汽车产品再制造模式及其可靠性分析
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摘要
再制造是汽车产品回收再利用的最高级形式,可以最大限度的保留制造过程中赋予零部件的附加值,是汽车工业发展循环经济,走可持续发展道路的最重要技术途径之一,是建设资源节约型、环境友好型和谐社会的必然选择。
再制造属于制造的范畴,但又不完全等同于制造。新品制造过程中毛坯原材料质量单一,易于保证产品的生产一致性和可靠性；然而再制造的毛坯来自于废旧汽车,零部件具有不同的技术状态和剩余寿命,每个毛坯可能来源于不同的废旧产品,可能经历不同的再制造修复技术,再制造系统也会包含原型或新型的新件。毛坯状态、失效形式、再制造修复方法都具有高度的随机性和不确定性,因此再制造汽车产品的质量控制相比新品制造要复杂的多。同时,再制造也不同于维修。维修是随机的、原位的、单一的过程,以恢复产品的功能为目的。而再制造过程具有批量化报废、修复的特点,再制造生产过程包含产品批量拆解、清洗、替换或修复失效件、再装配等工艺过程,并且对再制造产品的技术性能、可靠性的要求不低于原型新品。因此再制造汽车产品的可靠性建模和分析方法也将不同于新品制造和维修。
国外发达国家的汽车零部件再制造产业已有超过50多年的历史,从技术标准、加工技术、修复工艺到逆向物流、产品分销等各个方面都已发展相对成熟,形成较为完善的再制造体系。而目前我国汽车零部件再制造产业处于刚刚起步阶段。由于考虑到道路交通安全和环境保护等相关问题,国家政府主管部门多年来一直没有对汽车零部件再制造产业提供有效的政策支持。具有高附加值的发动机、变速器、转向器、前后桥和车架等零部件均不允许再制造使用,而是强制回炉炼钢。这造成了巨大的资源浪费和环境二次污染。出于推动汽车循环经济的考虑,汽车主管部门近几年公布了多家汽车零部件再制造试点企业,并对再制造汽车产品的质量提出了较高要求,要求保证再制造的零部件产品技术性能、可靠性和使用寿命接近或达到原产品的水平。
再制造过程主要的特点是原材料来料时间、毛坯质量状况以及采用的修复方法等都具有不确定性,再制造后的系统也可能不同于原型新产品,因此再制造后的产品的可靠性也存在着不确定性。如何评估、提高再制造汽车产品的可靠性是发展汽车零部件再制造产业的关键问题。
本文在综合分析国内外再制造产业发展现状及相关理论研究的基础上,对产品可靠性基本理论、汽车产品再制造模式、再制造汽车产品的可靠性建模、可靠性预计、可靠性分配以及可靠性试验等几个方面进行了深入分析,指出了影响再制造汽车产品系统可靠性的两方面因素：再制造系统结构变化和再制造系统中零部件可靠性的变化。
对于系统结构的变化,根据再制造汽车产品相对于原型新产品的技术换代及用途变化规律,提出了四种再制造型式,即进化型式、退化型式、滞化型式和转化型式；而通过分析再制造后产品系统结构的变化规律,提出了四种再制造模式,即再用模式、更新模式、改造模式以及重置模式等。
基于不同的再制造模式,构建了再制造汽车产品的系统可靠性模型,通过该模型,基于服从指数分布的串联系统,分析了再制造汽车产品的可靠性预计和可靠度分配方法。最后,对再制造汽车产品的可靠性验证试验以及FMEA在再制造中的应用等相关问题进行了分析,并以某再制造柴油发动机为例,对采用再用模式,对部分零部件进行高技术表面工程修复的再制造发动机进行1000h可靠性验证试验,对再制造柴油发动机关键修复考核件及整机系统的可靠性进行评价。
论文的主要研究结果,构建了相对完整的汽车产品再制造模式和再制造汽车产品的可靠性分析理论。对于汽车零部件再制造过程中,对直接再使用件、可再制造件以及弃用件的分类原则,再制造产品装配过程中三类零件的选用等几个方面都提供了基础指导,为再制造企业提高再制造汽车产品的质量和可靠性提供了理论支持。然而,由于我国汽车零部件再制造产业处于刚刚起步阶段,相关的汽车产品再制造企业、再制造产品和再制造技术还不是很丰富,因此对于本课题的研究还难以获得更加充足的再制造模式选择和可靠性试验数据支持。在下一步的工作过程中,还需要对此进一步的深入研究。
Remanufacturing is the ultimate form of automotive products recycling, which can recapture most value added in the components, and it will be one of the most important technological methods for the sustainable development of automotive industry circular economy, and will be the necessary choice in order to establish the resources-conservation and environment-friendly harmonious society.
