包装机械的MTBF计算和故障分析
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摘要
包装机械在包装工业中占有举足轻重的地位,包装机械的生产效率、自动化程度以及工作的可靠性直接影响到产品的包装的质量和速度。随着包装工业的迅速发展,包装机械已经成为国内机械工业中的十大行业之一。但是根据统计显示,目前我国的包装机械产品,在产品质量、可靠性、精度等各方面,与发达国家的产品仍存在着相当的差距。
评估包装机械的可靠性水平、分析包装机械的故障数据是提高产品的质量、增强企业市场竞争力的有效手段。鉴于目前包装机械可靠性工作研究的不足,论文利用可靠性工程的基本理论和数理统计的方法,借鉴其他领域的可靠性研究的方法,对包装机械的可靠性关键指标平均故障间隔时间(MTBF)的计算方法和故障分析的方法进行了详细的探讨,确立了指标的计算流程,初步建立了包装机械可靠性分析的基本理论。
课题结合无锡哈佛电子秤包装机有限公司生产的6RS电子秤包装机,阐述了包装机械的MTBF计算流程和故障分析方法。为了获得比较准确的MTBF,论文首先拟合故障间隔时间的分布模型,然后引入灰关联分析法寻求故障间隔时间的最佳分布函数,最后用数学期望法计算得到MTBF。为了提出有效的可靠性改进措施,论文综合运用故障模式及影响分析法和故障树分析法分析包装机械的故障。
同时,为了方便企业的可靠性信息统计和分析工作,论文以Visual Basic6.0编程语言为开发平台,采用Access数据库技术,开发了包装机械的可靠性信息管理系统。该系统主要有三大功能:可靠性信息的管理模块,包括故障数据的输入、维护和查询等;可靠性指标的计算模块,包括分布函数的拟合、假设检验、拟合择优以及MTBF的点估计和区间估计等;故障分析模块,包括整机和子系统的故障模式和故障原因分析。该系统为企业可靠性信息管理的规范化和产品的改进提供了有效的依据。
Packaging machinery plays an important role in the development of packaging Industry. The production efficiency, automation and reliability of packaging machinery determine the rate and quality of packaging. With the rapid development of packaging Industry, packaging machinery has become one of the top ten Industries of machinery. However, according to the related investigation, there is a gap between packaging machinery in China and those of developed countries, in aspects of quality, reliability, precision and so on.
Evaluating the reliability of packaging machinery and analyzing failure data can help improve quality of products and strengthen the competition of enterprises in market. Due to the deficiency of reliability research on packaging machinery, this paper utilizes basal theory of reliability engineering and method of statistic, and uses studying method of other field for reference. Methods of calculating mean time between failures(MTBF), a critical index of reliability, and ways of analyzing failures are discussed in detail. The best calculating flow is established and the basal theory on reliability analyzing for packaging machinery is built in this paper.
This paper takes the reliability analysis of 6RS Roto-Packer with electronic balance produced by Wuxi Haver Cement Machinery Company as an example to illustrate the method. To acquire accurate meantime between failures, the distribution function should be fitted, then the grey associative analysis is used to get the best distribution model, from which precise MTBF can be obtained by calculating the expectation. To provide effective methods of improving reliability of packaging machinery, Failure Mode and Effects Analysis is applied combined with Fault Tree Analysis to analyze failure data of the product.
In the meantime, to make the statistic and analysis of packaging machinery more convenient, the reliability information managing system is developed, taking the Visual Basic6.0 as a platform and using the Access database. This system has three major functions. The first part is reliability information management, including input and amending and inquiry of failure data and so on. The second part is to calculating the main reliability indexes, including fitting the distribution function, assumption test, choosing the best model, point and interval estimation of MTBF and so on. The last part is to analyze failures of products through counting failure modes and failure reasons of the product and its subsystems. This system provides enterprises effective basis for the standardization of reliability management and helps improve the product.
