设计验证和生产确认福特FORD

WelcomeDesignVerificationandProductionValidation设计验证和生产确认FordTechnicalEducationProgram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CourseStructure

课程结构DesignVerificationandProductionValidation

设计验证和

生产确认DesignVerificationandProductionValidation

设计验证和生产确认BenefittoFordMotorCompany

对福特汽车公司的益处DesignVerificationand

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。DV&PVWithinSystemsEngineering系统工程内的DV&PVVerificationandSystemicThinking

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

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Systems“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-SystemComponentDefiningRequirements

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VerificationBottom-up

验证自下至上

VehicleSystemSub-SystemComponentITERATIVE

PLANNINGTopDown自上至下BottomUp自下至上SEQUENTIAL

DOING反复计划工作顺序DV&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LowerLevelInteractions

较低级别的相互作用SystemsApproachtoManufacturing

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Note-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Design“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SISCPAPRCPLRJ1DV&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)—PVInputsUsedintheVerificationandValidationProcesses

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DV&PVasPartoftheProductCreationProcess

DV和PV作为产品创造过程的部分IntroductionoftheFEADExampleFEAD举例介绍FEADExample

FEAD范例TheFrontEndAccessoryDrive(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DesignVerificationatAllLevels

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。ProductionValidation

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。ConfirmingRobustandReliableDesign–Robustness

确认殷实及可靠的设计-殷实可靠性ToolsForDV&PV

DV&PV的工具MethodsUsedinEfficientandEffectiveVerification

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

(RED)殷实的工程设计NoiseFactorManagement

干扰因素的管理RobustEngineeringDesign

殷实可靠的工程设计RobustEngineeringDesign

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。ApplyingRED

应用REDREDAppliedatSub-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。REDAppliedatComponentLevel

RED应用于零部件级别REDintheDesignProcess

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FordDesignVerificationSystem福特设计验证系统FordDesignVerificationSystem–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）DesignVerificationMethod

设计验证方法TestingMethodologies试验方法学TesttoBogeyMinimumAcceptableFunction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TesttoFailure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DegradationTesting

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

ofThreeDesignAlternatives

范例：三种设计方案的功能退化CBATestLevelComparison

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退化失效概率StatisticalConfidence

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EngineeringConfidenceReducesSampleSize

工程可信度减小样本量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BogeyFailureDegradationRealWorldUsageProfiles真正顾客使用概况TypesofCustomerUsage

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

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

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）Example: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UsageProfileandCustomerDutyCycle

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DutyCycleExample

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AcceleratedTesting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portionofprocedurewithincreasedloads50mphFreeway50mph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KeyLifeTests关键寿命试验IS是ISNot否

ReliabilityandRobustnessDemonstrationMatrix可靠性和殷实可靠性实证矩阵图SelfAssessment自我评估VehicleLevelDV&PV

整车级别的DV&PVVehicleLevelDV&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—TransitFEADProblem

问题Customerswereexperiencingproblemsafterwashingtheirvehiclesordrivingthroughwater顾客在洗车或开车涉水后出现问题Global8D

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。ApplyingRED

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。VerifyingRobustness

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RevisedDVM

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PlanningandImplementingVerificationandValidation

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Global8DandDV&PV

全球8D和DV&PVSelfAssessment自评System/Sub-SystemLevelDV

系统/子系统级别DVFEADSub-System

FEAD子系统AFEADsystemistobedevelopedforanewvehicleprogram为一新车项目开发一个FEAD系统Sub-SystemLevelDesignVerification

子系统级别设计验证FEADDesignVerificationPlan

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FEADFunctionandOperation

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。CustomerRequirements

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ThereisanexistingDVMfortherequirement对该要求有一现有的DVMTheteamneedtoassessifthisDVMisappropriate小组需要评估该DVM是否合适REDinSub-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FEADAcceptanceCriteria

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。ApplicationofRED

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PreviousRobustnessStudies

之前的殷实可靠性研究CheckofDVMObjective

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ApplyingRED

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Global8DSummaryReport

全球8D总结报告Global8DSummaryFindings

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%ConfirmingRobustness

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。DesignFMEAReview

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-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FMEAtoP-DiagramCrossCheck