Remanufacturing belongs to the manufacturing category, but is not equal to manufacturing process. The difference is that the original condition of rough components in manufacturing is pure, the quality, reliability and products consistency could be easily controlled. While the rough components in remanufacturing come from end-of-life automotive products, most components have failed with a variety of unknown age distribution. Each component of the remanufactured system may have come from different failed products, experienced different remanufacturing techniques and may be a new component of the same type as the original one or different. The condition of cores, failure modes and remanufacturing methods of raw materials are random and uncertain. So the quality control method will be more complex than that of manufacturing. Remanufacturing is also different from repairing process. Repairing is stochastic and single process aiming to recover the products function, while remanufacturing is a volume-wasting and renewing process, which involves the production-batch disassembly, cleaning, replacement or refurbishment of worn components and reassembly process. The system reliability is required to not be lower than the original system reliability. So the reliability modeling and analysis methods will be different from that of manufacturing and repairing process.
Automotive components remanufacturing industry has a history of more than 50 years in some developed countries, a complete remanufacturing system formed from technical standards, processing techniques, fabricating machinery to reverse logistics and delivery, etc. While automotive components remanufacturing industry in China is just at the preliminary stage. With the consideration of transportation safety and environment protection, the Chinese government has been prohibiting the reuse and remanufacturing of important ELVs components, such as the engine, transmission, steering gear, front/rear axles and the vehicle frame, etc. These components have high value-added, but all of the five assemblies must be broken down and resmelted. This has caused a lot of resources waste and secondary pollution. In order to develop the circular economy of automotive industry, the Chinese government begins to promote the development of automotive components remanufacturing industry, and express high requirements on remanufactured automotive products so as to ensure the technical function, system reliability and products lifetime can be not lower than or reach the original products requirement.
Remanufacturing has an uncertain characteristic on coming time, technical condition and repairing method of cores, and the remanufactured system is different from that of original one. So how to assess and improve the system reliability of the remanufactured products is the key question to develop the automotive components remanufacturing.
In this paper, it focuses on the basic theory of product reliability, automotive remanufacturing modes, reliability modeling method of remanufactured automotive products and the reliability prediction, allocation and reliability experiment are also discussed in detail. It also points out two aspects that affect the system reliability of remanufactured automotive products, such as the change of system construction and reliability of components in the remanufactured system.
According to the variation of automotive products technical level in remanufacturing, it puts forward four kinds of remanufacturing style, such as evolutional style, stagnant style, and degenerate style, transformational style, etc. According to the different construction of remanufactured products from the original ones, it puts out four kinds of remanufacturing modes, and they are reuse mode, updating mode, and amelioration mode, reset mode, etc.
Reliability models are established on the base of these four different remanufacturing modes, and the reliability prediction and allocation methods are discussed deeply based on the series system and exponential distribution. In the end, the demonstration reliability experiment of remanufactured automotive products and the FMEA of remanufacturing are also analyzed. Take the remanufactured diesel engine as example, the engine was remanufactured with the reuse mode, some key components were remanufactured by high surface technologies. Assess these key components and system reliability by 1000h reliability experiment, the final results show that key components and system reliability are not lower than that of original requirements.
The preliminary main research builds a relatively complete theory on automotive components remanufacturing modes, reliability prediction and allocation method. It can be used as a guide for the classification principle of reuse components, remanufacturable components and abandoned components in remanufacturing, and it gives a theory support on the selection of these three types of components and help the remanufacturers to better the system reliability of remanufactured automotive products. While the automotive components remanufacturing industry in Chinese is just at the preliminary stage, there are few remanufacturers, remanufactured products and technics, so it is hard to get more remanufacturing modes and reliability data to support this paper, and it needs a further consideration in the future.
