CN110727673A - Fan product FMEA data processing method and system - Google Patents
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Abstract
The invention discloses a fan product FMEA data processing method and a processing system, wherein the processing method comprises the following steps: s1, acquiring fault and state information of a fan according to a preset work order; s2, arranging the fault and state information into structured field data, and storing the structured field data into a database; and S3, determining a fault mode and influence information by analyzing the fault and state information, perfecting the field data, and storing the field data into the database to obtain fault mode and fault influence analysis data. The fan product management system has the advantages that the fan product management system can realize standardization and structuralized effective management and statistics of the abnormity of fan products in production, operation and maintenance, feed back and push the abnormity to a design process end, efficiently realize improvement of fan product design, and through closed-loop design of the front end and the rear end, the data consistency is good, high data sharing can be realized, the data processing efficiency is high, the cost is low, and the like.
Description
Technical Field
The invention relates to the field of fan product information management, in particular to a fan product FMEA data processing method and system.
Background
The wind turbine generator is a large electromechanical integrated device integrating mechanical parts and an electrical system, and is mostly operated in places with severe natural conditions such as high temperature, severe cold, thunderstorm, high poster, strong wind and sand, and the design service life of the wind turbine generator is as long as 20 years. The effective product reliability design is a key factor for ensuring the fan to play the best performance in the whole life cycle. However, the reliability design of the wind power industry in China still has the following problems: 1) the core components depend on import, and the core technology depends heavily on foreign countries. 2) Most fan products establish an SCADA (Supervisory Control And Data Acquisition) And centralized Control system, And use established work orders And other informatization systems, but most Data accumulated by the work orders are unstructured Data such as characters And pictures, And structured Data statistics And analysis can not be performed around the products as cores. 3) The application scenes of fan products are many, the amount of product application data is large, but the failure modes and the influence data of the products cannot be effectively collected and refined, and good feedback cannot be given to product designers.
The application numbers are: 201710004745.9, entitled "a system for implementing FMEA data multidimensional processing" is a background document of the present application.
Disclosure of Invention
The technical problem to be solved by the invention is as follows: aiming at the technical problems in the prior art, the invention provides the FMEA data processing method and the FMEA data processing system for the fan product, which can realize the standardization and the structuralized effective management and statistics of the abnormity of the fan product in production, operation and maintenance, feed back and push the abnormity to the design process end so as to efficiently realize the improvement of the fan product design.
In order to solve the technical problems, the technical scheme provided by the invention is as follows: a fan product FMEA data processing method comprises the following steps:
s1, acquiring fault and state information of a fan according to a preset work order;
s2, arranging the fault and state information into structured field data, and storing the structured field data into a database;
and S3, determining a fault mode and influence information by analyzing the fault and state information, perfecting the field data, and storing the field data into the database to obtain fault mode and fault influence analysis data.
Further, the method also includes step S4: and synchronously adjusting the data information of the preset work order according to the fault mode and the fault influence analysis data.
Further, the method also includes step S5: and improving the design of the fan product according to the fault mode and the fault influence analysis data, and perfecting the fault mode and the fault influence analysis data according to improved feedback information.
Further, the fault and status information in step S1 includes: product position number, product material code, fault and corresponding code, problem and corresponding code, reason analysis and corresponding code, processing measure and corresponding code, and effective processing measure times.
Further, the product location number includes a product location and a function number;
the product material code comprises product technical parameter requirements; the parameter technical parameter requirements comprise model, function and requirement;
the fault and the corresponding codes comprise machine types, fault classification, system classification and fault codes;
the problem and corresponding codes comprise problem flow codes, product materials and position code information of problem parts and product problem description.
Further, the number of effective treatment measures is calculated according to the number of times that the fault reoccurs in a preset period after the fault occurs; if the fault does not occur in the preset period, the number of effective treatment measures is 1, otherwise, the number of effective treatment measures is the ratio of the number of occurrences to the base number corresponding to the preset period.
A fan product FMEA data processing system comprises a work order module, a data analysis processing module and a database;
the work order module is used for acquiring fault and state information of the fan according to a preset work order;
the data analysis processing module is used for organizing the fault and state information into structured field data and storing the structured field data into a database;
the data analysis processing module is also used for determining a fault mode and influence information by analyzing the fault and state information, perfecting the field data, and storing the field data in the database to obtain fault mode and fault influence analysis data.
Further, the device also comprises a synchronous processing module; and the synchronous processing module is used for synchronously adjusting the data information of the preset work order according to the fault mode and the fault influence analysis data.
Further, the system also comprises a feedback processing module; and the feedback processing module is used for improving the design of the fan product according to the fault mode and the fault influence analysis data and perfecting the fault mode and the fault influence analysis data according to improved feedback information.