FMEA对P图的交叉检查FMEAContents

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P-Diagram/FMEAInputsintoDVM

P图/FMEA输入到DVMOriginalDVM原始DVMUsingCAEasPartofVerification

使用CAE作为验证的一部分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ModificationofMeasurables/ObservablesandAcceptanceCriteria

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

振幅相对频率的分布要在可接受的限度内。Maximumtensioneramplitudeleaves10%oftotaltravelcleartoendstop.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。Measurables/Observations测量/观察AmplitudeofbeltspanvibrationandTensionerarmmovementasafunctionoffrequency.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PreviousResourcesandTestEquipmentRequired:

以前要求的资源和试验设备FullydressedenginetoCPlevelinstalledonenginedyno,Videocamera,tripod,strobelightandhighspeedvideocamera.把安装到台架上的发动机装配至完全符合CP水平。摄影机、三角架、闪光灯、和高速摄影机。ModifiedResourcesandTestEquipmentRequired:更改所要求的资源和试验设备FullydressedenginetoCPlevelinstalledonenginedyno,Lasermeasurementequipment,variousFEADconfigurationstosimulateNoiseconditions/CAE.把安装到台架上的发动机装配至完全符合CP水平。激光测量仪，各种FEAD配置到模拟干扰条件/CAE。AdvantagesofUsingCAE

使用CAE的优势AssumingthattheparallelCAEandhardwareverificationhasasuccessfuloutcome,CAEcanbespecifiedasthebasisoffutureverification.假设并行的CAE和硬件验证具有成功的结果，可以指定CAE为将来验证的基础。AvailabilityofParts

零件的有效性PiecetoPiecevariationwasincludedintheDVM:在DVM中包括件与件间的变差beltdimensions皮带的尺寸tensionerdimensions张紧轮的尺寸beltelasticprperties皮带的弹性特性tensionerelasticproperties张紧轮的弹性特性Assembly装配Productionbeltswerenotavailableintimetosupporthardwareverification生产皮带不能及时到位来支持硬件的验证CAEResults

CAE结果AcceptanceCriteria验收标准Amplitudeversusfrequencydistributionwithinacceptedlimit.

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

TotalResults

总的结果TheresultsoftheCAEandhardwareverificationshowedgoodcorrelation.CAE的结果和硬件验证显示了良好的相关性。Sub-SystemDVSummary

子系统DV总结Thissectioncoveredseveralimportantpoints:这一部分涵盖了几个重要点：DesignVerificationisconductedatthesub-systemleveltoconfirmtherobustnessofthedesign在子系统级别采用设计验证来确认设计的殷实可靠性VDS/SDSrepresentstheengineeringtranslationofcustomerrequirementsVDS/SDS代表了顾客需求的工程转化Designverificationshouldberequirementsdriven设计验证应该是需求驱动的ProductionvariationisacriticalNoisefactorwhoseinfluenceonthefunctionalperformanceofthedesignmusttobeverified生产变差是一个关键干扰因素，其对设计的功能性性能的影响必须得到验证ACAEmodelensuresthatverificationisconductedinatimelyandcosteffectivemanner,andallowsincorporationoftheeffectofmultipleNoisefactorsCAE模型确保以有效的时间和成本的方式进行验证，而且使得多重干扰因素的影响都结合在一起。SelfAssessment自评SelfAssessment自评ComponentLevelDV

零部件级别的DVRoleofComponentLevelDesignVerification

零部件级别设计验证的任务Thissectionofthecoursefocuseson:课程的这一部分着重于：TheDesignVerificationofthebeltandthetensioner皮带和张紧轮的设计验证DesignVerificationTeam

设计验证小组FEADProblems

FEAD问题RootCauseoftheBeltSlip

皮带打滑的根本原因4：根本原因：张紧轮性能随着时间的功能退化和皮带在长度规格的上限有关8D总结报告SystemDesignSpecification

系统设计规范InteractionsBetweenComponents

零件间的交互作用SystemInteractions

系统交互作用ParameterDesignStudy

参数设计研究Despitethissuccess,thebeltlengthmustbemaintainedwithincertainvalueswhichwillneedtobeverified.不管这个结果，皮带长度必须保持在一定的数值内，这一点需要验证。KLTDevelopmentSummary

