能退化CBAExample:FunctionalDegradatio48TestLevelComparison

测试水平比较Bogey标准Failure失效InformationQuality信息质量Cost成本Higher较高Lower较低Higher较高Lower较低Degradation退化TestLevelComparison

测试水平比较Bo49TestPrecision测试精度失效概率TestPrecision测试精度失效概率50StatisticalConfidence

统计可信度Statisticalconfidenceforagivenreliabilityestimateistheprobabilitythatthetruereliabilityofthepopulationisequaltoorgreaterthantheestimate.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StatisticalConfidence

统计可信度St51EngineeringConfidenceReducesSampleSize

工程可信度减小样本量Large

Sample大样本ReducedSample减少的样本Min:1sample/failuremode最小：1个样本/失效模式Severity/Accelerationofkeynoisesintests试验中关键干扰的严重度/加速Knowledgeofpriorperform-anceundersimilarconditions相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TestLevel测试水平BogeyFailureDegradationEngineeringConfidenceReduces52RealWorldUsageProfiles真正顾客使用概况RealWorldUsageProfiles真正顾客使53TypesofCustomerUsage

顾客使用的类型Normaluse一般使用Misuse误用Abuse?滥用？TypesofCustomerUsage

顾客使用的类54NormalUse一般使用NormalUse一般使用55Misuse误用Misuse误用56Abuse滥用Abuse滥用57DataSources

数据来源Yourself自身Instrumentation仪器ExistingData现有数据Observation观察DataSources

数据来源YourselfInstr58

Percentiles百分点ActualCustomerUsage真正顾客使用5%

Total95thPercentileuse95th

百分点使用CoreTargetCustomer(Marketing)

核心目标顾客（市场）Percentiles百分点ActualCustomer59Example:CoolingFan范例：冷却风扇Stress受力状态Europe欧洲SouthernEuropeanCities南欧城市NorthernEuropeanCities北欧城市Example:CoolingFanStressEuro60UsageProfileandCustomerDutyCycle

使用概况及顾客工况UsageProfile使用概况DutyCycle工况Howoftenthecustomeropensawindow顾客开启窗户的频次如何Numberofswitchactivationsormotorrunningtimesforthewindowmotor开关的次数或窗户电机运转次数Climateoroutsidetemperaturerangesinwhichthevehicleoperates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UsageProfileandCustomerDut61DutyCycleExample

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DutyCycleExample

工况范例同步齿形带发动62AcceleratedTesting加速测试AcceleratedTesting加速测试63AcceleratedTesting

加速测试Purpose:目的:Accumulateproductstresshistoryinashortperiodoftime在短时间内累积产品应力史Shortenverificationtime&reducedevelopmentcosts缩短验证时间&减少开发成本AcceleratedTesting

加速测试Purpos64AcceleratedTestingMethods

加速测试方法LoadFrequencyoveraSpecifiedTestProcedure在指定的试验规程上加大加载频次010020030040030%60%100%PercentFrequencyofOccurrence发生频次的百分比Load载荷NormalLoad正常负载IncreasedLoad加大负载DefineAcceleratedTestbasedonthisportionofprocedurewithincreasedloads50mphFreeway50mph高速公路Climbinghillin1stgear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AcceleratedTestingMethods

加速65AcceleratedTestingCautions

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Preventunrepresentativefailuremodes预防不具备代表性的失效模式Notallfailuremodescanbeaccelerated不是所有的失效模式都可以加速的AcceleratedTestingCautions

加66KeyLifeTests关键寿命试验KeyLifeTests关键寿命试验67KeyLifeTests

关键寿命试验KeyLifeTestsfocusonthekeystress(es)whichdrivelossoffunctionand/orfailuremechanismsassociatedwithrealworldusage.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KeyLifeTests

