设计验证和生产确认[福特FORD].ppt

Welcome,Design Verification and Production Validation 设计验证和生产确认,Ford Technical Education Program福特技术培训项目,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 and 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。,DVPV Within Systems Engineering,系统工程内的DVPV,Verification and Systemic Thinking 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,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,DVPV is a requirements driven process DV和PV 是一个需求驱动的过程 DVPV is 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。,Defining 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,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。,反复计划,工作顺序,DV PV and PDSA,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,设计,制 造,Note - S5/P5 Timing,FPDS Timing FPDS时间,Full DVP Created Reqts Targets Frozen 生成完整的DVP 需求目标冻结,Design “V” and FPDS Timing DVPV 设计V形图及FPDS时间的DVPV,Low 低,High 高,Activity Level 活动级别,Time时间 = Design Verification设计验证 = Production Process Validation生产过程确认,SI,SC,PA,PR,CP,LR,J1,DV PV and FPDS,DV PV are key requirements for sign off of a vehicle program DV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) PV,Inputs Used in the Verification and Validation Processes 在验证和确认过程中使用的输入,DVPV as Part of the Product 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 requirements DV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 exploratory DV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” DVPV comes after the design phase not during the design phase DV 和PV 要在设计以后而不是在设计阶段中进行,Introduction of the FEAD Example,FEAD举例介绍,FEAD Example FEAD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DVPV,The Front End Accessory Drive (FEAD) How It Works 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 energy FEAD传输该能量,Design Verification at All Levels 所有级别上的设计验证,Design Verification 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 design 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 PV DVPV的工具,Methods Used in Efficient and Effective Verification 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 Profiles 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 DVPV incorporate Noise factors and their effects in order 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 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 DVPV as RED will drive the type of DVPV 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DVPV试验的类型。 RED focuses on identification and management of noise factors RED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 V RED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 process RED是以小组为基础的过程 RED applies throughout Ford (Design and Manufacturing) and at suppliers RED应用于整个福特（设计和制造）以及供应商。,Applying RED 应用RED,RED allows testing at the lowest possible level RED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 Level RED应用于子系统级别,When developing Design Verification Methods at the system/sub-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 Level RED应用于零部件级别,At the component level testing is 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 the 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,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-FDVS,FDVS 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 includes 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 contain all the information required to conduct testing and record results DVM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 general 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 Bogey,Minimum 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,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,Bogey,Complete Degradation History,Example: Functional Degradation of Three Design Alternatives 范例：三种设计方案的功能退化,C,B,A,Test 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 greater 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相似条件下优先性能的知识,Normal通常,High高,High高,Low低,Failure Severity Occurrence失效严重度发生,Test Level测试水平,Bogey,Failure,Degradation,Real 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,Observation 观察,Percentiles百分点,Actual Customer Usage 真正顾客使用,5% Total,95th Percentile use 95th 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,Southern European Cities 南欧城市,Northern European Cities 北欧城市,Usage Profile and Customer Duty Cycle 使用概况及顾客工况,Duty Cycle 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: 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 Specified Test Procedure,在指定的试验规程上加大加载频次,0,100,200,300,400,30%,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 loads,50 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,Accelerated 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 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 competitive 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 Demonstration 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DVPV,Vehicle Level DV PV 整车级别的DVPV,Verification and Validation 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 FEAD,Problem 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8D,A Global 8D was conducted on the van 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RED,Having 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, 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 were 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DVM,The 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 DVPV 全球8D和DVPV,Global 8D studies 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 error 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DV,FEAD Sub-System FEAD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 functional 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 CAE Quality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 Plan FEAD设计验证计划,FEAD Function and Operation FEAD功能和运行,Ideal function of the FEAD is to transfer torque to the accessories FEAD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 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 requirement 对该要求有一现有的DVM The 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RED,System 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 Criteria FEAD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，但仍需要小的改进。,Application of RED RED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 were incorporated into the new design. 这些策略可以并入新的设计中,Check of DVM Objective DVM目标的检查,The design team did not think that the objective in the existing DVM covered robustness 设计小组不认为现有DVM中的目标涵盖了殷实可靠性 DVM Objective revised to include robustness 修正DVM目标，使其包括殷实可靠性,DVM Test Method DVM试验方法,The team then turned its attention to the test method 然后小组把注意力转向试验方法 This method had been used on previous programs but these programs had experienced 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RED,A RED approach, was used to modify the DVM. 采用RED的方法修改DVM A G8D study had been conducted to resolve the belt squeal problem on the previous vehicle. 采用了全球8D的研究来解决原来车辆上皮带尖叫的问题 The G8D is key information for RED 全球8D对于RED是关键的信息,Global 8D Summary Report 全球8D总结报告,Global 8D Summary 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,The successful improvement of the FEAD robustness to different accessory loading conditions meant that one of the teams priorities was to ensure that this robustness would be confirmed by the revised 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。,Design FMEA Review 计划FMEA评审,P-Diagram as Source of Information 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,FMEA to P-Diagram Cross Check FMEA对P图的交叉检查,FMEA Contents FMEA内容,P-Diagram/FMEA Inputs into DVM P图/FMEA 输入到DVM,Original DVM 原始DVM,Using CAE as Part of Verification 使用CAE作为验证的一部分,The Design Teams CAE representative has highlighted to the team that a CAE model of the FEAD is available 设计小组的CAE代表向小组强调FEAD的CAE模型已经具备 The CAE model needs to be calibrated CAE模型需要进行校准 The calibration will allow the model to have ongoing usefulness 标定将使得模型具有正在进行的有效性,Modification of DVM Test Description DVM试验描述的更改,Modification of Measurables/ Observables and Acceptance Criteria 测量/观察和验收标准的更改,Modification of Resource and Test Equipment 资源和试验设备的更改,Advantages of Using CAE