基于FMECA的可靠性软件开发
摘要
随着可靠性理论的广泛应用,故障模式、影响和危害性分析FMECA (Failure Mode Effects and Criticality Analysis,简称FMECA)技术在机械行业内的应用得到普遍推广,尤其是在大型复杂机械设计领域,对机械工程项目进行FMECA是不可缺少的重要环节。随着FMECA分析理论的不断完善,设计开发相关可靠性软件已是大势所趋,机械工程领域,有机械设计人员根据机械工程的相关应用背景设计的可靠性开发软件具有很多优势,对可靠性理论进一步的广泛应用及普及具有一定的推进作用。
本文在详细阐述FMECA基本操作的基础上,结合现阶段各行业内FMECA应用现状,编制实用的FMECA操作软件。依据工程中对FMECA方法应用的不同类别,分别设计出定量FMECA分析模块,定性分析中的风险优先数法分析模块以及危害性矩阵法分析模块。在进行具体的定量、定性分析之前,针对系统的功能描述及系统分层过程,设置框图绘制与系统分层模块统一实现。建立数据库文件,分别用来存取系统分层,定性FMECA分析数据,定量FMECA分析数据等。利用数据库自带的排序功能实现定量FMECA中针对产品危害度值的排序,以及定性FMECA中针对风险优先数值的排序,从而确定系统的薄弱环节,及时采取改进补偿措施。危害性矩阵法的软件实现,采用在Bitmap位图上标定点的方式生成危害性矩阵表,根据危害度增长的方向,判断系统的薄弱环节,采取适当的改进补偿措施。在数据库文件中设置数据库报表格式,将数据库的相关数据最终以通用报表格式输出。
本文利用所设计的软件对FMECA分析过程进行了实例应用,引用《带式输送机系统可靠性分析》中的实例,利用软件对驱动装置分系统进行定量分析；引用《FMECA在船舶主机系统中的应用》中的实例,利用软件对船舶主机系统进行危害度矩阵法分析；引用导气筒工艺潜在失效模式及后果分析(PFMEA)进行风险优先数法的分析。软件分析结果与手工分析结果一致,验证了软件应用的合理性和可行性。
With the extensive application of reliability theory, FMECA technology in the machinery industry has been widespread applicated, especially in large and complex field of mechanical design. The FMECA of mechanical engineering project is an essential part of that proposal. As the continuous improvement of FMECA analysis, the design and development related to the reliability of software has become an irresistible trend. In the field of mechanical engineering, the reliability analysis software has many advantages which is designed by whom has the knowledge of machine design, and it plays a certain role in the promotion of reliability theory wide application and popularity.
In this paper, the basic operation of FMECA is described in detail, combining the industry of the application of FMECA at this stage and the software of FMECA is designed. Based on the FMECA methods for different types of applications, design the module of quantitative analysis, the module of qualitative analysis of the risk priority number of analysis, as well as the criticality matrix analysis. Carrying out specific quantitative, qualitative analysis, the functions of the system description and system delamination process use stratified module and system delamination module. Using the built-in database functions sort the value of the criticality ranking of the quantitative product FMECA, as well as the risk priority number of the qualitative FMECA, in order to determine the weak links in the system, to take timely measures to improve the compensation. The software implementation of the criticality matrix take superscript Bitmap and fixed-point on the matrix to generate the dangers. According to the direction of the growth of criticality to determine the weak links in the system, take appropriate measures to improve the compensation. In the database file set the format of the database statements, and then output the general statements.
In this paper, examples have been taken by the FMECA. Citing the case from《System Reliability Analysis of Belt Conveyor》, software quantitative analysis the subsystem of driven device. Quoted the example from《FMECA used in ship host system》, using the software analysis the criticality matrix of the mainframe systems of the ship. Reference guide pump technology and the consequences of potential failure modes analysis (PFMEA) method, using the software analysis risk priority number. The results of the software analysis and the results of the manual analysis are consistent, so as to finally verify the rationality and feasibility of the FMECA software.
