汽车变速器维修决策方法研究
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摘要
随着经济发展的全球化,科技的发展,现有工业设备日益精密化、复杂化、高性能化,制造企业为了在全球市场上最大程度的提高自己的制造能力和满足客户的需要,在提高产品质量的同时,也必须提高服务和维修的水平,随之而来的就是企业必须花费大量的人力资源和维修资源。本文从这点出发,做了以下研究内容,主要工作如下:
首先,通过对FMEA理论的分析和探讨,寻找到FMEA应用到汽车变速器维修决策的方法和途径,并通过以CAS5-20A变速器为具体研究对象来分析,对该变速器的部分零部件进行故障模式影响分析,列出其可能发生的故障模式,确定其故障等级,并利用危害度计算将故障模式加以量化,可以清晰的看到每个故障模式的危害度,更好的对设备进行维护。
其次,通过对FTA理论的分析和探讨,建立CAS5-20A变速器的完整故障树,对该故障树的定性分析确定其最小割集,找出导致顶事件发生的底事件或底事件组合,从而更好的预防故障的发生,并对其进行定量分析,计算出顶事件发生概率和底事件重要度。
然后,通过对AHP的理论分析,以及对变速器维修决策的可行性分析,根据设备的可靠性、维修性、经济性等影响因素,构造了变速器的层次分析模型,通过大量的数据分析,构造判断矩阵并进行一致性检验,最终计算出事后维修、定期预防维修和视情维修三种维修方式的权重。从而为汽车变速器的维修方式提供有价值的理论参考。
最后,综合上述研究成果,开发了汽车变速器维修决策支持系统,能对变速器进行FMEA分析和FTA分析,并利用AHP决策出最佳维修方式。
With the development of economic globalization,science and technology,and industrial equipment becoming precise treatment,complexity,and high-performance, the manufacturing enterprises are in order to improve their manufacturing ability and satisfy customers' requirements in the global market,so they must improve the product quality,raise the service and maintenance level.And as followed,the enterprises must spend a lot of human resources and maintenance resources.From this point,this article has been done the following studies:
First,through the theory of FMEA analysis and discussion,find a method to apply FMEA to automobile transmission maintenance decision-making.Through the analysis of CAS5-20A transmission,list the failure mode and effect analysis,possible failure modes of the transmission parts,and determine the fault level.Then quantify the failure mode by density of infection calculation.Users can see the density of infection of every failure mode clearly,and then can maintain the transmission properly.
Second,through the theory of FTA analysis and discussion,construct the fault tree of CAS5-20A transmission.And then do the qualitative analysis of the fault tree; find its minimum cut set.The can find out the bottom events or assemble of the bottom event which can cause the Top Event to happen,in order to prevent the fault to happen.Then do quantitative analysis of the fault tree,calculate the incidence of top event and the importance of bottom events.
Third,through the theory of AHP analysis and discussion,analyze the feasibility of maintenance decision of the transmission.Based on the reliability,maintainability and economic factors,construct the transmission modal of AHP.Then construct judgment matrixes by empirical data,and inspection their consistency.Finally, calculate the weight of three maintenance method,such as breakdown maintenance, preventive maintenance and regulation maintenance.For the maintenance of automobile transmission theory provide valuable reference.
Finally,synthesized the research results,and develop decision support system of the automobile transmission maintenance.It can carry out analysis FMEA analysis and FTA analysis of automobile transmission,and it can be used AHP to decide the best maintenance methods.
