提高内燃机产品使用可靠性的捷径与对策(潍柴胡金寿).ppt

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ProductreliabilitydirectorofWeichaiPower胡金寿HuJinshou2014年3月30日March30th,2014,目录Contents,前言INTRODUTION,一、前言Introduction,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,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Fueloilquality,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,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Itsquiteefficienttoconsummatedesignwiththeseexperienceandlesson,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,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,制造可靠性案例-曲轴连杆烧坏Manufacturereliabilitycaseconnectingrodburned,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,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,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,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,三、提高产品使用可靠性从故障（失效）分析抓起Productusereliabilityimproving,failureanalysiscomesfirst,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,三、提高产品使用可靠性从故障（失效）分析抓起Productusereliabilityimproving,failureanalysiscomesfirst,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,propaneandbutanesinktobottom.outletpipebelowthegas-holderconveypropaneandbutanetocombustor,causingknockeasily.,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,设计对标是快速提高内燃机设计可靠性的捷径Benchmarkingdesignisashortcuttoimproveproductreliability,四、设计对标是快速提高内燃机设计可靠性的捷径Benchmarkingdesignisashortcuttoimproveproductreliability,四、设计对标是快速提高内燃机设计可靠性的捷径Benchmarkingdesignisashortcuttoimproveproductreliability,四、设计对标是快速提高内燃机设计可靠性的捷径Benchmarkingdesignisashortcuttoimproveproductreliability,对标,四、设计对标是快速提高内燃机设计可靠性的捷径Benchmarkingdesignisashortcuttoimproveproductreliability,四、设计对标是快速提高内燃机设计可靠性的捷径Benchmarkingdesignisashortcuttoimproveproductreliability,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SuitablematchmainlyrelyonOEMsresearchinthepast,nowitsbuyersmarket,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,externalexhaustmanifoldwithoutsupportcausesuperchargerbrokenandunsuitableairfiltercausedieselengineprematurewearetc.,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、建立产品可靠性数据库Constructproductreliabilitydatabase,全面收集分析本企业产品所有问题，系统总结本企业成功经验和失败教训，编写故障分析案例、设计准则、建立质量可靠性信息系统Collectalltheproductproblems,summarizesuccessfulexperienceandfailurelessonsbythenumbers,compilefailureanalysiscase,designstandard,establishqualityreliabilityinformationsystem.企业可靠性工作的重点应放在实际消除现场失效上Enterpriseshouldputemphasisofreliabilityworkintofieldfailureelimination.,六、建立