提高內(nèi)燃機(jī)產(chǎn)品使用可靠性的捷徑和對(duì)策概述

提高內(nèi)燃機(jī)產(chǎn)品使用可靠性的捷徑和對(duì)策THESHORTCUTANDCOUNTERMEASURESTOIMPROVETHERELIABILITYOFINTERNALCOMBUSTIONENGINE濰柴動(dòng)力產(chǎn)品可靠性總監(jiān)ProductreliabilitydirectorofWeichaiPower胡金壽HuJinshou2014年3月30日March30th,2014一、前言Introduction二、內(nèi)燃機(jī)存在的主要使用可靠性問題及原因分析Majorreliabilityproblemsofcombusionengineandcauseanalysis三、提高產(chǎn)品使用可靠性從失效分析抓起Improveproductreliability,startfromfailureanalysis四、設(shè)計(jì)對(duì)標(biāo)是快速調(diào)高內(nèi)燃機(jī)設(shè)計(jì)可靠性的捷徑Benchmarkingdesignisashortcuttoimproveproductreliability五、合理配套是確保內(nèi)燃機(jī)使用可靠性的關(guān)鍵Suitablematchisthekeytoguaranteecombusionreliability六、建立產(chǎn)品可靠性數(shù)據(jù)庫Constructproductreliabilitydatabase七、結(jié)束語Endingwords目錄Contents前言INTRODUTION一、前言Introduction作為造福于人類的動(dòng)力設(shè)備,內(nèi)燃機(jī)已被廣泛應(yīng)用于工程機(jī)械、卡車、發(fā)電機(jī)組、船舶、長途客車、工程用車、城市公交車以及農(nóng)機(jī)等Ashuman’sbeneficialpowerequipments,combustionshavealreadybeenusedinmanyareasofengineeringmachinery、truck、generatingunit、ships、coachbus、citybus、agriculturemachinery…etc.1內(nèi)燃機(jī)成為個(gè)體用戶發(fā)家致富的強(qiáng)有力工具,因而提高內(nèi)燃機(jī)的可靠性就顯得特別的緊迫

Combustionshavebeenpowerfultoolsofindividualsubscriptionstogetrich,Withtheresultthatimprovingcombustionreliabilityseemstobeparticularlyurgency.2激烈的市場(chǎng)競爭是質(zhì)量、服務(wù)、價(jià)格的競爭，可靠性是質(zhì)量的核心，良好的可靠性會(huì)使企業(yè)、客戶、社會(huì)獲得三贏Fiercemarketcompetitionisthequality