首先,通过对FMEA理论的分析和探讨,寻找到FMEA应用到汽车变速器维修决策的方法和途径,并通过以CAS5-20A变速器为具体研究对象来分析,对该变速器的部分零部件进行故障模式影响分析,列出其可能发生的故障模式,确定其故障等级,并利用危害度计算将故障模式加以量化,可以清晰的看到每个故障模式的危害度,更好的对设备进行维护。
其次,通过对FTA理论的分析和探讨,建立CAS5-20A变速器的完整故障树,对该故障树的定性分析确定其最小割集,找出导致顶事件发生的底事件或底事件组合,从而更好的预防故障的发生,并对其进行定量分析,计算出顶事件发生概率和底事件重要度。
然后,通过对AHP的理论分析,以及对变速器维修决策的可行性分析,根据设备的可靠性、维修性、经济性等影响因素,构造了变速器的层次分析模型,通过大量的数据分析,构造判断矩阵并进行一致性检验,最终计算出事后维修、定期预防维修和视情维修三种维修方式的权重。从而为汽车变速器的维修方式提供有价值的理论参考。
最后,综合上述研究成果,开发了汽车变速器维修决策支持系统,能对变速器进行FMEA分析和FTA分析,并利用AHP决策出最佳维修方式。
With the development of economic globalization,science and technology,and industrial equipment becoming precise treatment,complexity,and high-performance, the manufacturing enterprises are in order to improve their manufacturing ability and satisfy customers' requirements in the global market,so they must improve the product quality,raise the service and maintenance level.And as followed,the enterprises must spend a lot of human resources and maintenance resources.From this point,this article has been done the following studies:
First,through the theory of FMEA analysis and discussion,find a method to apply FMEA to automobile transmission maintenance decision-making.Through the analysis of CAS5-20A transmission,list the failure mode and effect analysis,possible failure modes of the transmission parts,and determine the fault level.Then quantify the failure mode by density of infection calculation.Users can see the density of infection of every failure mode clearly,and then can maintain the transmission properly.
Second,through the theory of FTA analysis and discussion,construct the fault tree of CAS5-20A transmission.And then do the qualitative analysis of the fault tree; find its minimum cut set.The can find out the bottom events or assemble of the bottom event which can cause the Top Event to happen,in order to prevent the fault to happen.Then do quantitative analysis of the fault tree,calculate the incidence of top event and the importance of bottom events.
Third,through the theory of AHP analysis and discussion,analyze the feasibility of maintenance decision of the transmission.Based on the reliability,maintainability and economic factors,construct the transmission modal of AHP.Then construct judgment matrixes by empirical data,and inspection their consistency.Finally, calculate the weight of three maintenance method,such as breakdown maintenance, preventive maintenance and regulation maintenance.For the maintenance of automobile transmission theory provide valuable reference.
Finally,synthesized the research results,and develop decision support system of the automobile transmission maintenance.It can carry out analysis FMEA analysis and FTA analysis of automobile transmission,and it can be used AHP to decide the best maintenance methods.
引文
[1]陈学楚.现代维修理论[M].北京:国防工业出版社,2003.
[2]秦英孝.可靠性维修性保障性概论[M].北京:国防工业出版社,2002.
[3]易运辉.装备维修策略及其决策技术研究[D].国防科技大学,2005,11
[4]吴建忠,何海龙.维修思想发展概述[J].装备指挥技术学院学报,2003,6第14卷第3期
[5]王军.发动机缸体生产线模糊动态维修优化决策方法研究[D].吉林大学,2006,6
[6]仓安裕.发动机缸体生产线维修决策方法研究[D].吉林大学,2003,6
[7]催宁博.设备诊断技术[M].天津:南开大学出版社,1993
[8]Block H W,Langberg N A,Savits T H.Repair replacement policies[J].J Appl Prob,1993,30.
[9]Moubray JM,(1995),Maintenance management-A new paradigm,Third annual conference of the society of maintenance &reliability professional.Chicago Illionis.
[10]刘伟,臧铁钢,郭顺生.基于ERP系统的柔性维修技术研究[J].机械工程师,2004,3
[11]吴波,丁毓峰,黎明发.机械系统可靠性维修及决策模型[M].北京:化学工业出版社,2006.
[12]Zhang Haijun,Zuo Hongfu.Maintenance Level Decision of Aero-engine Based on VPRS Theory[J].Transactions of Nanjing University of Aeronautics &Astronautics,2005,12,Vol.22 No.4
[13]李佩玲.设备综合管理[M].北京:中国设备管理培训中心,1993,3
[14]黄昭毅.从美国维修体制的变迁论我国加强预防维修工作的重要性[M].北京:中国设备管理,1994,11
[15][日]北村秀树.机械设备的维修管理系统的现状与展望[M].北京:中国设备管理,1995,3
[16]谢小鹏.设备状态识别与维修决策[M].北京:中国石化出版社,2000,9
[17][美]George E.Connaughton.北美维修技术状况(续)[J].中国设备工程,2001,7:51-52.