KLT开发总结KLTDevelopmentSummary

KLT开发总结KeyLifeTestingRegime

关键寿命测试状况高温耐久性试验状况摘录RevisedDVMforTensionerDurability

针对张紧轮耐久性修正DVMCrossCheckwithDFMEA

和DFMEA交叉检查皮带跳动是因为：由于下列情况引起的不受控制的张紧轮响应：和起动时大的发动机扭矩脉冲相关联的高附件惯性和快速发动机减速相关联的高附件惯性。潜在原因/失效机理IncludingtheEffectofNoiseintheDVM

在DVM中包括干扰的影响RevisedDVMforTensionerDurability

针对张紧轮耐久性修正DVMAcceleratedTesting

加速测试高温耐久性测试状况摘录MeasuringFunctionalDegradation

测量功能退化Life(Cycles,Yearsetc)寿命（循环，年等）Performance性能TargetLife目标寿命TargetPerformance目标性能VerificationResults

验证结果

验收标准1400个加速试验循环后弹簧扭矩＞NM加速试验循环失效标准张紧轮弹簧退化图VerificationFailure

验证失效VerificationFailure

验证失效InadequateDesign

不充分的设计DesignImprovement

设计改进ByusingtheParameterDesignfindingstheteamwereabletomakeadesignimprovement通过使用参数设计的已得数据，小组能进行设计的改进Thenewdesignmustnowbeverified现在必须验证新的设计VerificationResults

验证结果

SelfAssessment自评System/Sub-SystemLevelPV

系统/子系统级别的PVSystem/Sub-SystemLevelPV

系统/子系统级别的PVPreviously,welookedathowtheFEADsub-systemunderwentdesignverificationtoensurethattheFEADperformancewasrobusttotensionerandbeltvibration.以前，我们着眼于FEAD子系统如何通过设计验证以确保FEAD的性能对张紧轮和皮带的振动是殷实可靠的InthisscenarioManufacturingProductionValidationoftheFEADsub-systemisgoingtobepresented.在这里将会介绍FEAD子系统的制造生产确认ThePVTeam

PV小组Again,acrossfunctionteamisrequired:同样，要求一个交叉功能小组：AQualityandReliabilityEngineer一个质量和可靠性工程师AProcessEngineerfromProduction一个生产工艺工程师TheFEADsub-systemEngineerfromProductDesignFEAD子系统产品设计工程师AQualityEngineerfromthetensioningequipmentsupplier一个来自张力调整设备供应商的质量工程师TheProductionManagerfromtheFEADbeltsupplier一个来自FEAD皮带供应商的生产经理FEADProductionValidation

FEAD生产确认ThepurposeofProductionValidationistovalidatethatthemanufacturingandassemblyprocessesareabletoproduceaproductthatmeetsitsdesignintentandatneededvolumes.生产确认的目的是确认制造和装配工艺能按照所需要的产量生产出符合设计意图的产品Inthescenariothatwillbeused,thisinvolvesvalidatingthatthebelttensioningoperationisabletoadjustbeltstotheappropriatetensionconsistently.这里将会采用这种方式，这包括了确认皮带张力调整操作始终能调整皮带至适当的张紧力ProductionValidationwithinAPQP

在APQP内的生产确认APQPisakeytoolforsuppliersthatdefinesthestepstosatisfycustomerrequirementsAPQP是针对供应商的一个关键工具，定义了满足顾客需求的一系列步骤。DVandPVarebothelementsofAPQPDV和PV都是APQP的要素APQPispartofFord’sQualityOperatingSystem(QOS)APQP是福特质量操作系统的一部分。APQP,RED&FPDSProductandProcessValidationRobustnessProcessFlowProductDesignandDevelopmentProcessDesignandDevelopmentAPQPProcessCustomerInputRequirementsCraftsmanshipDFMEADVP&RDrawingsandSpecificationsManufacturingProcessFlowChartProcessFMEAPreliminaryProcessCapabilityProductionValidationTestingMeasurementSystemEvaluationSISCPASTPHPRCCLSFSCPKOLRJ1PlanandDefineProductandProcessValidationRobustnessProcessFlowRobustnessProcessFlowProductDesignandDevelopmentProcessDesignandDevelopmentAPQPProcessCustomerInputRequirementsCraftsmanshipDFMEADVP&RDrawingsandSpecificationsManufacturingProcessFlowChartProcessFMEAPreliminaryProcessCapabilityProductionValidationTestingMeasurementSystemEvaluationSISCPASTPHPRCCLSFSCPKOLRJ1PlanandDefinePlanandDefine策划和定义产品设计和开发工艺设计和开发产品和工艺确认顾客输入需求精致工艺图纸和技术规范制造工艺流程工艺FMEA测量系统评估初始工艺能力生产确认试验ProductionValidationandPPAP