本文在详细阐述FMECA基本操作的基础上,结合现阶段各行业内FMECA应用现状,编制实用的FMECA操作软件。依据工程中对FMECA方法应用的不同类别,分别设计出定量FMECA分析模块,定性分析中的风险优先数法分析模块以及危害性矩阵法分析模块。在进行具体的定量、定性分析之前,针对系统的功能描述及系统分层过程,设置框图绘制与系统分层模块统一实现。建立数据库文件,分别用来存取系统分层,定性FMECA分析数据,定量FMECA分析数据等。利用数据库自带的排序功能实现定量FMECA中针对产品危害度值的排序,以及定性FMECA中针对风险优先数值的排序,从而确定系统的薄弱环节,及时采取改进补偿措施。危害性矩阵法的软件实现,采用在Bitmap位图上标定点的方式生成危害性矩阵表,根据危害度增长的方向,判断系统的薄弱环节,采取适当的改进补偿措施。在数据库文件中设置数据库报表格式,将数据库的相关数据最终以通用报表格式输出。
本文利用所设计的软件对FMECA分析过程进行了实例应用,引用《带式输送机系统可靠性分析》中的实例,利用软件对驱动装置分系统进行定量分析；引用《FMECA在船舶主机系统中的应用》中的实例,利用软件对船舶主机系统进行危害度矩阵法分析；引用导气筒工艺潜在失效模式及后果分析(PFMEA)进行风险优先数法的分析。软件分析结果与手工分析结果一致,验证了软件应用的合理性和可行性。
With the extensive application of reliability theory, FMECA technology in the machinery industry has been widespread applicated, especially in large and complex field of mechanical design. The FMECA of mechanical engineering project is an essential part of that proposal. As the continuous improvement of FMECA analysis, the design and development related to the reliability of software has become an irresistible trend. In the field of mechanical engineering, the reliability analysis software has many advantages which is designed by whom has the knowledge of machine design, and it plays a certain role in the promotion of reliability theory wide application and popularity.
In this paper, the basic operation of FMECA is described in detail, combining the industry of the application of FMECA at this stage and the software of FMECA is designed. Based on the FMECA methods for different types of applications, design the module of quantitative analysis, the module of qualitative analysis of the risk priority number of analysis, as well as the criticality matrix analysis. Carrying out specific quantitative, qualitative analysis, the functions of the system description and system delamination process use stratified module and system delamination module. Using the built-in database functions sort the value of the criticality ranking of the quantitative product FMECA, as well as the risk priority number of the qualitative FMECA, in order to determine the weak links in the system, to take timely measures to improve the compensation. The software implementation of the criticality matrix take superscript Bitmap and fixed-point on the matrix to generate the dangers. According to the direction of the growth of criticality to determine the weak links in the system, take appropriate measures to improve the compensation. In the database file set the format of the database statements, and then output the general statements.
In this paper, examples have been taken by the FMECA. Citing the case from《System Reliability Analysis of Belt Conveyor》, software quantitative analysis the subsystem of driven device. Quoted the example from《FMECA used in ship host system》, using the software analysis the criticality matrix of the mainframe systems of the ship. Reference guide pump technology and the consequences of potential failure modes analysis (PFMEA) method, using the software analysis risk priority number. The results of the software analysis and the results of the manual analysis are consistent, so as to finally verify the rationality and feasibility of the FMECA software.
引文
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13.陈晓彤,姚绍华译.故障模式影响分析FMEA从理论到实践(第2版)[M],北京：国防工业出版社.
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28.李长福等.迫—7引言FMEA及危害性与定量分析[J],现代引言,1995,1(12)：42-45.
29.刘江南.项目风险管理中失效模式与影响分析的应用研究[D],天津：天津大学,2001.
30.刘秋军.柴油机缸套的故障现象、成因及预防[J],煤矿机械,2005,10(5)：21-24.
31.盐见弘等.故障模式影响及危害性分析(FMECA) [M],村械工业出版社,1988.
32.王超.机械可靠性工程[M],北京：冶金工业出版社,1992.
33.李海泉等.系统可靠性分析与设计[M],北京：科学出版社,2003.
34.金壁辉.系统可靠性工程[M],北京：国防工业出版社,2005.
35.金兴明,屠庆慈,陆廷孝.结合FMECA可靠性预计法[J],北京航空航天大学学报,1992,1：32-37.
36.鞠鲁粤.模糊致命度分析及其在矩阵FMECA中的应用[J],上海大学学报(自然科学版),1999,5(10)：51-53.
37.崔玉莲.国内外机械产品典型可靠型设计方法[J],质量与可靠性,2000年,6：24-28.
38.杨宏伟.机械系统FMECA应用中的几个问题[J],装甲兵工程院学报,1995年,1：86-91.
39.鞠鲁粤等.用矩阵方法实施故障模式、影响及致命度分析[J],上海工业大学学报,1993,41(5)：44-50.
40.鞠鲁粤.矩阵FMECA研究及计算机辅助分析程序[J],航空部“八五”攻关项目《航空发动机齿轮箱可靠性、安全性研究》课题报告(KT2992SM 21),1994,15(2)：2-30.
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2. GJB 1391-92故障模式、影响及危害性分析程序.
3. GB 7826-87火效模式和效应分析(FMEA).
4. 王绍印.故障模式和影响(FMEA) [M],广州：中山出版社,2003.