Further, the fault and status information in the work order module includes: product position number, product material code, fault and corresponding code, problem and corresponding code, reason analysis and corresponding code, processing measure and corresponding code, and effective processing measure times.
Further, the product location number includes a product location and a function number;
the product material code comprises product technical parameter requirements; the parameter technical parameter requirements comprise model, function and requirement;
the fault and the corresponding codes comprise machine types, fault classification, system classification and fault codes;
the problem and corresponding codes comprise problem flow codes, product materials and position code information of problem parts and product problem description.
Further, the number of effective treatment measures is calculated according to the number of times that the fault reoccurs in a preset period after the fault occurs; if the fault does not occur in the preset period, the number of effective treatment measures is 1, otherwise, the number of effective treatment measures is the ratio of the number of occurrences to the base number corresponding to the preset period.
Compared with the prior art, the invention has the advantages that:
1. according to the method and the system, the fault and state information of the fan is obtained through the work order, and the fault mode and the influence information are analyzed and determined, so that normalized and structured fault mode and fault influence analysis (FMEA) data are obtained and stored in the database, complete and efficient management can be conveniently performed on the fault data, and the management and statistics cost of the data is reduced.
2. The invention feeds back the failure mode and failure impact analysis (FMEA) data to a product full life cycle management (PDM) system for guiding the research and development design work of products, and feeds back the improved information in the research and development design of the products to a failure mode and failure impact analysis database to form a closed loop feedback, so that the effectiveness and the utilization rate of the data are higher, and the high sharing of the data is realized.
3. The invention adjusts the work order data information according to the failure mode and failure impact analysis (FMEA) data, thereby keeping the normalization and consistency of the data information input by the work order at the front end.
4. The invention carries out statistical calculation on the times of effective treatment measures in the work order module, automatically stores the calculated times of the effective treatment measures into the database when the work order is closed and submitted for representing the severity of the fault, can determine that only batch problems found during production, operation and maintenance can enter the work order and are stored into the database through subsequent steps, can effectively save the workload of professional technicians, and can realize the focusing on the fault.
Drawings
FIG. 1 is a schematic flow chart of an embodiment of the present invention.
FIG. 2 is a diagram illustrating a data structure of a data table in a database according to an embodiment of the present invention.
Detailed Description
The invention is further described below with reference to the drawings and specific preferred embodiments of the description, without thereby limiting the scope of protection of the invention.
The method for processing the FMEA data of the fan product comprises the following steps: s1, acquiring fault and state information of a fan according to a preset work order; s2, arranging the fault and state information into structured field data, and storing the structured field data in a database; and S3, determining a fault mode and influence information by analyzing the fault and state information, perfecting field data, and storing the field data in a database to obtain fault mode and fault influence analysis data.
In this embodiment, the method further includes step S4: and synchronously adjusting the data information of the preset work order according to the fault mode and the fault influence analysis data. Further comprising step S5: and improving the design of the fan product according to the fault mode and the fault influence analysis data, and perfecting the fault mode and the fault influence analysis data according to the improved feedback information.
In this embodiment, a specific application scenario is used for illustration, And a complete application scenario is shown in fig. 1, where a front end of the method of the present invention is connected to an SCADA (Supervisory Control And Data Acquisition) system of the fan, so as to automatically acquire fault And state information of the fan. Specifically, the fault and state information of the fan can be pushed in the form of an intermediate table through the SCADA system, the pushed information is filled in a preset work order, the work order is in an electronic form, and the information pushed by the SCADA system can be automatically read and filled in the work order. Specifically, the information pushed by the SCADA system can be received by an operation and maintenance service management system of the wind turbine manufacturing enterprise, and a work order is automatically generated. When the work order is closed, the information recorded in the work order is arranged into structured field data, and the field data is recorded and stored in a structured FMEA database. In the work order closing, the information described in the work order is organized into structured field data, which may be implemented in the operation and maintenance service management system or in the FMEA database.
In this embodiment, the fault and status information in step S1 includes: product position number, product material code, fault and corresponding code, problem and corresponding code, reason analysis and corresponding code, processing measure and corresponding code, and effective processing measure times. The product position number comprises a product position and a function number; the product material codes comprise the technical parameter requirements of the products; the parameter technical parameter requirements comprise model, function and requirement; the fault and corresponding codes comprise machine types, fault classification, system classification and fault codes; the question and corresponding code comprises a question flow code, product material and position code information of a question part and product question description.
In this embodiment, the product position number conforms to an international wind power industry position coding standard (RDS-PP position coding standard) issued by the germany military industry, the product material code is a material main data code of the ERP system of the manufacturing enterprise, the product material code may include product technical parameter requirements, and the parameter technical parameter requirements include a model, a function and requirements, wherein the requirements further include environmental requirements and maintenance requirements.
