减速机械的可靠性维修及其维修决策研究
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摘要
本文围绕减速机械的维修方式决策和最佳预防维修决策的研究，提出了针对减速机械的维修策略，并根据N42蜗杆减速机的具体情况，确定其主要零部件的故障分布模型、维修方式和最佳预防维修周期。具体工作如下：
1)首先从维修决策在我国制造业中的重要作用出发，介绍了可靠性维修的发展历程，系统的地分析了可靠性维修在国内外的研究现状和发展趋势，概括描述了目前维修决策在实际应用中暴露出的一系列问题，详细介绍了RCM的理论基础、原则、基本问题、关键技术和基本实施步骤，为本文针对减速机械的维修决策研究奠定理论基础。
2)深入分析了N42蜗杆减速机主要部件的故障模式和影响，计算了各个零部件的致命度，建立了N42蜗杆减速机失效分析故障树。经过对N42蜗杆减速机的FMECA和FTA分析，构建了该减速机的可靠性模型和维修性模型。
3)从可靠性、维修性和经济性三个方面来考虑N42蜗杆减速机中蜗轮蜗杆的维修方式，利用层次分析法对其详细的计算，决策出蜗轮蜗杆的主要维修方式。然后随机给出一组蜗轮蜗杆的故障数据，利用数理统计方法对其进行研究，确定蜗轮蜗杆的故障分布规律。最后按照有效度最大计算预防性维修周期的计算模型，对蜗轮蜗杆的维修周期进行决策。
4)开发了减速机维修决策支持系统，该系统能够完成减速机械的基础信息管理，能够根据用户选择的影响因素确定减速机械的维修方式，根据用户选择的维修周期决策模型计算减速机械零部件的最佳预防维修周期。
The paper revolves the research of the maintenance way decision and the best preventive maintenance decision of the reducer, proposes maintenance strategy aimed at the reducer, and according to special details of the N42 worm reducer, determines failure distribution model, maintenance way and the best preventive maintenance period of its main parts. The concrete works of the paper are summarized as follows:
1) Beginning from the vital effect of maintenance decision in the manufacturing industry of our country, introduced the development course of the reliability maintenance, systematically analyzed research present situation and the development tendency of reliability maintenance in the domestic and foreign, synoptically described a series of problems at present to maintenance decision which exposed in the practical application, detailed introduced the theoretic, the principle, the basic question, the essential technology and the basic implementation step of RCM, established theoretic foundation for the maintenance decision research of the reducer.
2) For the N42 worm reducer , analyzed deeply failure model and effect of its main parts, calculated the criticality of each part, established the invalidation analysis failure tree of N42 worm reducer, constructed reliability model and maintenance model from FMECA and the FTA analysis to N42 worm reducer.
3) From the reliability, maintenance and economy three aspects to considered maintenance way of the worm in the N42 worm reducer, using Analytic Hierarchy Process to calculate in detail, decided main maintenance way of the worm. Then randomly produces a group of failure data of the worm, using the mathematical statistic method to research it, made sure the distributed law of the worm. Finally deferred to the biggest availability to calculate the preventive maintenance cycle, and carried on the maintenance cycle decision to the worm.
4) Developed the reducer maintenance decision support system, this system can complete the reducer the basic information management, and decide the maintenance way of the reducer according to the influence factor user chooses, and calculate the best preventive maintenance period of reducer parts according to maintenance cycle decision model user chooses.
