基于危害性分析的数控机床主传动系统可靠性分析
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摘要
数控机床是国民经济和国防建设发展的重要装备,数控机床主传动系统可靠性直接影响被加工零件精度、加工质量和生产率以及刀具的寿命。3F技术作为一种重要的可靠性技术,对保证机床系统的正常工作具有重要意义。但3F技术在实际运用中,采用故障树分析法时,顶事件的选择往往凭经验设定,缺乏有力的理论依据和技术支持;并且3F技术本身要求危害性分析只作为故障模式与影响分析的补充,从而限制了危害性分析结果的使用,同时也使危害性分析技术在运用故障报告、分析和纠正措施系统技术时发挥不出本身具有的作用,最终影响了可靠性分析的全面性。
针对这一现状,本文首先对数控机床主传动系统进行危害性分析,将其输出作为故障树分析的输入;然后结合对主传动系统进行危害性分析的结果完成了故障模式及影响分析;同时,本文对数控机床主传动系统实施故障报告、分析和纠正措施系统技术时运用了对系统实施危害性分析、故障模式及影响分析和故障树分析的输出,建立了主传动系统外场使用故障闭环控制系统,使得系统可靠性分析由潜在故障模式到“现实故障”得到有效控制。
Computer Numerical Control machine tools are the important equipment to the development of national economy and national defense construction. The accuracy, processing quality and productivity of machined components and tool’s life are directly influenced by the reliability of CNC machine tools’main transmission system. As an important technology, 3F—the Fault Mode and Effect Analysis (FMEA), Fault Tree Analysis (FTA) and Fault Reporting Analysis and Corrective Analysis (FRACAS)—has great significance to ensure the reliability of the machine system’s normal work. But in practice, 3F technology is lack of strong theoretical basis and technical support for the choice of top event in FTA often by experience. And the fact that Functional Hazard Analysis (FHA) can be only taken as supplement for FMEA is required by the technology itself, limiting the use of FHA result and also making FHA can’t play its own important role in using FRACAS, finally the comprehensiveness of reliability analysis is affected.
In this situation, FHA to CNC machine tools’main transmission system is done firstly in this paper, and its output is taken as the input of the Fault Tree Analysis. Then the FMEA is finished by combining that with the result of FHA to Main Drive System. Meanwhile, in this paper, the output of FHA, FMEA and FTA to the system is applied and the closed-loop control system at outfield of main transmission system is established when the FRACAS technology is implemented to Main transmission system of CAN machine tools. As the result, system reliability analysis can be effectively controlled from potential fault mode to "reality fault ".
针对这一现状,本文首先对数控机床主传动系统进行危害性分析,将其输出作为故障树分析的输入;然后结合对主传动系统进行危害性分析的结果完成了故障模式及影响分析;同时,本文对数控机床主传动系统实施故障报告、分析和纠正措施系统技术时运用了对系统实施危害性分析、故障模式及影响分析和故障树分析的输出,建立了主传动系统外场使用故障闭环控制系统,使得系统可靠性分析由潜在故障模式到“现实故障”得到有效控制。
Computer Numerical Control machine tools are the important equipment to the development of national economy and national defense construction. The accuracy, processing quality and productivity of machined components and tool’s life are directly influenced by the reliability of CNC machine tools’main transmission system. As an important technology, 3F—the Fault Mode and Effect Analysis (FMEA), Fault Tree Analysis (FTA) and Fault Reporting Analysis and Corrective Analysis (FRACAS)—has great significance to ensure the reliability of the machine system’s normal work. But in practice, 3F technology is lack of strong theoretical basis and technical support for the choice of top event in FTA often by experience. And the fact that Functional Hazard Analysis (FHA) can be only taken as supplement for FMEA is required by the technology itself, limiting the use of FHA result and also making FHA can’t play its own important role in using FRACAS, finally the comprehensiveness of reliability analysis is affected.
In this situation, FHA to CNC machine tools’main transmission system is done firstly in this paper, and its output is taken as the input of the Fault Tree Analysis. Then the FMEA is finished by combining that with the result of FHA to Main Drive System. Meanwhile, in this paper, the output of FHA, FMEA and FTA to the system is applied and the closed-loop control system at outfield of main transmission system is established when the FRACAS technology is implemented to Main transmission system of CAN machine tools. As the result, system reliability analysis can be effectively controlled from potential fault mode to "reality fault ".
引文
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[4] Blanks H S. Quality and reliability research into the next century [J]. Quality and Reliability Engineering International, 1994, 10(3): 179-184.