生产确认和PPAPOneofthelastelementsofAPQPistheProductionPartApprovalProcess(PPAP).APQP最后的要素之一是生产零件认可过程（PPAP）ProductionValidationispartofthisprocess.生产确认是这个过程的一部分MeasurementSystemsAnalysisandProcessCapability

测量系统分析和过程能力MeasurementSystemAnalysisandProcessCapabilityareimportantaspectsofProductionValidation.测量系统分析和过程能力是生产确认的重要方面。MeasurementSystemAnalysisverifiestheperformanceoftheequipmentusedtomeasuretheprocess;inthiscase,FEADbelttension.测量系统分析是验证用来测量过程的设备性能，在这里即指FEAD皮带张紧力ProcessCapabilityisanassessmentoftheabilityofthemanufacturingprocesstoproduceproducttoitsengineeringspecification.过程能力是生产产品符合其工程技术规范的产品的制造过程能力的评估FEADBeltTensioning

FEAD皮带张力调整Inadjustingthebelttothecorrecttension,atensioningunitisplacedontheFEAD.要调整皮带至正确的张紧力时，把张紧装置放在FEAD上FortheFEADshownhere,tensioningisaccomplishedbyadjustingthepositionofanidlerpulleyusingajackscrew.针对这里所示的FEAD，使用螺旋起重机通过调整惰轮的位置来完成张力调整FEADTensioningOperation

FEAD张力调整操作Theteamreviewedhistoricalinformationontensioningoperationssimilartotheoperationtheyweregoingtovalidate.小组审核了与他们即将确认的操作相类似的张紧操作的历史信息TheywereparticularlyinterestedinaG8Dstudythathadbeenconductedonaproblemencounteredduringongoingproduction.他们尤其对现生产中所遇问题采取的G8D研究感兴趣ProbleminProduction

生产中的问题TheproblemwiththeFEADtensioningoperationoccurreddespitethefactthatProcessCapabilityhadbeenachievedasapartofProductionValidationafterthemachinehadbeeninstalled.尽管作为生产确认的一部分，过程能力已经达到，在安装机器后FEAD张力调整操作的问题还是出现了RepresentativeValidationMethod

典型确认方法OnreviewingthebelttensioningproblemtheteamrecognizedtheneedtoreviewthewayinwhichProcessCapabilityoftheFEADbelttensionwasassessed.评审皮带张力调整问题时，小组意识到需要审核FEAD皮带张紧力过程能力的评估方式TheteamagreedthataValidationmethodshouldbedevisedthatwouldbemorerepresentativeofongoingproduction.小组同意应该设计一种更具有现生产代表性的确认方法。VerificationofRobustness

殷实可靠性的验证VerificationofRobustnessneedstobeconsideredfortheprocessaswellastheproduct对过程和产品都需要考虑殷实可靠性的验证。ApplyingREDinManufacturing

在制造应用REDThesamenoisefactorconsiderationsapply相同干扰因素考虑事项应用ThesameNoiseFactorManagementStrategiesapply相同干扰因素管理策略应用EachneedstobethoughtofalittledifferentlytoREDfortheproduct对于该产品，每一项都需要对RED有不同的考虑NoisesinthePFMEA

PFMEA中的干扰InthesamewaythatnoisesappearinthecausesectionoftheDFMEA,theshouldalsoappearintheCausesectionofthePFMEA同样的方式，干扰在DFMEA的原因部分出现，也应该在PFMEA的原因部分出现NoiseFactorManagementStrategy

噪声干扰因素