再制造属于制造的范畴,但又不完全等同于制造。新品制造过程中毛坯原材料质量单一,易于保证产品的生产一致性和可靠性；然而再制造的毛坯来自于废旧汽车,零部件具有不同的技术状态和剩余寿命,每个毛坯可能来源于不同的废旧产品,可能经历不同的再制造修复技术,再制造系统也会包含原型或新型的新件。毛坯状态、失效形式、再制造修复方法都具有高度的随机性和不确定性,因此再制造汽车产品的质量控制相比新品制造要复杂的多。同时,再制造也不同于维修。维修是随机的、原位的、单一的过程,以恢复产品的功能为目的。而再制造过程具有批量化报废、修复的特点,再制造生产过程包含产品批量拆解、清洗、替换或修复失效件、再装配等工艺过程,并且对再制造产品的技术性能、可靠性的要求不低于原型新品。因此再制造汽车产品的可靠性建模和分析方法也将不同于新品制造和维修。
国外发达国家的汽车零部件再制造产业已有超过50多年的历史,从技术标准、加工技术、修复工艺到逆向物流、产品分销等各个方面都已发展相对成熟,形成较为完善的再制造体系。而目前我国汽车零部件再制造产业处于刚刚起步阶段。由于考虑到道路交通安全和环境保护等相关问题,国家政府主管部门多年来一直没有对汽车零部件再制造产业提供有效的政策支持。具有高附加值的发动机、变速器、转向器、前后桥和车架等零部件均不允许再制造使用,而是强制回炉炼钢。这造成了巨大的资源浪费和环境二次污染。出于推动汽车循环经济的考虑,汽车主管部门近几年公布了多家汽车零部件再制造试点企业,并对再制造汽车产品的质量提出了较高要求,要求保证再制造的零部件产品技术性能、可靠性和使用寿命接近或达到原产品的水平。
再制造过程主要的特点是原材料来料时间、毛坯质量状况以及采用的修复方法等都具有不确定性,再制造后的系统也可能不同于原型新产品,因此再制造后的产品的可靠性也存在着不确定性。如何评估、提高再制造汽车产品的可靠性是发展汽车零部件再制造产业的关键问题。
本文在综合分析国内外再制造产业发展现状及相关理论研究的基础上,对产品可靠性基本理论、汽车产品再制造模式、再制造汽车产品的可靠性建模、可靠性预计、可靠性分配以及可靠性试验等几个方面进行了深入分析,指出了影响再制造汽车产品系统可靠性的两方面因素：再制造系统结构变化和再制造系统中零部件可靠性的变化。
对于系统结构的变化,根据再制造汽车产品相对于原型新产品的技术换代及用途变化规律,提出了四种再制造型式,即进化型式、退化型式、滞化型式和转化型式；而通过分析再制造后产品系统结构的变化规律,提出了四种再制造模式,即再用模式、更新模式、改造模式以及重置模式等。
基于不同的再制造模式,构建了再制造汽车产品的系统可靠性模型,通过该模型,基于服从指数分布的串联系统,分析了再制造汽车产品的可靠性预计和可靠度分配方法。最后,对再制造汽车产品的可靠性验证试验以及FMEA在再制造中的应用等相关问题进行了分析,并以某再制造柴油发动机为例,对采用再用模式,对部分零部件进行高技术表面工程修复的再制造发动机进行1000h可靠性验证试验,对再制造柴油发动机关键修复考核件及整机系统的可靠性进行评价。
论文的主要研究结果,构建了相对完整的汽车产品再制造模式和再制造汽车产品的可靠性分析理论。对于汽车零部件再制造过程中,对直接再使用件、可再制造件以及弃用件的分类原则,再制造产品装配过程中三类零件的选用等几个方面都提供了基础指导,为再制造企业提高再制造汽车产品的质量和可靠性提供了理论支持。然而,由于我国汽车零部件再制造产业处于刚刚起步阶段,相关的汽车产品再制造企业、再制造产品和再制造技术还不是很丰富,因此对于本课题的研究还难以获得更加充足的再制造模式选择和可靠性试验数据支持。在下一步的工作过程中,还需要对此进一步的深入研究。
Remanufacturing is the ultimate form of automotive products recycling, which can recapture most value added in the components, and it will be one of the most important technological methods for the sustainable development of automotive industry circular economy, and will be the necessary choice in order to establish the resources-conservation and environment-friendly harmonious society.