评估包装机械的可靠性水平、分析包装机械的故障数据是提高产品的质量、增强企业市场竞争力的有效手段。鉴于目前包装机械可靠性工作研究的不足,论文利用可靠性工程的基本理论和数理统计的方法,借鉴其他领域的可靠性研究的方法,对包装机械的可靠性关键指标平均故障间隔时间(MTBF)的计算方法和故障分析的方法进行了详细的探讨,确立了指标的计算流程,初步建立了包装机械可靠性分析的基本理论。
课题结合无锡哈佛电子秤包装机有限公司生产的6RS电子秤包装机,阐述了包装机械的MTBF计算流程和故障分析方法。为了获得比较准确的MTBF,论文首先拟合故障间隔时间的分布模型,然后引入灰关联分析法寻求故障间隔时间的最佳分布函数,最后用数学期望法计算得到MTBF。为了提出有效的可靠性改进措施,论文综合运用故障模式及影响分析法和故障树分析法分析包装机械的故障。
同时,为了方便企业的可靠性信息统计和分析工作,论文以Visual Basic6.0编程语言为开发平台,采用Access数据库技术,开发了包装机械的可靠性信息管理系统。该系统主要有三大功能:可靠性信息的管理模块,包括故障数据的输入、维护和查询等;可靠性指标的计算模块,包括分布函数的拟合、假设检验、拟合择优以及MTBF的点估计和区间估计等;故障分析模块,包括整机和子系统的故障模式和故障原因分析。该系统为企业可靠性信息管理的规范化和产品的改进提供了有效的依据。
Packaging machinery plays an important role in the development of packaging Industry. The production efficiency, automation and reliability of packaging machinery determine the rate and quality of packaging. With the rapid development of packaging Industry, packaging machinery has become one of the top ten Industries of machinery. However, according to the related investigation, there is a gap between packaging machinery in China and those of developed countries, in aspects of quality, reliability, precision and so on.
Evaluating the reliability of packaging machinery and analyzing failure data can help improve quality of products and strengthen the competition of enterprises in market. Due to the deficiency of reliability research on packaging machinery, this paper utilizes basal theory of reliability engineering and method of statistic, and uses studying method of other field for reference. Methods of calculating mean time between failures(MTBF), a critical index of reliability, and ways of analyzing failures are discussed in detail. The best calculating flow is established and the basal theory on reliability analyzing for packaging machinery is built in this paper.
This paper takes the reliability analysis of 6RS Roto-Packer with electronic balance produced by Wuxi Haver Cement Machinery Company as an example to illustrate the method. To acquire accurate meantime between failures, the distribution function should be fitted, then the grey associative analysis is used to get the best distribution model, from which precise MTBF can be obtained by calculating the expectation. To provide effective methods of improving reliability of packaging machinery, Failure Mode and Effects Analysis is applied combined with Fault Tree Analysis to analyze failure data of the product.
In the meantime, to make the statistic and analysis of packaging machinery more convenient, the reliability information managing system is developed, taking the Visual Basic6.0 as a platform and using the Access database. This system has three major functions. The first part is reliability information management, including input and amending and inquiry of failure data and so on. The second part is to calculating the main reliability indexes, including fitting the distribution function, assumption test, choosing the best model, point and interval estimation of MTBF and so on. The last part is to analyze failures of products through counting failure modes and failure reasons of the product and its subsystems. This system provides enterprises effective basis for the standardization of reliability management and helps improve the product.
引文
1、美包装机消费近70亿美元中国紧跟其后[J].中国新包装,2007,(4):44.
2、孔凡真.欧美包装机械市场需求及产销[J].中国包装,2006,(5):54—55.
3、郑莹.我国包装机械发展提速在即[J].中国医药报,2007,(14).
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5、鄢腊梅,饶居华,曾晓红.真空包装机的智能化故障诊断系统[J].包装工程,2002,23 (3): 65-66.