service

pricecompetition,andreliabilityisthecoreofquality.Betterreliabilitywillleadenterprises、customers、societytobeallthewinners.3要提高內(nèi)燃機(jī)的使用可靠性，必須要從設(shè)計(jì)、工藝、制造、物流、儲(chǔ)存、主機(jī)配套以及用戶使用全過程來提高可靠性Toimprovetheusingreliabilityofcombustion,peoplemustworkfromthewholeprocessofdesigningcraftmanufacturetransportstorematchingandallcustomers’operation.4要使內(nèi)燃機(jī)可靠性不斷增長，必須要有最大限度滿足用戶需要的理念，除了千方百計(jì)提高零部件本身的可靠性外，還要充分考慮用戶實(shí)際使用和保養(yǎng)的情況，盡可能地消除用戶使用和保養(yǎng)過程中可能要產(chǎn)生的問題，只有真正樹立“用戶第一”的思想，才能確保內(nèi)燃機(jī)可靠性的不斷增長Tokeepcombustionreliabilityimprovingconstantly,wemustunderstandtheconceptofcustomers’maximumsatisfaction.Notonlydoeverythingpossibletoimprovethereliabilityofcomponentitself,butalsoconsidersituationsofcustomers’actualuseandmaintenancesufficiently,eliminatepossiblyproblemsintheprocessofuseandmaintenance.Onlyifsetupuserfirstideologycouldweensurecombustionreliabilityimprovingconstantly.5一、前言Introduction內(nèi)燃機(jī)存在的主要使用可靠性問題及原因分析Majorreliabilityproblemsofcombustionengineandcauseanalysis二、內(nèi)燃機(jī)存在的主要使用可靠性問題及原因分析Majorreliabilityproblemsofcombustionengineandcauseanalysis主要可靠性可分為兩大類Twomajorkindsofreliabilityproblems性能performance零部件故障（失效）Componetsfailure性能可靠性問題Performancereliabilityproblems空氣質(zhì)量Airquality相關(guān)零部件如配氣機(jī)構(gòu)和四配套工作表面的耗損Relevantcomponentssurfaceweared(suchasvalvemechanismandpistoncomponent)油品、天然氣氣源Fuel\oilquality使用保養(yǎng)Useandmaintenance二、內(nèi)燃機(jī)存在的主要使用可靠性問題及原因分析Majorreliabilityproblemsofcombusionengineandcauseanalysis零部件可靠性問題-故障（失效）Componentreliability-broken(failure)用戶使用保養(yǎng)正確性Correctuseandmaintenance物流儲(chǔ)存可靠性Transportandstorereliability本身設(shè)計(jì)可靠性Designreliability油品環(huán)境適應(yīng)性Fuelenvironmentadaptability工藝制作可靠性Processreliability與主機(jī)配套合理性Suitablematching二、內(nèi)燃機(jī)存在的主要使用可靠性問題及原因分析Majorreliabilityproblemsofcombustionengineandcauseanalysis提高產(chǎn)品使用可靠性從故障（失效）分析抓起Productusereliabilityimproving,