关键寿命试验KeyLife68KeyLifeTests

关键寿命试验AKeyLifeTest:一个关键寿命试验IsbasedontheRWUP是以RWUP为基础的Providesatooltoevaluateproductreliability提供了一个工具以评估产品的可靠性Allowscomparisonofdesignswithbenchmarkedcompetitiveproductssothatthebestdesigncanbeidentified使其与竞争产品进行设计的比较，从而可以确定最佳设计Validatesmodelsandassumptionsinthedesignprocess在设计过程中确认模型和设想Validatesthedesign确认设计KeyLifeTests

关键寿命试验AKeyLif69KeyLifeTests

关键寿命试验IS是ISNot否

KeyLifeTests

关键寿命试验IS是ISNot70ReliabilityandRobustnessDemonstrationMatrix可靠性和殷实可靠性实证矩阵图ReliabilityandRobustnessDem71ReliabilityandRobustnessDemonstrationMatrix

可靠性和殷实可靠性实证矩阵图

ReliabilityandRobustnessDemonstrationMatrix(RRDM)

capturesanddisplaysthekeyverificationmethodsandallCriticalNoisefactors.RRDM吸取并显示了关键验证方法以及所有的关键干扰因素。ReliabilityandRobustnessDem72SelfAssessment自我评估SelfAssessment自我评估73VehicleLevelDV&PV

整车级别的DV&PVVehicleLevelDV&PV

整车级别的DV&74VehicleLevelDV&PV

整车级别的DV&PVVerificationandValidationofVehiclelevelrequirements整车级别的验证和确认的要求Illustratedwithanexamplearoundarealworldproblem–TransitFEAD穿插了一个真实问题的范例—TransitFEADVehicleLevelDV&PV

整车级别的DV&75Problem

问题Customerswereexperiencingproblemsafterwashingtheirvehiclesordrivingthroughwater顾客在洗车或开车涉水后出现问题Problem

问题Customerswereexper76Global8D

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。Global8D

全球8DAGlobal8Dwas77ApplyingRED

应用REDHavingdevelopedafixfortheproblemtheteamneededtoverifythechange针对问题制定出解决方案，该小组需要验证其更改Verificationisakeypartofthe8Dprocess,justasitisforthePDP验证是8D过程中的一个关键部分，就象其相对于PDP一样。TodothistheyneedtoapplyREDprinciplestotheverification为了进行该工作，他们需要把RED的原理应用到验证上。ApplyingRED

应用REDHavingdevel78VerifyingRobustness

验证殷实可靠性Existingverificationmethodsusedasastartingpoint使用现有的验证方法作为起点Fromstudyingthedata,theteamnewthattheexistingDVM’swereinsufficient通过研究该数据，小组发现现有的DVM还不充分NewDVMsmustincludeREDconsiderations新的DVM必须包括RED需要考虑的事项VerifyingRobustness

验证殷实可靠性Ex79RevisedDVM

修正的DVMTheDVMswerethenmodified.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RevisedDVM

修正的DVMTheDVMswer80PlanningandImplementingVerificationandValidation

计划并实施验证和确认PlanningoccursdowntheV–planthevehiclelevelfirst沿着V形方式向下作计划—首先计划整车级别VerificationandValidationoccursuptheV–VerifyandValidatethevehiclelast沿着V形方式向上进行验证和确认—最后验证和确认整车PlanningandImplementingVeri81Global8DandDV&PV

全球8D和DV&PVGlobal8Dstudiesonprevioussimilarproductsorprocesseshelpidentifypotentialerrorstates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Thisisanimportantinputtothedesignofverificationmethodsforanewproductormanufacturingprocess.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。Global8DandDV&PV

全球8D和DV&PV82SelfAssessment自评SelfAssessment自评83System/Sub-SystemLevelDV

系统/子系统级别DVSystem/Sub-SystemLevelDV

系统/84FEADSub-System

FEAD子系统AFEADsystemistobedevelopedforanewvehicleprogram为一新车项目开发一个FEAD系统FEADSub-System