1)首先从维修决策在我国制造业中的重要作用出发，介绍了可靠性维修的发展历程，系统的地分析了可靠性维修在国内外的研究现状和发展趋势，概括描述了目前维修决策在实际应用中暴露出的一系列问题，详细介绍了RCM的理论基础、原则、基本问题、关键技术和基本实施步骤，为本文针对减速机械的维修决策研究奠定理论基础。
2)深入分析了N42蜗杆减速机主要部件的故障模式和影响，计算了各个零部件的致命度，建立了N42蜗杆减速机失效分析故障树。经过对N42蜗杆减速机的FMECA和FTA分析，构建了该减速机的可靠性模型和维修性模型。
3)从可靠性、维修性和经济性三个方面来考虑N42蜗杆减速机中蜗轮蜗杆的维修方式，利用层次分析法对其详细的计算，决策出蜗轮蜗杆的主要维修方式。然后随机给出一组蜗轮蜗杆的故障数据，利用数理统计方法对其进行研究，确定蜗轮蜗杆的故障分布规律。最后按照有效度最大计算预防性维修周期的计算模型，对蜗轮蜗杆的维修周期进行决策。
4)开发了减速机维修决策支持系统，该系统能够完成减速机械的基础信息管理，能够根据用户选择的影响因素确定减速机械的维修方式，根据用户选择的维修周期决策模型计算减速机械零部件的最佳预防维修周期。
The paper revolves the research of the maintenance way decision and the best preventive maintenance decision of the reducer, proposes maintenance strategy aimed at the reducer, and according to special details of the N42 worm reducer, determines failure distribution model, maintenance way and the best preventive maintenance period of its main parts. The concrete works of the paper are summarized as follows:
1) Beginning from the vital effect of maintenance decision in the manufacturing industry of our country, introduced the development course of the reliability maintenance, systematically analyzed research present situation and the development tendency of reliability maintenance in the domestic and foreign, synoptically described a series of problems at present to maintenance decision which exposed in the practical application, detailed introduced the theoretic, the principle, the basic question, the essential technology and the basic implementation step of RCM, established theoretic foundation for the maintenance decision research of the reducer.
2) For the N42 worm reducer , analyzed deeply failure model and effect of its main parts, calculated the criticality of each part, established the invalidation analysis failure tree of N42 worm reducer, constructed reliability model and maintenance model from FMECA and the FTA analysis to N42 worm reducer.
3) From the reliability, maintenance and economy three aspects to considered maintenance way of the worm in the N42 worm reducer, using Analytic Hierarchy Process to calculate in detail, decided main maintenance way of the worm. Then randomly produces a group of failure data of the worm, using the mathematical statistic method to research it, made sure the distributed law of the worm. Finally deferred to the biggest availability to calculate the preventive maintenance cycle, and carried on the maintenance cycle decision to the worm.
4) Developed the reducer maintenance decision support system, this system can complete the reducer the basic information management, and decide the maintenance way of the reducer according to the influence factor user chooses, and calculate the best preventive maintenance period of reducer parts according to maintenance cycle decision model user chooses.
引文
[1] 催宁博．设备诊断技术．天津：南开大学出版社，1993
[2] 川崎义人著，吴关昌译．可靠性、维修性总论[M]．北京：机械工业出版社，1988
[3] 三根久，河合一著，王树田，周世杰译．可靠性、维修性的数理基础[M]．北京：机械工业出版社，1988
[4] Moubray JM., (1995), Maintenance management—A new paradigm, Third annual conference of the society of maintenance & reliability professional. Chicago Illionis.
[5] Genève, Suisse. Reliability and maintainability, International Electrotechnical Commission, 1995: 238～244.
[6] 薛辉．可靠性分析软件现状及展望．质量与可靠性，1999．1：27～29
[7] GJB1379-92，《装备预防性维修大纲的制定要求与方法》，1992，国防科工委军用标准化中心
[8] 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
[9] 孙有朝，樊蔚勋．以可靠性为中心的维修(RCM)—维修科学的发展趋势．机械工程师，1997．4：55～56
[10] 陈学楚．维修理论基础．北京：科学出版社，1998．12：82～85
[11] W.A.Thompsom, On the foundation of reliability, Tchnometrics, v23, 1981, Feb:1～13
[12] Maintenance Steering Group-3 Task Force. ATA MSG3: Operator/Manufacturer Scheduled Maintenance Development: Revision 2001.1. Washington DC: Air Transport Association(ATA) of America, 2001
[13] Smith, David John, Reliability and maintainability in perspective: practical, contractual, commercial, and software aspects New York: Wiley, 1988: 110～116.
[14] Birolini, Alessandro, Reliability engineering: theory and practice, New York: Springer-Vedag, 2004: 289～294.