failureanalysiscomesfirst成功失敗常言道：失敗乃成功之母！三、提提高產(chǎn)產(chǎn)品使使用可可靠性性從故故障（（失效效）分分析抓抓起Productusereliabilityimproving,failureanalysiscomesfirst要提高高內(nèi)燃燃機(jī)使使用可可靠性性首先先要提提高易易發(fā)生生故障障（失失效））零部部件的的使用用可靠靠性Toimprovecombustionusereliability,weshouldimprovefailureeasilycomponentsusereliabilityfirst要提高高易發(fā)發(fā)生故故障（（失效效）零零部件件的使使用可可靠性性必須須要弄弄清楚楚零部部件故故障（（失效效）的的根本本原因因Toimprovefailureeasilycomponentsusereliability,wemustfigureouttherootcause要找出出根本本原因因應(yīng)對(duì)對(duì)故障障（失失效））件、、故障障（失失效））模式式進(jìn)行行分析析，，即從從故障障（失失效））分析析抓起起Tofigureouttherootcause,weshouldanalysisfailurepartsandfailuremode,namelyfailureanalysiscomesfirst可靠性的核心任務(wù)是與故障（失效）作斗爭Thecoretaskofreliabilityisfailurefighting!與故障作斗爭積累出經(jīng)驗(yàn)和教訓(xùn)Fightfailure,accumulateexperienceandlesson應(yīng)用這些經(jīng)驗(yàn)和教訓(xùn)設(shè)計(jì)極為有效It’squiteefficienttoconsummatedesignwiththeseexperienceandlesson三、提高產(chǎn)品品使用可靠性性從故障（失失效）分析抓抓起Productusereliabilityimproving,failureanalysiscomesfirst設(shè)計(jì)可靠性案例—推桿彎曲Designreliabilitycase─pushrodbent1三、提高產(chǎn)品品使用可靠性性從故障（失失效）分析抓抓起Productusereliabilityimproving,failureanalysiscomesfirst三、提高產(chǎn)品品使用可靠性性從故障（失失效）分析抓抓起Productusereliabilityimproving,failureanalysiscomesfirst設(shè)計(jì)可靠性案例—繼電器易損壞Designreliabilitycase─relaybrokeneasily2三、提高產(chǎn)品品使用可靠性性從故障（失失效）分析抓抓起Productusereliabilityimproving,failureanalysiscomesfirst3制造可靠性案案例--曲軸連桿燒壞壞Manufacturereliabilitycase─connectingrodburned制作可靠性案例--增壓器斷軸Manufacturereliabilitycase─superchargershaftcut4三、提高產(chǎn)品品使用可靠性性從故障（失失效）分析抓抓起Productusereliabilityimproving,failureanalysiscomesfirst三、提高產(chǎn)品品使用可靠性性從故障（失失效）分析抓抓起Productusereliabilityimproving,failureanalysiscomesfirst制作可靠性案例--機(jī)油泵故障Manufacturereliabilitycase─oilpumpbroken5三、提高產(chǎn)品品使用可靠性性從故障（失失效）分析抓抓起Productusereliabilityimproving,failureanalysiscomesfirst儲(chǔ)運(yùn)可靠性案例--風(fēng)扇葉片裂Storagereliabilitycase─fanbladebroken6三、提高產(chǎn)品品使用可靠性性從故障（失失效）分析抓抓起Productusereliabilityimproving,failureanalysiscomesfirst儲(chǔ)運(yùn)可靠性案例—吊裝不當(dāng)砸壞機(jī)器Storagereliabilitycase─wronghoisting7三、提高產(chǎn)品品使用可靠性性從故障（失失效）分析抓抓起Productusereliabilityimproving,failureanalysiscomesfirst與主機(jī)配套合理性—飛輪殼拉裂Suitablematch─flywheelcoverpulledcrack8三、提高產(chǎn)品品使用可靠性性從故障（失失效）分析抓抓起Productusereliabilityimproving,failureanalysiscomesfirst與主機(jī)配套合理性—離合器分離力過大Suitablematch─clutchseparatingoverforced9三、提高產(chǎn)品品使用可靠性性從故障（失失效）分析抓抓起Productusereliabilityimproving,failureanalysiscomesfirst與主機(jī)配套合理性—離合器選配不當(dāng)Suitablematch─unsuitableclutch10油品環(huán)境適應(yīng)性—不良油品導(dǎo)致連桿化瓦Oilenvironmentadaptation─bearingmilledcausebybadoil11三、提高產(chǎn)品品使用可靠性性從故障（失失效）分析抓抓起Productusereliabilityimproving,failureanalysiscomesfirst三、提高產(chǎn)品品使用可靠性性從故障（失失效）分析抓抓起Productusereliabilityimproving,failureanalysiscomesfirst油品環(huán)境適應(yīng)性—空氣臟引起空壓泵竄油Oilenvironmentadaptation─badaircausecompressedairpumpoilexpelling12某礦用車在送送車途中發(fā)生生重大事故，，車輛下坡途途中突然聽到咔咔聲，停車車后發(fā)現(xiàn)飛輪輪殼開裂，起起動(dòng)機(jī)掉地，，取力器、變變速器、排氣氣筒、傳動(dòng)軸軸等損壞司機(jī)在空檔溜溜坡時(shí)誤操作作誤將變速器器掛入低檔三、提高產(chǎn)品品使用可靠性性從故障（失失效）分析抓抓起Productusereliabilityimproving,failureanalysiscomesfirst用戶使用可靠性—下坡溜車掛錯(cuò)擋Customerusereliability─downslopewrongshift13三、提高產(chǎn)品品使用可靠性性從故障（失失效）分析抓抓起Productusereliabilityimproving,failureanalysiscomesfirst用戶使用可靠性—下坡溜車掛錯(cuò)擋Customerusereliability─downslopewrongshift13某客車公司一一批新氣體機(jī)機(jī)汽車停車場(chǎng)場(chǎng)停置30天后，司機(jī)在在駕駛時(shí)猛加加油、急加速速引起爆震，，沖壞缸墊。Inonebuscompany,abatchofnewgasenginebusesstopinparkinglotfor30days.Driversspeedupheavilyduringdriving,causedetonation,headgasketrushed.LNG發(fā)動(dòng)機(jī)，在氣氣罐中，甲烷烷位于上層，，而丙烷、丁丁烷下沉，位位于下層。位位于氣罐下部部的出氣管使使下層的丙烷烷、丁烷進(jìn)入入燃燒室燃燒燒，易造成成爆震LNGengine:thegas-holderinterior,methaneuptothetoplayer,propaneandbutanesinktobottom.outletpipebelowthegas-holderconveypropaneandbutanetocombustor,causingknockeasily.三、提高產(chǎn)品品使用可靠性性從故障（失失效）分析抓抓起Productusereliabilityimproving,failureanalysiscomesfirst用戶使用可靠性—猛加速引起爆震，沖壞缸墊Customerusereliability─heavilyspeedingupcausedetonation,rushingheadgasket14三、提高產(chǎn)品品使用可靠性性從故障（失失效）分析抓抓起Productusereliabilityimproving,failureanalysiscomesfirst用戶使用可靠性—猛加速引起爆震，沖壞缸墊Customerusereliability─heavilyspeedingupcausedetonation,rushingheadgasket14設(shè)計(jì)對(duì)標(biāo)是快快速提高內(nèi)燃燃機(jī)設(shè)計(jì)可靠靠性的捷徑Benchmarkingdesignisashortcuttoimproveproductreliability一個(gè)正確的設(shè)計(jì)不能憑空產(chǎn)生，他是前人經(jīng)驗(yàn)的積累和繼承。一個(gè)成熟的部件也會(huì)由于環(huán)境和使用工況的變動(dòng)而失效，產(chǎn)品結(jié)構(gòu)設(shè)計(jì)的持續(xù)改進(jìn)是一個(gè)永恒的話題。Arightdesignationdoesn’tgenerategroundless.Itdependsonpredecessors’accumulatedexperience.Amaturepartalsoloseefficacybythechangingenvironmentandusingsituation.Sustainedimprovingofproductstructuredesignationwillbeaforevertopic.