FEAD子系统AFEAD85Sub-SystemLevelDesignVerification

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AimtoverifyatthelowestpossiblelevelontheV瞄准V模形最低可能级别上进行验证Sub-SystemLevelDesignVerifi86FEADDesignVerificationPlan

FEAD设计验证计划DVPlanDV计划SDSRequirementsSDS要求LegalRequirements法规要求EngineeringSpecifications工程技术规范ConceptandDesignFMEAs概念和设计FMEARealWorldUsageProfile真实顾客使用概况P-DiagramP图ExistingDVPs现有DVPGenericDVMs一般DVMHistorical8Ds历史上的8DKeyLifeTests关键寿命试验FEADDesignVerificationPlan

87FEADFunctionandOperation

FEAD功能和运行IdealfunctionoftheFEADistotransfertorquetotheaccessoriesFEAD的理想功能是把扭矩传递给附件Irregularityinrotationisakeynoise旋转不规则是一个关键的干扰Thetensionercompensatesforthenoise张紧轮对该干扰进行补偿ThecorrectfunctioningofthetensionerisapriorityfortheFEADteam张紧轮的正确机能对于前端驱动附件组是最首要的。FEADFunctionandOperation

FE88CustomerRequirements

顾客需求FEADSDSRequirementFEADSDS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。ADVMisrequiredtoverifythisrequirement需要DVM来验证这一要求CustomerRequirements

顾客需求FEAD89ExistingDVTest

现有的DV试验ThereisanexistingDVMfortherequirement对该要求有一现有的DVMTheteamneedtoassessifthisDVMisappropriate小组需要评估该DVM是否合适ExistingDVTest

现有的DV试验There90REDinSub-SystemDV

子系统DV中的REDSystemandSub-SystemlevelDVMsmustincludeconsiderationofnoises系统和子系统级别的DVM必须包括干扰需要考虑的事项IntheFEADexampleexcessivebeltvibrationwasidentifiedasacriticalerrorstate.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TheDVMwasassessedtobeinadequateforthisfailuremodeinthepresenceofnoise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REDinSub-SystemDV

子系统DV中的RE91FEADAcceptanceCriteria

FEAD验收标准TheacceptancecriteriawasassessedbytheteamandfoundtocovertheSDSrequirement,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。FEADAcceptanceCriteria

FEAD验92ApplicationofRED

RED的应用Theteamneedstoconsiderallkeynoisefactors小组需要考虑所有关键干扰因素Thekeynoisefactorswereidentifiedas:确认关键噪声为：Carryovertensionerinanewenvironment在新的环境中借用张紧轮装置Accessoryloading附加载荷TheseNoisefactorswerenottakenintoaccountinthepreviousDVM.在以前的DVM中没有考虑这些干扰因素ApplicationofRED

RED的应用Thet93PreviousRobustnessStudies

之前的殷实可靠性研究Previousrobustnessstudiesareakeysourceofinformation之前的殷实可靠性研究是信息的关键来源Theteamcanusethisinformationfortheirdesignandtesting小组可以把这一信息用于设计和测试Thistypeofinformationcancomefromsimilarordifferentvehicles这种类型的信息可以来自相似或不同的车辆Thesestrategieswereincorporatedintothenewdesign.这些策略可以并入新的设计中PreviousRobustnessStudies

之前94CheckofDVMObjective

DVM目标的检查ThedesignteamdidnotthinkthattheobjectiveintheexistingDVMcoveredrobustness设计小组不认为现有DVM中的目标涵盖了殷实可靠性DVMObjectiverevisedtoincluderobustness修正DVM目标，使其包括殷实可靠性CheckofDVMObjective

DVM目标的检95DVMTestMethod

DVM试验方法Theteamthenturneditsattentiontothetestmethod然后小组把注意力转向试验方法Thismethodhadbeenusedonpreviousprogramsbuttheseprogramshadexperiencedfailures