6、倪合青,浅谈包装机械可靠性评定中的几个问题[J].包装与食品机械,1991,(2): 28-32.
7、赵明光,赖启原,赵安墉等.PLC控制的榨菜自动包装机控制系统的可靠性研究及其通讯监测.四川联合大学学报,1997,1(4):59—66.
8、贾亚洲.提高国产数控机床的可靠性[J].数控机床市场,2006,5:92—99.
9、Gupta,Y.P.Somers,T.M.Louisville,Univ.KY.Availability of CNC machines: multiple—input transfer—function modeling[J],IEEE Transactions on reliability,1989,08: 285—295.
10、Jason R.W.Merrick.Re’k SoyeR.A Bayesian Semiparametric Analysis of the Reliability and Maintenance of Machine Tools[J],Technometrics,2003,2(45):58—69.
11、GEETA AGNIHOTRI;SUDHIR TIWARI,17th National Convention of Mechanical Engineers,Nov 26-27,2001.
12、Yiqiang Wang,Richard C.M.Yam,Ming J.Zuo,A comprehensive reliability allocation method for design of CNC lathes[J], Reliability Engineering and Systerm Safety,2001,6(72):247—252.
13、王义强,贾亚洲,于骏一等人.CNC车床的故障概率模型[J].数理统计与管理,1999, 18(2):9—12.
14、张英芝,贾亚洲,张学文等.数控冲床的故障概率分布模型[J].吉林大学学报2004, 34(2):264—267.
15、张英芝,贾亚洲,申桂香等.数控机床故障分布的灰关联分析法[J].农业机械学报2004,35(6):195—197.
16、Jia Yazhou,Wang Molin,Jia Zhixin.Probability distribution of machining center failures[J].Reliability Engineering and System Safety,1995,1(50):121-125.
17、张海波,贾亚洲,周广文等.数控系统故障模式、影响及危害度分析(FMECA)[J].中国机械工程2004,15(6):491-494.
18、贾亚洲,于捷,姜巍巍等.国产加工中心故障模式及影响分析(FMEA)[J].江苏机械制造与自动化,2001,4:111—114.
19、于捷CAK系列数控车床FTA分析[J].长春大学学报,2000,10(4):3—5.
20、申桂香,贾亚洲,马健等.CNC机床故障分析及其可靠性[J].中国机械工程,1996, 7(6):67-69.
21、Yiqiang Wang,Guixiang Shen,Yazhou Jia,Multidimensional force spectra of CNC machine tools and their applications,part two:reliability design of elements[J].International Journal of Fatigue,2003,5(25):447-452.
22、金伟娅,张康达.可靠性工程[M].北京:化学工业出版社,2005:5-202.
23、王桂萍,贾亚洲.MTBF分布模型的案例分析[J].吉林工程技术师范学院学报,2005, 21(3):20—24.
24、周广文,贾亚洲.专用计算机数控机床故障率实验研究[J].2005(1):45—48.
25、吴永平编著.工程机械可靠性[M].北京:人民交通出版社,2002,3:26—27.
26、刘峰,曹正清.机械可靠性数据处理中优选分布模型的探讨[J].机械设计与制造, 1998,(12):3-5.
27、王义强,贾亚洲,于骏一等人.CNC车床的故障概率模型[J].数理统计与管理,1999, 18(2):9—12.
28、吴有炜.试验设计与数据处理[M].苏州:苏州大学出版社,2002.
29、吕峰,刘翔,刘泉.七种灰色系统关联度的比较研究[J].武汉工业大学学报,2000, 22(2):41—43.
30、周媛,张颖超,张大庆.基于灰关联分析的综合评价模型的应用研究[J].科技管理研究, 2006,(1):230-232.
31、王坚强.关于灰色绝对关联计算模型的探讨[J].数学理论与应用,2000(3):103-108.
32、盛骤,谢式千,潘承毅.概率论与数理统计[M].北京:高等教育出版社,2001,12: 62—241.