提高產(chǎn)品的使用可靠性最關(guān)鍵的是要提高產(chǎn)品的設(shè)計(jì)可靠性，而要提高產(chǎn)品的設(shè)計(jì)可靠性最快捷的方法是“設(shè)計(jì)對(duì)標(biāo)”。

Thekeytoimproveproductusereliabilityistoimproveproductdesignreliability,andtheshotcutwaytoimproveproductdesignreliabilityis“benchmarkingdesign”.綜述overview四、設(shè)計(jì)對(duì)標(biāo)標(biāo)是快速提高高內(nèi)燃機(jī)設(shè)計(jì)計(jì)可靠性的捷徑Benchmarkingdesignisashortcuttoimproveproductreliability“設(shè)計(jì)對(duì)標(biāo)”就是與其它系列的產(chǎn)品進(jìn)行結(jié)構(gòu)設(shè)計(jì)對(duì)比，從結(jié)構(gòu)設(shè)計(jì)的角度找出產(chǎn)品使用中發(fā)生故障的真正原因，參照其它產(chǎn)品成熟的設(shè)計(jì)來改善自己的產(chǎn)品。“Benchmarkingdesign”isthecomparisontootherseriesproductofstructuredesign.Findoutrealfailurecausethroughproductusingfromtheangleofstructuredesign.Consultothermaturedesigntoimproveourselves.“設(shè)計(jì)對(duì)標(biāo)”不僅改進(jìn)速度快，而且風(fēng)險(xiǎn)極小，能以最短的時(shí)間迅速提高產(chǎn)品的使用可靠性?！癇enchmarkingdesign”,notonlyimprovefast,butalsosafety,couldspeedilyimproveproductusereliabilitywithintheshortesttime.綜述四、設(shè)計(jì)對(duì)標(biāo)標(biāo)是快速提高高內(nèi)燃機(jī)設(shè)計(jì)計(jì)可靠性的捷徑Benchmarkingdesignisashortcuttoimproveproductreliability飛輪殼裂紋問題flywheelcrackle1對(duì)標(biāo)四、設(shè)計(jì)對(duì)標(biāo)標(biāo)是快速提高高內(nèi)燃機(jī)設(shè)計(jì)計(jì)可靠性的捷徑Benchmarkingdesignisashortcuttoimproveproductreliability傳動(dòng)皮帶易開裂問題transmissionbeltcracking