[18]蒋太立.基于RCM理论的维修决策研究[D].武汉理工大学,2006,5
[19]刘混举.机械设备的维修思想与主动预防性维修决策的研究[J].全国故障诊断学术会议论文集,武汉,1996
[20]范世东.复杂设备维修类型决策策略探讨[J].武汉交通科技大学学报,1995,12
[21]陈国芳.设备大修计划与管理[M].设备管理与维修,1994,2
[22]严立.港口机械设备针对性维修管理体制[M].中国设备管理,1995,3
[23]Zhu Xinhe,Yan Zhi jun.Maintenance decision of marine machinery based on lubricants monitoring[J].Dalian Maritime University,2002,8,Vol.28,Suppl.
[24]贾希胜,程中华.以可靠性为中心的维修(RCM)发展动态.军械工程学院学报,2002.9(14):29-32
[25]孙有朝,樊蔚勋.以可靠性为中心的维修(RCM)一维修科学的发展趋势.机械工程师,1997.4:55-56
[26]陈刚.减速机械的可靠性维修及其维修决策研究[D].武汉理工大学,2007,5
[27]陈学楚.维修理论基础.北京:科学出版社,1998.12
[28]W.A.Thompsom,On the foundation of reliability,Tchnometries,v23,1981,Feb:1-13
[29]许林,杨健.奥拓轿车够着使用与维修[M].北京:人民交通出版社,2003,3
[30]往敏智,于江,王黎明.微型汽车构造、使用与维修[M].北京:人民交通出版社,1999,9
[31]沈锦.汽车地盘构造与检修[M].北京:机械工业出版社,2006,12
[32](美)D.H.Stamatis.故障模式影响分析:FMEA从理论到实践[M].北京:国防工业出版社,2005
[33](日)盐见弘.故障模式和影响分析与故障树分析的应用[M].北京:机械工业出版社,1987
[34]Potential Failure Mode and Effects Analysis In Design(Design FMEA) and For Manufacturing and Assembly Process(Process FMEA) Instruction Manual·Ford Motor Company,1988,9
[35]K.G.Johnson,M.K.Khan.A study into the use of the Process failure mode and effects analysis(PFMEA) in the automotive industry in the UK[J].Materials Processing Technology,2003,pp.348-356
[36]David J.Russomanno,Ronald D.Bonnell.ABlaekboard Model of an Expert System for Failure Mode and Effects Analysis.PROCEEDINGS Annual RELIABILITY and MAINTAINABILITY Symposium,1992,PP.483-490
[37]ZhaoTingdi,Su Tiejun.Intelligent FMEA Based On Model FIORN.RAMS 2004,pp.386-391
[38]李增辉.FMEA及FTA在汽车产品开发中的应用研究[D].合肥工业大学硕士论文,2006
[39]冒天诚.故障树与船舶自动控制系统的故障诊断[M].大连:大连海事大学出版社,2000,9
[40]王清.基于FMEA和FTA的故障诊断技术及其在DEH系统中的应用[D].华北电力大学,2004,5
[41]Ireza E,Seyed G M.FPGA-based Monte Carlo Simulation for Fault Tree Analysis[J].Microelectronics Reliability,2004,44(6):1017-1028
[42]Sohn S D.Seong P H.Quantitative Evaluation of Safety Critical Software Test ability Based on Fault Tree Analysis and Entropy[J].Systems and Software.2004,73(2):351-360
[43]王莲芬,许树柏.层次分析法导论[M].北京:中国人民大学出版社,1990
[44]吴扬,杨青.基于AHP和模糊数学的建筑节能性能评估[J].建筑经济,2007年第三期
[45]董艳.层次分析法在合理选择网络攻击时间中的应用[D].电子科技大学,2005,6
[46]Saaty T.L.Fundamentals of Decision Making and Priority Theory with the Analytic Hierarchy Process[M].Pitisburgh:RWSPublications,1994.