33、中国标准出版社编.统计方法应用国家标准汇编——可靠性统计方法卷[M].中国标准出版社,2000,3:119—134.
34、顾瑛.可靠性工程数学[M].北京:电子工业出版社,2004:127—159.
35、Gianfranco Adimari,Paolo Preo.Robust confidence intervals for log-location—scale models with right censored data[J].Joumal of Statistical Planning and Inference,2007(137):2832—2849.
36、Anindya Roy,Thomas Mathew.A generalized confidence limit for the reliability function of a two—parameter exponential distribution[J].Journal of Statistical Planning and Inference, 2005(128):509—517.
37、Yi Dai,Yun—fei Zhou,Ya-zhou Jia.Distribution of time between failures of machining center based on type I censored data[J].Reliability Engineering and System Salty,2003 (79):377-379.
38、顾嘉麟,郭建英.截尾数据下威布尔分布的参数估计问题[J].哈尔滨理工大学学报, 10(2):61-63.
39、邹林全.Weibull分布定时截尾寿命试验参数的近似联合置信域.南京航空航天大学学报,2001,33(2):194—196.
40、周源泉,翁朝曦.可靠性评定[M].科学出版社,1990:27—160.
41、金星,洪延姬,沈怀荣等.可靠性数据计算与应用[M].北京:国防工业出版社,2003, 4: 42-45.
42、崔文彬.船舶安全评估使用FMEA方法的分析及改进[J].航海技术,2006(5):50—51.
43、K.G Johnson and 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].Journal of Materials Processing Technology.2003(139):348—356.
44、刘义乐,梁斌,师文涛.改进的FMEA过程[J].国防技术基础,2006(9):36—38.
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47、沈宝杰.数控车床可靠性增长技术研究[D]:[硕士毕业论文].山东:山东大学.2004.
48、陈华生主编.Visual Basic程序设计教程[M].苏州:苏州大学出版社,1999.8:42—159.
49、周国民编著.Visual Basic+Access数据库项目开发实践[M].北京:中国铁道出版社, 2004,12:1—118.
50、高春艳,李艳,谷伟东.Visual Basic数据库开发关键技术与实例应用[M].北京:人民邮电出版社,2004:25—29.
2、孔凡真.欧美包装机械市场需求及产销[J].中国包装,2006,(5):54—55.
3、郑莹.我国包装机械发展提速在即[J].中国医药报,2007,(14).
4、王世萍,朱敏波.电子机械可靠性与维修性[M].清华大学出版社,2000:1-6.
5、鄢腊梅,饶居华,曾晓红.真空包装机的智能化故障诊断系统[J].包装工程,2002,23 (3): 65-66.
6、倪合青,浅谈包装机械可靠性评定中的几个问题[J].包装与食品机械,1991,(2): 28-32.
7、赵明光,赖启原,赵安墉等.PLC控制的榨菜自动包装机控制系统的可靠性研究及其通讯监测.四川联合大学学报,1997,1(4):59—66.
8、贾亚洲.提高国产数控机床的可靠性[J].数控机床市场,2006,5:92—99.
9、Gupta,Y.P.Somers,T.M.Louisville,Univ.KY.Availability of CNC machines: multiple—input transfer—function modeling[J],IEEE Transactions on reliability,1989,08: 285—295.
10、Jason R.W.Merrick.Re’k SoyeR.A Bayesian Semiparametric Analysis of the Reliability and Maintenance of Machine Tools[J],Technometrics,2003,2(45):58—69.
11、GEETA AGNIHOTRI;SUDHIR TIWARI,17th National Convention of Mechanical Engineers,Nov 26-27,2001.
12、Yiqiang Wang,Richard C.M.Yam,Ming J.Zuo,A comprehensive reliability allocation method for design of CNC lathes[J], Reliability Engineering and Systerm Safety,2001,6(72):247—252.