In this embodiment, the fault and the corresponding code are fault codes of a fan control system after the fault code of the fan control system is standardized, specifically including the fault code of the fan control system and the fault code of the early warning system; the fault codes of the fan control system comprise machine types, fault classification, system classification, control system fault codes and the like; the fault codes of the early warning system are early warning fault codes obtained by extracting the early warning model after data analysis, and comprise early warning fault models, early warning fault classifications, system classifications, early warning code serial numbers and the like. In this embodiment, the fault code of the control system and the fault code of the early warning system both control the same rule unique code. The system classification is a wind power complete machine product system classification carried out according to a product SBOM (SALE Bill of Material), and comprises information such as blades, a tower drum, a cabin cabinet, cabin electrical, yaw, variable pitch control, a hub, a tower footing cabinet, a converter and an auxiliary transformation cabinet. The product SBOM is a product service BOM generated for a wind turbine product, and comprises minimum replaceable units of the product in a wind farm and a production workshop.
In this embodiment, the problem and the corresponding code are a problem and a running code corresponding to the control system or the early warning system, or an abnormal problem found by the operation and maintenance staff in the inspection process, and the problem includes product material and position code information of a problem part, product problem description, and product problem description to form a structured and standardized code. Can be automatically generated through a work order
In this embodiment, the reason analysis and the corresponding code are the reason corresponding to each problem after the mechanism analysis, and the reason is structured and standardized to form the corresponding reason code. Can be automatically generated through a work order.
In this embodiment, the processing measure and the corresponding code are used to analyze a solution formed after actual processing for each cause, and the processing measure is structured and standardized to form a corresponding processing measure code. Can be automatically generated through a work order.
In this embodiment, the number of effective processing measures is calculated after the fan state information is backfilled by the work order according to the SCADA system, and the specific calculation method is as follows: the effective treatment measure times are calculated according to the times of the fault reoccurrence in a preset period after the fault occurs; if the fault does not occur in the preset period, the number of effective treatment measures is 1, otherwise, the number of effective treatment measures is the ratio of the number of occurrences to the base number corresponding to the preset period. If a certain number of faults of a certain fan are processed, the fault diagnosis expert system can regularly read the state of the centralized control system related to the fan once, the preset period is 240 hours, and if the fan reports the same fault again within 1 hour, the number of knowledge validity is 1/240; if the same fault is reported within n (n is less than 240) hours, the number of the knowledge validity is n/240; if the same fault is not reported in 240 hours, the number of the knowledge validity is 1.
In this embodiment, the information in the work order is organized into structured field data, and the field data is recorded and stored in a structured FMEA database, and the basic data structure of the FMEA database is as shown in fig. 2. In fig. 2, the product code is formed by combining a RDS-PP-based product position number and a PDM drawing number, and after the product code is determined, the corresponding Material model in the BOM (Bill of Material ) can be uniquely determined. The PDM picture number is the only code for a certain subclass or a certain material during product design. The BOM is a product SBOM in a PDM (product full life cycle management) system, and the SBOM comprises a minimum replaceable unit of a fan product in the operation and maintenance service process of a wind power plant. The product material code is a unique product material code in the ERP main data of the wind power enterprise, one product code is used for identifying specification, model, function, maintenance requirement and the like of the material, and the material identification standard of the product material code is a material technical specification. The material specification is a product specification written by product design developers to restrict material technical attributes, including functions and requirements for the product. Therefore, the unique material at the unique position in the wind turbine generator can be locked through the product code, the FMEA data statistical analysis of the product is important, and the function, the requirement and the product name of the product can be derived through the PDM system through the product code. The PDM system is primarily data and process management for the product development process.
In this embodiment, as shown in fig. 2, failure mode encoding of FMEA data is automatically imported for a problem and corresponding code, high-level influence and high-level influence encoding of FMEA data is automatically imported for a fault and corresponding code (including a fault of a control system and a fault of an early warning system), a potential failure cause and potential failure cause encoding of FMEA data are automatically imported for a reason analysis and corresponding code, the number of times of effective failure handling measures is confirmed by SCADA data, and then the severity of FMEA data is automatically imported, and the frequency of FMEA data is a ratio of the severity of FMEA of a single product to the full value.
In this embodiment, by the above method, part of the core requirements of the structured FMEA data is automatically imported from the work order into the fan structured FMEA database by using an informatization means. The structured FMEA database of the fan summarizes and counts the structured FMEA data, extracts the data with the FMEA data severity larger than 5, and pushes the data, professional application technicians analyze the data and edit and perfect the structured FMEA data, and perfect fields comprise local influence, final influence, control prevention and suggestion measures.
In this embodiment, a severity of greater than 5 means that the potential cause of failure is identified by the work order closed loop more than 5 times in the actual product failure mode of the product, and the closed loop is formed by the need to eradicate the problem through reliability design or process improvement for batch problems. Reliability design and process improvements include improvements in development design, manufacturing processes, service processes.