[47]Saaty T.L.,Highlights and critical points in the theory and application of the Analytic Hierarchy Process,European Journal of Operational Research[J],Vol.74,No.3,p426-447,1994.
[48]E.zio ect..The Assessment of Expert Weight via the Analytic Hierarchy Process Application.In:Probabilistic Safety Assessment and Management'96.ESREL'96-PSAM-Ⅲ.1996:864.
[49]Frankel E G.Hierarchical logic in shipping Policy and deeisions-making[J].Maritime Policy and Management,1992,19(3):211-221
[50]彭祖赠,孙韫玉.模糊(Fuzzy)数学及其应用[M].武汉:武汉大学出版社,2002,3
[51]Yam R C M.Intelligent predictive decision support system for condition based maintenance[J].The international journal of Advanced Manufacturing Technology,2001(17).
[52]Sheng-Tsaing Tseng,Ruey Huei Yeh,Wen-tsung Ho.Imperfect maintenance policies for deteriorating production systems[J].Int.J.Production Economics,1998(55).
[2]秦英孝.可靠性维修性保障性概论[M].北京:国防工业出版社,2002.
[3]易运辉.装备维修策略及其决策技术研究[D].国防科技大学,2005,11
[4]吴建忠,何海龙.维修思想发展概述[J].装备指挥技术学院学报,2003,6第14卷第3期
[5]王军.发动机缸体生产线模糊动态维修优化决策方法研究[D].吉林大学,2006,6
[6]仓安裕.发动机缸体生产线维修决策方法研究[D].吉林大学,2003,6
[7]催宁博.设备诊断技术[M].天津:南开大学出版社,1993
[8]Block H W,Langberg N A,Savits T H.Repair replacement policies[J].J Appl Prob,1993,30.
[9]Moubray JM,(1995),Maintenance management-A new paradigm,Third annual conference of the society of maintenance &reliability professional.Chicago Illionis.
[10]刘伟,臧铁钢,郭顺生.基于ERP系统的柔性维修技术研究[J].机械工程师,2004,3
[11]吴波,丁毓峰,黎明发.机械系统可靠性维修及决策模型[M].北京:化学工业出版社,2006.
[12]Zhang Haijun,Zuo Hongfu.Maintenance Level Decision of Aero-engine Based on VPRS Theory[J].Transactions of Nanjing University of Aeronautics &Astronautics,2005,12,Vol.22 No.4
[13]李佩玲.设备综合管理[M].北京:中国设备管理培训中心,1993,3
[14]黄昭毅.从美国维修体制的变迁论我国加强预防维修工作的重要性[M].北京:中国设备管理,1994,11
[15][日]北村秀树.机械设备的维修管理系统的现状与展望[M].北京:中国设备管理,1995,3
[16]谢小鹏.设备状态识别与维修决策[M].北京:中国石化出版社,2000,9
[17][美]George E.Connaughton.北美维修技术状况(续)[J].中国设备工程,2001,7:51-52.
[18]蒋太立.基于RCM理论的维修决策研究[D].武汉理工大学,2006,5
[19]刘混举.机械设备的维修思想与主动预防性维修决策的研究[J].全国故障诊断学术会议论文集,武汉,1996
[20]范世东.复杂设备维修类型决策策略探讨[J].武汉交通科技大学学报,1995,12
[21]陈国芳.设备大修计划与管理[M].设备管理与维修,1994,2
[22]严立.港口机械设备针对性维修管理体制[M].中国设备管理,1995,3
[23]Zhu Xinhe,Yan Zhi jun.Maintenance decision of marine machinery based on lubricants monitoring[J].Dalian Maritime University,2002,8,Vol.28,Suppl.