Remanufacturing belongs to the manufacturing category, but is not equal to manufacturing process. The difference is that the original condition of rough components in manufacturing is pure, the quality, reliability and products consistency could be easily controlled. While the rough components in remanufacturing come from end-of-life automotive products, most components have failed with a variety of unknown age distribution. Each component of the remanufactured system may have come from different failed products, experienced different remanufacturing techniques and may be a new component of the same type as the original one or different. The condition of cores, failure modes and remanufacturing methods of raw materials are random and uncertain. So the quality control method will be more complex than that of manufacturing. Remanufacturing is also different from repairing process. Repairing is stochastic and single process aiming to recover the products function, while remanufacturing is a volume-wasting and renewing process, which involves the production-batch disassembly, cleaning, replacement or refurbishment of worn components and reassembly process. The system reliability is required to not be lower than the original system reliability. So the reliability modeling and analysis methods will be different from that of manufacturing and repairing process.
Automotive components remanufacturing industry has a history of more than 50 years in some developed countries, a complete remanufacturing system formed from technical standards, processing techniques, fabricating machinery to reverse logistics and delivery, etc. While automotive components remanufacturing industry in China is just at the preliminary stage. With the consideration of transportation safety and environment protection, the Chinese government has been prohibiting the reuse and remanufacturing of important ELVs components, such as the engine, transmission, steering gear, front/rear axles and the vehicle frame, etc. These components have high value-added, but all of the five assemblies must be broken down and resmelted. This has caused a lot of resources waste and secondary pollution. In order to develop the circular economy of automotive industry, the Chinese government begins to promote the development of automotive components remanufacturing industry, and express high requirements on remanufactured automotive products so as to ensure the technical function, system reliability and products lifetime can be not lower than or reach the original products requirement.
Remanufacturing has an uncertain characteristic on coming time, technical condition and repairing method of cores, and the remanufactured system is different from that of original one. So how to assess and improve the system reliability of the remanufactured products is the key question to develop the automotive components remanufacturing.
In this paper, it focuses on the basic theory of product reliability, automotive remanufacturing modes, reliability modeling method of remanufactured automotive products and the reliability prediction, allocation and reliability experiment are also discussed in detail. It also points out two aspects that affect the system reliability of remanufactured automotive products, such as the change of system construction and reliability of components in the remanufactured system.
According to the variation of automotive products technical level in remanufacturing, it puts forward four kinds of remanufacturing style, such as evolutional style, stagnant style, and degenerate style, transformational style, etc. According to the different construction of remanufactured products from the original ones, it puts out four kinds of remanufacturing modes, and they are reuse mode, updating mode, and amelioration mode, reset mode, etc.
Reliability models are established on the base of these four different remanufacturing modes, and the reliability prediction and allocation methods are discussed deeply based on the series system and exponential distribution. In the end, the demonstration reliability experiment of remanufactured automotive products and the FMEA of remanufacturing are also analyzed. Take the remanufactured diesel engine as example, the engine was remanufactured with the reuse mode, some key components were remanufactured by high surface technologies. Assess these key components and system reliability by 1000h reliability experiment, the final results show that key components and system reliability are not lower than that of original requirements.
The preliminary main research builds a relatively complete theory on automotive components remanufacturing modes, reliability prediction and allocation method. It can be used as a guide for the classification principle of reuse components, remanufacturable components and abandoned components in remanufacturing, and it gives a theory support on the selection of these three types of components and help the remanufacturers to better the system reliability of remanufactured automotive products. While the automotive components remanufacturing industry in Chinese is just at the preliminary stage, there are few remanufacturers, remanufactured products and technics, so it is hard to get more remanufacturing modes and reliability data to support this paper, and it needs a further consideration in the future.
引文
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