5. 陈晓彤,姚绍华译.故障模式影响分析FMEA从理论到实践(第2版)[M],北京：国防工业出版社.
6. 徐有良.多故障模式结构系统设计中的风险评估[D],上海：上海大学,1999.
7. 孙权,马孝尊,周经伦.计算机辅助FMECA计算机应用研究[J],1998年,10(6)：26-28.
8. 栾竟恩,沈祖培,王兴仁.计算机辅助FMECA方法[J],微型机与应用,1994,17(9)：54-68.
9. 赵延弟,孙琳玲,屠庆慈.计算机辅助FMECA软件模型[J],北京航空航天大学学报,2000,26(2)：78-80.
10.国防科学技术工业委员会.GJB1391292故障模式、影响及危害性分析程序[M],北京：国防科工委军标出版社,1992.
11.国防科工委军用标准化中心.《故障模式、影响及危害性分析程序》《故障树分析》实施指南[M],1994.
12.刘正高,吴江.陈宪章博十&航天工程系统FMECA技术培训与交流会[J],研究与讨论：1998年,5：9-10.
13.陈晓彤,姚绍华译.故障模式影响分析FMEA从理论到实践(第2版)[M],北京：国防工业出版社.
14.朱一凡,马昕.计算机辅助系统FMECA及FTA[J],国防科技参考,1995,16(5)：113-118.
15. Lind J A. Improved methods for computerized FMECA[C], Proc Reliab Maint Symp IEEE,1985, 102(5):213-216.
16. Legg J M. Computerized aproach for matrix-from FMECA [J], IEEE Trans Rel,1978, 17(5):254-257.
17. Wolf P. CAD frameworks:principles and architecture [M], Netherlands:Kluwer academic publishers,1994.
18. John B. Boweles and Ronald D. Bonnell Fail Mode, Effects and Criticalty Analysis Proceedings Annual Reliability and Maintainability Symp [J],1996,120(8)152-160.
19. Stephanie A. Herrin Maintainability Applications Using the Matrix FMEA Technique IEEE TRANSACTIONS on Reliability [J],1981,12(6):12-25.
20. Barbour G L. Failure modes and effects analysis by matrix method [J], Proc Reliab Maint Symp IEEE 1979,105(2):114-119.
21.金仲达.船舶概论[M],哈尔滨：哈尔滨工程大学出版社,2002,3.
22.李萨扬.汽轮机及其辅助设备基于维修的FMEA[D],学位论文,2002,北京：华北电力大学(北京).
23.孙建波等.船机管理与故障处理[D],大连：大连海事大学,2002,12.
24.胡金寿.柴油机设计与工艺可靠性探讨及案例分析[J],柴油机：Diesel Engine,2003,3(5)：20-24.
25.段潇.“设计失效模式及后果分析”在车辆产品开发中的应用[J],产品开发,2002,4(12)：30-35.
26.张建国等.大型机械产品FMEA和FTA综合分析方法[J],机械设计与制造,2002,5(2)：34-36.
27.邵德生.故障模式影响及危害性分析(FMECA)技术[J],“三F”技术讲座,1995,10(2)：51-54.
28.李长福等.迫—7引言FMEA及危害性与定量分析[J],现代引言,1995,1(12)：42-45.
29.刘江南.项目风险管理中失效模式与影响分析的应用研究[D],天津：天津大学,2001.
30.刘秋军.柴油机缸套的故障现象、成因及预防[J],煤矿机械,2005,10(5)：21-24.
31.盐见弘等.故障模式影响及危害性分析(FMECA) [M],村械工业出版社,1988.
32.王超.机械可靠性工程[M],北京：冶金工业出版社,1992.
33.李海泉等.系统可靠性分析与设计[M],北京：科学出版社,2003.
34.金壁辉.系统可靠性工程[M],北京：国防工业出版社,2005.
35.金兴明,屠庆慈,陆廷孝.结合FMECA可靠性预计法[J],北京航空航天大学学报,1992,1：32-37.
36.鞠鲁粤.模糊致命度分析及其在矩阵FMECA中的应用[J],上海大学学报(自然科学版),1999,5(10)：51-53.
37.崔玉莲.国内外机械产品典型可靠型设计方法[J],质量与可靠性,2000年,6：24-28.
38.杨宏伟.机械系统FMECA应用中的几个问题[J],装甲兵工程院学报,1995年,1：86-91.
39.鞠鲁粤等.用矩阵方法实施故障模式、影响及致命度分析[J],上海工业大学学报,1993,41(5)：44-50.
40.鞠鲁粤.矩阵FMECA研究及计算机辅助分析程序[J],航空部“八五”攻关项目《航空发动机齿轮箱可靠性、安全性研究》课题报告(KT2992SM 21),1994,15(2)：2-30.
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