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DVMTestMethod

DVM试验方法Thetea96ApplyingRED

应用REDAREDapproach,wasusedtomodifytheDVM.采用RED的方法修改DVMAG8Dstudyhadbeenconductedtoresolvethebeltsquealproblemonthepreviousvehicle.采用了全球8D的研究来解决原来车辆上皮带尖叫的问题TheG8DiskeyinformationforRED全球8D对于RED是关键的信息ApplyingRED

应用REDAREDapproa97Global8DSummaryReport

全球8D总结报告Global8DSummaryReport

全球8D总98Global8DSummaryFindings

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%Global8DSummaryFindings

全球899ConfirmingRobustness

确定殷实可靠性ThesuccessfulimprovementoftheFEADrobustnesstodifferentaccessoryloadingconditionsmeantthatoneoftheteam'sprioritieswastoensurethatthisrobustnesswouldbeconfirmedbytherevisedDVM.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。ConfirmingRobustness

确定殷实可靠性T100DesignFMEAReview

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DesignFMEAReview

计划FMEA评审项目潜101P-DiagramasSourceofInformation

P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P-DiagramasSourceofInforma102FMEAtoP-DiagramCrossCheck

FMEA对P图的交叉检查FMEAtoP-DiagramCrossCheck

103FMEAContents

FMEA内容PotentialCause(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-diagramNoisefactor)ExternalEnvironment（P图干扰噪声因素）外部环境Drivingterrain行驶地形Temperature温度Humidity湿度Water水Contamination污染PotentialCause(s)/Mechanism(s)ofFailure潜在原因/失效机理FEADSub-SystemDesignFMEAFEAD子系统设计FMEABeltspanVibrationdueto:Insufficientsystemdampingduetocrankshaftcyclicirregularitygreaterthansystemdesignassumptions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SystemInteractions:系统交互作用Enginecalibration发动机标定Crankshaftirregularity曲轴不规则Accessoryloadrequirements附加载荷的要求Numberandtypeofaccessories附件的数量及类型Routing(with/withoutAC)路由（带/不带空调）Accessorywear附件磨损Torsionalvibration扭转振动Wrapanglevariation包角振动FMEAContents

FMEA内容Potential104P-Diagram/FMEAInputsintoDVM

P图/FMEA输入到DVMOriginalDVM原始DVMP-Diagram/FMEAInputsintoDVM105UsingCAEasPartofVerification

使用CAE作为验证的一部分TheDesignTeam’sCAErepresentativehashighlightedtotheteamthataCAEmodeloftheFEADisavailable设计小组的CAE代表向小组强调FEAD的CAE模型已经具备TheCAEmodelneedstobecalibratedCAE模型需要进行校准Thecalibrationwillallowthemodeltohaveongoingusefulness标定将使得模型具有正在进行的有效性UsingCAEasPartofVerificat106ModificationofDVMTestDescription

DVM试验描述的更改PreviousTestDescription以前的试验描述Usingavideocameraand,ifnecessary,astrobelight,recordtheFEADsystemwhiletheengineisonadynosubjecttoload.ScalesmaybeplacedalongsidethebeltandtensionersothataroughestimatecanbemadeofAmplitudeofmovement.Sweeptheenginefromidletomaximumspeed.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。ModifiedTestDescription更改后的试验描述CAEsimulation:Modelbasedonparameterdesignexperimentandincludetheeffectofcyclicirregularityatthecrankpulleyonbeltandtensionervibration.TheeffectofthefollowingtobeincludedasNoisefactors: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(includingworstcase)附件载荷（的不同级别）（包括最糟糕的情况）Beltrouting皮带的路由Variationofbeltelasticproperties皮带弹性特性的变差Temperature温度Aging/durabilityofFEADcomponentsFEAD零件的老化/耐久性ManufacturingPiece-to-PieceVariation件与件间的制造变差ModificationofDVMTestDescr107ModificationofMeasurables/ObservablesandAcceptanceCriteria

测量/观察和验收标准的更改AcceptanceCriteria标准Amplitudeversusfrequencydistributionw