[15] 王超，王金．机械可靠性工程．北京：冶金工业出版社，1992
[16] J．莫布雷．以可靠性为中心的维修．北京：机械工业出版社，1995
[17] 1990 proceedings Annual Reliability and Maintainability Symposium. Reliability and Maintainability Symposium. New York: Institute of Electrical and Electronics Engineers, 1979: 412～419.
[18] 黄雅罗，黄树红．发电设备状态检修[M]．北京：中国电力出版社，2000
[19] 张展．减速器设计选用手册．上海：上海科学技术出版社，2001
[20] [德]G．莱希纳，B．贝尔契．机械产品的可靠性[M]．北京：机械工业出版社，1994
[21] [日]盐见弘等．故障模式和影响分析与故障树分析的应用[M]．上海：上海教育出版社，1987
[22] Henley, Ernest J. Kumamoto, Hiromitsu. Reliability engineering and risk assessment. Englewood Cliffs, N.J.: Prentice-Hall, 1981: 264～270.
[23] 史定华．故障树分析技术方法和理论[M]．北京：北京师范大学出版社。1993
[24] 朱继洲．故障树原理和应用[M]．陕西：西安交通大学出版社，1989
[25] 陈琳，王国丽，孟惠荣等．抽油泵故障树分析方法[J]．石油学报．1995．16(3)：145～151
[26] 倪文馨．可靠性工程与机械维修．北京：机械工业出版社，1983．3：30～36
[27] 吴利荣，王建华．基本可靠性和任务可靠性模型研究[J]．现代制造工程，2004(5)
[28] 吴波，黎明发．机械零件与系统可靠性模型[M]．北京：化工工业出版社，2003
[29] 甘茂治主编．维修性设计与验证．北京：国防工业出版社，1995
[30] Wassell, H.J.H.Reliability of engineering products. [Oxford]: Oxford University Press, 1999: 128～226.
[31] 张友诚．维修方式的优化选择．中国设备管理，1995(10)：17
[32] 张金隆，王雄，陶守宝等．设备维修方式决策方法．中国建材装备，2001．5：29～30．
[33] 贺仲雄．模糊数学及其应用．天津：天津科学技术出版社，1983
[34] 贺仲雄．模糊数学及其派生决策方法．北京：中国铁道出版社，1992
[35] S.K.Yang. A condition-based failure-prediction and processing-scheme for preventive maintenance[J]. Transactions on Reliabilitym, Vol.52,No.3,September 2003:373～383.
[36] 黄德才．层次分析方法中层次单排序的新方法．控制与决策，1998(6)
[37] 韩伯棠．管理运筹学[M]．北京：高等教育出版社，2000
[38] 杜清玲，李美芳，刘家科．机械系统预防维修周期的确定[J]．机床与液压，2000(6)：92～94
[39] 张宁．机械系统预防维修的故障率与最小费用周期[J]．系统工程理论与实践，1998．10：33～37
[40] 包菊芳．机械系统预防维修周期的确定[J]．中国机械系统管理，1999(6)：10～11
[41] 傅桂生．用可靠性理论确定机械系统最佳维修周期[J]．中国机械系统管理，2000(10)：12～13
[42] 催宁博．设备诊断技术．天津：南开大学出版社．1993
[2] 川崎义人著，吴关昌译．可靠性、维修性总论[M]．北京：机械工业出版社，1988
[3] 三根久，河合一著，王树田，周世杰译．可靠性、维修性的数理基础[M]．北京：机械工业出版社，1988
[4] Moubray JM., (1995), Maintenance management—A new paradigm, Third annual conference of the society of maintenance & reliability professional. Chicago Illionis.
[5] Genève, Suisse. Reliability and maintainability, International Electrotechnical Commission, 1995: 238～244.