[24]贾希胜,程中华.以可靠性为中心的维修(RCM)发展动态.军械工程学院学报,2002.9(14):29-32
[25]孙有朝,樊蔚勋.以可靠性为中心的维修(RCM)一维修科学的发展趋势.机械工程师,1997.4:55-56
[26]陈刚.减速机械的可靠性维修及其维修决策研究[D].武汉理工大学,2007,5
[27]陈学楚.维修理论基础.北京:科学出版社,1998.12
[28]W.A.Thompsom,On the foundation of reliability,Tchnometries,v23,1981,Feb:1-13
[29]许林,杨健.奥拓轿车够着使用与维修[M].北京:人民交通出版社,2003,3
[30]往敏智,于江,王黎明.微型汽车构造、使用与维修[M].北京:人民交通出版社,1999,9
[31]沈锦.汽车地盘构造与检修[M].北京:机械工业出版社,2006,12
[32](美)D.H.Stamatis.故障模式影响分析:FMEA从理论到实践[M].北京:国防工业出版社,2005
[33](日)盐见弘.故障模式和影响分析与故障树分析的应用[M].北京:机械工业出版社,1987
[34]Potential Failure Mode and Effects Analysis In Design(Design FMEA) and For Manufacturing and Assembly Process(Process FMEA) Instruction Manual·Ford Motor Company,1988,9
[35]K.G.Johnson,M.K.Khan.A study into the use of the Process failure mode and effects analysis(PFMEA) in the automotive industry in the UK[J].Materials Processing Technology,2003,pp.348-356
[36]David J.Russomanno,Ronald D.Bonnell.ABlaekboard Model of an Expert System for Failure Mode and Effects Analysis.PROCEEDINGS Annual RELIABILITY and MAINTAINABILITY Symposium,1992,PP.483-490
[37]ZhaoTingdi,Su Tiejun.Intelligent FMEA Based On Model FIORN.RAMS 2004,pp.386-391
[38]李增辉.FMEA及FTA在汽车产品开发中的应用研究[D].合肥工业大学硕士论文,2006
[39]冒天诚.故障树与船舶自动控制系统的故障诊断[M].大连:大连海事大学出版社,2000,9
[40]王清.基于FMEA和FTA的故障诊断技术及其在DEH系统中的应用[D].华北电力大学,2004,5
[41]Ireza E,Seyed G M.FPGA-based Monte Carlo Simulation for Fault Tree Analysis[J].Microelectronics Reliability,2004,44(6):1017-1028
[42]Sohn S D.Seong P H.Quantitative Evaluation of Safety Critical Software Test ability Based on Fault Tree Analysis and Entropy[J].Systems and Software.2004,73(2):351-360
[43]王莲芬,许树柏.层次分析法导论[M].北京:中国人民大学出版社,1990
[44]吴扬,杨青.基于AHP和模糊数学的建筑节能性能评估[J].建筑经济,2007年第三期
[45]董艳.层次分析法在合理选择网络攻击时间中的应用[D].电子科技大学,2005,6
[46]Saaty T.L.Fundamentals of Decision Making and Priority Theory with the Analytic Hierarchy Process[M].Pitisburgh:RWSPublications,1994.
[47]Saaty T.L.,Highlights and critical points in the theory and application of the Analytic Hierarchy Process,European Journal of Operational Research[J],Vol.74,No.3,p426-447,1994.
[48]E.zio ect..The Assessment of Expert Weight via the Analytic Hierarchy Process Application.In:Probabilistic Safety Assessment and Management'96.ESREL'96-PSAM-Ⅲ.1996:864.
[49]Frankel E G.Hierarchical logic in shipping Policy and deeisions-making[J].Maritime Policy and Management,1992,19(3):211-221
[50]彭祖赠,孙韫玉.模糊(Fuzzy)数学及其应用[M].武汉:武汉大学出版社,2002,3
[51]Yam R C M.Intelligent predictive decision support system for condition based maintenance[J].The international journal of Advanced Manufacturing Technology,2001(17).
[52]Sheng-Tsaing Tseng,Ruey Huei Yeh,Wen-tsung Ho.Imperfect maintenance policies for deteriorating production systems[J].Int.J.Production Economics,1998(55).