[5]贾亚洲,杨兆军.数控机床可靠性国内外发展现状与技术发展策略[J].中国制造业信息化, 2008, (4): 35-7.
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[8]邓三鹏.数控机床结构及维修[M].北京:国防工业出版社, 2008.
[9]张英志.应用“3F”技术提高航天型号产品质量与可靠性[J].质量与可靠性, 1997, (3): 33-39.
[10]曾慧娥,周庆忠.基于“3F”装备可靠性设计与管理系统研究[J].计算机系统应用, 2002, (2): 48-50.
[11]李淑庆,张根保,任显林.基于3F技术的产品可靠性工程研究[J].现代工程, 2007, (3): 5-7.
[12]陈圣斌,周晓光.“4F”技术在直升机研制中的应用与经验教训[J].直升机技术, 2008, (1): 25-29.
[13]孔伟.数控机床主传动比的确定[J].设计与研究, 2003, (3): 14-15.
[14]张福荣.数控机床主传动系统的噪声分析与控制[J].机械研究与应用, 2005, 18(2): 39-45.
[15]蒋洪平.数控设备故障诊断与维修[M].北京:北京理工大学出版社, 2006.
[16]潘海丽.数控机床故障分析与维修[M].西安:西安电子科技大学出版社, 2006.
[17]龚仲华.数控机床故障诊断与维修500例[M].北京:机械工业出版社, 2004.
[18]韩鸿鸾.数控机床维修实例[M].北京:中国电力出版社, 2006.
[19]周振兴,德威,王宏伟.加工中心和数控车床故障分析和维护[J].机械工程, 2005, (6): 55.
[20]王爱玲.数控机床故障诊断与维修[M].北京:机械工业出版社, 2006.
[21]李淑庆. 3F一体化技术研究及其在新产品开发中的应用[D].重庆:重庆大学硕士论文, 2007.
[22]故障模式分析—FMEA教程[D].北京:北京运通恒达科技有限公司,
[23]甘传付,林干,牛中兴等.大型装备可靠性维修性FMECA开展方法研究[J].现代雷达, 2008, 30(7): 33-35.
[24] Kai M T, Chee P L. Fuzzy FMEA with a guided rules reduction system for prioritization of failures [J]. The International Journal of Quality and Reliability Management, 2006, 23(8): 10-47.
[25]车庆军.推动失效模式和效果分析(FMEA)[J].航空科学技术, 2006, 4: 31-34.
[26]张行军,戴怡.加工中心故障模式影响及危害性分析[J].机械制造, 2007, 45(11): 64-65.
[27]王元达,宋笔锋.系统可靠性预计方法综述[J].飞机设计, 2008, 28(1): 38-42.
[28]王彬,唐晓青.基于知识模型的产品设计方案失效风险评估[J].北京航空航天大学学报, 2008, 34(7): 764-768.
[29] Patrick D T, Connor O. Quantifying uncertainty in reliability and safety studies [J]. Microelectronics and Reliability. 1995, 35(9-10): 1374-1356.
[30] Nune R S, Bantwal S P. Modified approach for prioritization of failures in a system failure mode and effects analysis [J]. The International Journal of Quality and Reliability Management, 2001, 18(3): 3-24.
[31]王海波,王俊华,吴昌.提高FMECA实施效果的探索[J].质量与可靠性, 2006, (6): 50-42.
[32]何国伟,角淑媛,张云中.反向需求广义FME(C)A-FRACAS及系统(产品)可靠性[J].质量与可靠性, 2008, (3): 41-43.
[33]苗雨奇. FMECA在航空发动机研制工作中的应用[J].航空发动机, 2000, (3): 56-60.
[34]史定华,王松瑞.故障树分析方法和理论[M ].北京师范大学出版社, 1993.
[35]李建华.基于故障树分析的长输管道定量风险评价方法研究[D].兰州理工大学,2008.
[36]陈光宇.不完全覆盖多阶段任务系统的静态和动态故障树综合研究[D].电子科技大学, 2006.
[37] Sawyer J.P. Fault Tree Analysis of Mechanical Systems [J]. Micro electron and Reliability, 1994, 54 (4): 653-667.
[38] Misra K B, Webe G.G. A New Method for Fuzzy Fault Tree Analysis [J]. Micro electron and Reliability, 1989, 29(2): 195-216.
[39]赵太平.故障树分析法在数控车床故障诊断中的应用[J].铁道车车辆工人, 2006, 6(6): 19-22.
[40]迟向磊.加工中心故障树分析[J].北京机电通讯, 2001, 28: 14-18.
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