[6] 薛辉．可靠性分析软件现状及展望．质量与可靠性，1999．1：27～29
[7] GJB1379-92，《装备预防性维修大纲的制定要求与方法》，1992，国防科工委军用标准化中心
[8] 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
[9] 孙有朝，樊蔚勋．以可靠性为中心的维修(RCM)—维修科学的发展趋势．机械工程师，1997．4：55～56
[10] 陈学楚．维修理论基础．北京：科学出版社，1998．12：82～85
[11] W.A.Thompsom, On the foundation of reliability, Tchnometrics, v23, 1981, Feb:1～13
[12] Maintenance Steering Group-3 Task Force. ATA MSG3: Operator/Manufacturer Scheduled Maintenance Development: Revision 2001.1. Washington DC: Air Transport Association(ATA) of America, 2001
[13] Smith, David John, Reliability and maintainability in perspective: practical, contractual, commercial, and software aspects New York: Wiley, 1988: 110～116.
[14] Birolini, Alessandro, Reliability engineering: theory and practice, New York: Springer-Vedag, 2004: 289～294.
[15] 王超，王金．机械可靠性工程．北京：冶金工业出版社，1992
[16] J．莫布雷．以可靠性为中心的维修．北京：机械工业出版社，1995
[17] 1990 proceedings Annual Reliability and Maintainability Symposium. Reliability and Maintainability Symposium. New York: Institute of Electrical and Electronics Engineers, 1979: 412～419.
[18] 黄雅罗，黄树红．发电设备状态检修[M]．北京：中国电力出版社，2000
[19] 张展．减速器设计选用手册．上海：上海科学技术出版社，2001
[20] [德]G．莱希纳，B．贝尔契．机械产品的可靠性[M]．北京：机械工业出版社，1994
[21] [日]盐见弘等．故障模式和影响分析与故障树分析的应用[M]．上海：上海教育出版社，1987
[22] Henley, Ernest J. Kumamoto, Hiromitsu. Reliability engineering and risk assessment. Englewood Cliffs, N.J.: Prentice-Hall, 1981: 264～270.
[23] 史定华．故障树分析技术方法和理论[M]．北京：北京师范大学出版社。1993
[24] 朱继洲．故障树原理和应用[M]．陕西：西安交通大学出版社，1989
[25] 陈琳，王国丽，孟惠荣等．抽油泵故障树分析方法[J]．石油学报．1995．16(3)：145～151
[26] 倪文馨．可靠性工程与机械维修．北京：机械工业出版社，1983．3：30～36
[27] 吴利荣，王建华．基本可靠性和任务可靠性模型研究[J]．现代制造工程，2004(5)
[28] 吴波，黎明发．机械零件与系统可靠性模型[M]．北京：化工工业出版社，2003
[29] 甘茂治主编．维修性设计与验证．北京：国防工业出版社，1995
[30] Wassell, H.J.H.Reliability of engineering products. [Oxford]: Oxford University Press, 1999: 128～226.
[31] 张友诚．维修方式的优化选择．中国设备管理，1995(10)：17
[32] 张金隆，王雄，陶守宝等．设备维修方式决策方法．中国建材装备，2001．5：29～30．
[33] 贺仲雄．模糊数学及其应用．天津：天津科学技术出版社，1983
[34] 贺仲雄．模糊数学及其派生决策方法．北京：中国铁道出版社，1992
[35] S.K.Yang. A condition-based failure-prediction and processing-scheme for preventive maintenance[J]. Transactions on Reliabilitym, Vol.52,No.3,September 2003:373～383.
[36] 黄德才．层次分析方法中层次单排序的新方法．控制与决策，1998(6)
[37] 韩伯棠．管理运筹学[M]．北京：高等教育出版社，2000
[38] 杜清玲，李美芳，刘家科．机械系统预防维修周期的确定[J]．机床与液压，2000(6)：92～94
[39] 张宁．机械系统预防维修的故障率与最小费用周期[J]．系统工程理论与实践，1998．10：33～37
[40] 包菊芳．机械系统预防维修周期的确定[J]．中国机械系统管理，1999(6)：10～11
[41] 傅桂生．用可靠性理论确定机械系统最佳维修周期[J]．中国机械系统管理，2000(10)：12～13
[42] 催宁博．设备诊断技术．天津：南开大学出版社．1993