13、王义强,贾亚洲,于骏一等人.CNC车床的故障概率模型[J].数理统计与管理,1999, 18(2):9—12.
14、张英芝,贾亚洲,张学文等.数控冲床的故障概率分布模型[J].吉林大学学报2004, 34(2):264—267.
15、张英芝,贾亚洲,申桂香等.数控机床故障分布的灰关联分析法[J].农业机械学报2004,35(6):195—197.
16、Jia Yazhou,Wang Molin,Jia Zhixin.Probability distribution of machining center failures[J].Reliability Engineering and System Safety,1995,1(50):121-125.
17、张海波,贾亚洲,周广文等.数控系统故障模式、影响及危害度分析(FMECA)[J].中国机械工程2004,15(6):491-494.
18、贾亚洲,于捷,姜巍巍等.国产加工中心故障模式及影响分析(FMEA)[J].江苏机械制造与自动化,2001,4:111—114.
19、于捷CAK系列数控车床FTA分析[J].长春大学学报,2000,10(4):3—5.
20、申桂香,贾亚洲,马健等.CNC机床故障分析及其可靠性[J].中国机械工程,1996, 7(6):67-69.
21、Yiqiang Wang,Guixiang Shen,Yazhou Jia,Multidimensional force spectra of CNC machine tools and their applications,part two:reliability design of elements[J].International Journal of Fatigue,2003,5(25):447-452.
22、金伟娅,张康达.可靠性工程[M].北京:化学工业出版社,2005:5-202.
23、王桂萍,贾亚洲.MTBF分布模型的案例分析[J].吉林工程技术师范学院学报,2005, 21(3):20—24.
24、周广文,贾亚洲.专用计算机数控机床故障率实验研究[J].2005(1):45—48.
25、吴永平编著.工程机械可靠性[M].北京:人民交通出版社,2002,3:26—27.
26、刘峰,曹正清.机械可靠性数据处理中优选分布模型的探讨[J].机械设计与制造, 1998,(12):3-5.
27、王义强,贾亚洲,于骏一等人.CNC车床的故障概率模型[J].数理统计与管理,1999, 18(2):9—12.
28、吴有炜.试验设计与数据处理[M].苏州:苏州大学出版社,2002.
29、吕峰,刘翔,刘泉.七种灰色系统关联度的比较研究[J].武汉工业大学学报,2000, 22(2):41—43.
30、周媛,张颖超,张大庆.基于灰关联分析的综合评价模型的应用研究[J].科技管理研究, 2006,(1):230-232.
31、王坚强.关于灰色绝对关联计算模型的探讨[J].数学理论与应用,2000(3):103-108.
32、盛骤,谢式千,潘承毅.概率论与数理统计[M].北京:高等教育出版社,2001,12: 62—241.
33、中国标准出版社编.统计方法应用国家标准汇编——可靠性统计方法卷[M].中国标准出版社,2000,3:119—134.
34、顾瑛.可靠性工程数学[M].北京:电子工业出版社,2004:127—159.
35、Gianfranco Adimari,Paolo Preo.Robust confidence intervals for log-location—scale models with right censored data[J].Joumal of Statistical Planning and Inference,2007(137):2832—2849.
36、Anindya Roy,Thomas Mathew.A generalized confidence limit for the reliability function of a two—parameter exponential distribution[J].Journal of Statistical Planning and Inference, 2005(128):509—517.
37、Yi Dai,Yun—fei Zhou,Ya-zhou Jia.Distribution of time between failures of machining center based on type I censored data[J].Reliability Engineering and System Salty,2003 (79):377-379.
38、顾嘉麟,郭建英.截尾数据下威布尔分布的参数估计问题[J].哈尔滨理工大学学报, 10(2):61-63.
39、邹林全.Weibull分布定时截尾寿命试验参数的近似联合置信域.南京航空航天大学学报,2001,33(2):194—196.
40、周源泉,翁朝曦.可靠性评定[M].科学出版社,1990:27—160.
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