2對(duì)標(biāo)四、設(shè)計(jì)對(duì)標(biāo)標(biāo)是快速提高高內(nèi)燃機(jī)設(shè)計(jì)計(jì)可靠性的捷徑Benchmarkingdesignisashortcuttoimproveproductreliability增壓器止推片異常磨損superchargerthrustplateabnormalwear3四、設(shè)計(jì)對(duì)標(biāo)標(biāo)是快速提高高內(nèi)燃機(jī)設(shè)計(jì)計(jì)可靠性的捷徑Benchmarkingdesignisashortcuttoimproveproductreliability風(fēng)扇托架失效問題fanbracketfailure

4四、設(shè)計(jì)對(duì)標(biāo)標(biāo)是快速提高高內(nèi)燃機(jī)設(shè)計(jì)計(jì)可靠性的捷徑Benchmarkingdesignisashortcuttoimproveproductreliability對(duì)標(biāo)合理配套是確確保內(nèi)燃機(jī)使使用可靠性的的關(guān)鍵Suitablematchisthekeytoguaranteecombustionreliability為了確保內(nèi)燃燃機(jī)的使用可可靠性，內(nèi)燃燃機(jī)與主機(jī)的的配套合理性性極為關(guān)鍵Toguaranteecombustionusereliability,asuitablematchisquiteimportant合理性問題過過去以主機(jī)廠廠研究為主，，現(xiàn)在是買方方市場(chǎng)，應(yīng)主主動(dòng)與主機(jī)配配套好SuitablematchmainlyrelyonOEM’sresearchinthepast,nowitsbuyers’market,weshouldmatchinitiatively.配套不良造成成的零部件機(jī)機(jī)械故障。如如水箱與風(fēng)扇扇之間的距離離安裝不合適適引起柴油機(jī)機(jī)水溫不正常常，外接排氣氣總管沒有支支撐易引起增增壓器損壞以以及空氣濾清清器選用不當(dāng)當(dāng)引起柴油機(jī)機(jī)早期磨損等Componentmechanicalfailurecausedbyunsuitablematch.suchasunsuitabledistancebetweenwatertankandfancauseabnormalwatertemperature,externalexhaustmanifoldwithoutsupportcausesuperchargerbrokenandunsuitableairfiltercausedieselengineprematurewear…etc.五、合理配套套是確保內(nèi)燃燃機(jī)使用可靠靠性的關(guān)鍵Suitablematchisthekeytoguaranteecombustionreliability五、合理配套套是確保內(nèi)燃燃機(jī)使用可靠靠性的關(guān)鍵Suitablematchisthekeytoguaranteecombustionreliability要進(jìn)行配套合合理性評(píng)定必必須要有一個(gè)個(gè)評(píng)定的規(guī)范范Astandardmustbesettoevaluatematchsuitability.規(guī)范編寫的依據(jù)有有兩點(diǎn)：一是是將常規(guī)的要要求編進(jìn)去;二是把過去失失敗的經(jīng)驗(yàn)總總結(jié)編進(jìn)去therearetwopointstowritestandard:oneistowriteconventionalrequest,anotheristowritefailureexperienceinthepast.把過去發(fā)生過過的各種失效效模式和解決決方法進(jìn)行總總結(jié)變成評(píng)定定的規(guī)范summarizeallkindsoffailuremodeandsolutionsinthepastandmakethemtobeevaluatestandard.派有經(jīng)驗(yàn)的人人員按規(guī)范的的要求并結(jié)合合自己的實(shí)踐踐經(jīng)驗(yàn)對(duì)配套套合理性進(jìn)行行評(píng)定Accordingtostandardrequirementdispatchexperiencestaffandcombineyourownexperiencetoevaluatematchsuitability.系列柴油機(jī)首首次與整車配配套安裝評(píng)定定檢查表seriesdieselenginefirstmatchingevaluatechecklist五、合理配套套是確保內(nèi)燃燃機(jī)使用可靠靠性的關(guān)鍵Suitablematchisthekeytoguaranteecombustionreliability建立產(chǎn)品可靠靠性數(shù)據(jù)庫Constructprodu