福特公司DV&PV培训教材.ppt

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1、Design Verification and Production Validation设计验证和生产确认,Welcome,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 Leve

2、l 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 pr

3、oduct 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。,DV&PV Within Systems Engin

4、eering,系统工程内的DV&PV,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,S

5、ystems“V”Model系统V模型,DV&PV is a requirements driven processDV和PV 是一个需求驱动的过程DV&PV 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

6、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 M

7、anufacturing进行制造的系统方法,设计,制 造,Note-S5/P5 Timing,FPDS TimingFPDS时间,Full DVP CreatedReqts&Targets Frozen生成完整的DVP需求&目标冻结,Design“V”and FPDS TimingDV&PV设计V形图及FPDS时间的DV&PV,Low低,High高,ActivityLevel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

8、&PV are key requirements for sign off of a vehicle programDV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,DV&PV 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 Compone

9、nts and system robustly meet customer requirementsDV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 exploratoryDV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”DV&PV comes after the design phase not during the design phaseDV 和PV 要在设计以后而不是在设

10、计阶段中进行,Introduction of the FEAD Example,FEAD举例介绍,FEAD ExampleFEAD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DV&PV,The Front End Accessory Drive(FEAD)How It WorksFEAD-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

11、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 energyFEAD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 le

12、vels.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

13、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&PVDV&PV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 effic

14、ient 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 Tes

15、ts(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 DV&PV incorporate Noise factors and their effects in order to ensure that the product will meet its design intent under all condit

16、ions.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 D

17、esign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 DV&PV as RED will drive the type of DV&PV 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DV&PV试验的类型。RED focuses on identification and management of noise factorsRED着重于干扰因素的

18、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 VRED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 processRED是以小组为基础的过程RED applies throughout Ford(Design and Manufacturing)and at suppliersRED应用于整个福特（设计和制造）以及供应商。,Applying RED应用RED,RED allows test

19、ing at the lowest possible levelRED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 LevelRED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

20、 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 LevelRED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

21、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 engineer

22、s 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

23、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 Meth

24、ods(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 resultsDVM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,

25、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

26、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 DegradationHistory,Example:Functiona

27、l 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

28、 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 nois

29、es 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,FailureSeverity&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？,Nor

30、mal 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 use95th 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,SouthernEuropeanCities南

31、欧城市,NorthernEuropeanCities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

32、&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 pr

33、ocedure 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 acc

34、elerated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

35、 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

36、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

37、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DV&PV,Vehicle Level DV&PV整车级别的DV&PV,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 experi

38、encing 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

39、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

40、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

41、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Ve

42、rification 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 DV&PV全球8D和DV&PV,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

43、 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-Sys

44、temFEAD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CAEQuality质量Reliability可靠性Aim to verify at the lowest possible level on the V瞄准V模形最低

45、可能级别上进行验证,FEAD Design Verification PlanFEAD设计验证计划,FEAD Function and OperationFEAD功能和运行,Ideal function of the FEAD is to transfer torque to the accessoriesFEAD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

46、 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

47、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DVMThe team need to assess if this DVM is appropriate小组需要评估该DVM是否合适,RED

48、 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

49、 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 CriteriaFEAD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 REDRED的应用,The team needs to consider all key noise fa

50、ctors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