In this embodiment, the local influence is an influence on other parts of a sub-class system where a product is located in the product BOM structure, the local influence encoding rule is P10XX, and XX is a serial number automatically generated by the system. The final influence is the final influence caused by the fan, such as product failure shutdown, product power generation performance reduction and the like, the final influence coding rule is P20XX, and XX is a serial number automatically generated by the system. And controlling and preventing by which mode to carry out reliability Design and process improvement, such as increasing product Design allowance and optimizing materials, wherein a control and prevention code is D00XX, D represents Design, and XX is a serial number automatically generated by the system. The suggested measures are specific reliability design and process improvement opinions. Each recommended measure corresponds to a potential failure reason, and the recommended measure coding rule is that 2 bits are added to the potential failure reason coding in the beginning, R00XXXX, and the last 2 bits XX are serial numbers provided by the system. After the application technicians analyze the FMEA data, the four fields are confirmed and then are subjected to structured standardization, and the data are input into an FMEA database, so that complete FMEA analysis statistical data of batch problems are formed.
In this embodiment, FMEA data of all product codes are collected and transmitted to the PDM system, and specifically, the data may be transmitted and synchronized in the form of an intermediate table. Therefore, the research and development of the PDM system and the process personnel carry out reliable design on batch problems, and the improved PDM system is fed back to the FMEA database in a closed loop mode. Meanwhile, the data fed back by the closed loop can be synchronized to the work order. The basic principle is as follows: the work order real-time synchronous PDM system feeds back the latest problem code, reason code and processing measure code in the FMEA database, the work order firstly carries out the retrieval and confirmation of the structured problem, reason analysis, processing measure and the code in the original problem, if a newly added problem exists, the newly added problem is added in the work order, and the newly added problem is added after the verification and confirmation.
The fan product FMEA data processing system comprises a work order module, a data analysis processing module and a database; the work order module is used for acquiring the fault and state information of the fan according to a preset work order; the data analysis processing module is used for sorting the fault and state information into structured field data and storing the structured field data into a database; the data analysis processing module is also used for determining a fault mode and influence information by analyzing the fault and state information, perfecting field data and storing the field data in a database to obtain fault mode and fault influence analysis data. The fan product FMEA data processing system of the present embodiment performs data processing according to the data processing method described above.
In this embodiment, the system further includes a synchronization processing module; and the synchronous processing module is used for synchronously adjusting the data information of the preset work order according to the fault mode and the fault influence analysis data. The device also comprises a feedback processing module; the feedback processing module is used for improving the design of the fan product according to the failure mode and the failure influence analysis data and perfecting the failure mode and the failure influence analysis data according to improved feedback information.
In this embodiment, the fault and status information in the work order module includes: product position number, product material code, fault and corresponding code, problem and corresponding code, reason analysis and corresponding code, processing measure and corresponding code, and effective processing measure times. The product position number comprises a product position and a function number; the product material codes comprise the technical parameter requirements of the products; the parameter technical parameter requirements comprise model, function and requirement; the fault and corresponding codes comprise machine types, fault classification, system classification and fault codes; the question and corresponding code comprises a question flow code, product material and position code information of a question part and product question description. The effective treatment measure times are calculated according to the times of the fault reoccurrence in a preset period after the fault occurs; if the fault does not occur in the preset period, the number of effective treatment measures is 1, otherwise, the number of effective treatment measures is the ratio of the number of occurrences to the base number corresponding to the preset period.
The foregoing is considered as illustrative of the preferred embodiments of the invention and is not to be construed as limiting the invention in any way. Although the present invention has been described with reference to the preferred embodiments, it is not intended to be limited thereto. Therefore, any simple modification, equivalent change and modification made to the above embodiments according to the technical spirit of the present invention should fall within the protection scope of the technical scheme of the present invention, unless the technical spirit of the present invention departs from the content of the technical scheme of the present invention.
Claims (12)
1. A fan product FMEA data processing method is characterized by comprising the following steps:
s1, acquiring fault and state information of a fan according to a preset work order;
s2, arranging the fault and state information into structured field data, and storing the structured field data into a database;
and S3, determining a fault mode and influence information by analyzing the fault and state information, perfecting the field data, and storing the field data into the database to obtain fault mode and fault influence analysis data.
2. The blower product FMEA data processing method of claim 1, wherein: further comprising step S4: and synchronously adjusting the data information of the preset work order according to the fault mode and the fault influence analysis data.
3. The blower product FMEA data processing method of claim 2, wherein: further comprising step S5: and improving the design of the fan product according to the fault mode and the fault influence analysis data, and perfecting the fault mode and the fault influence analysis data according to improved feedback information.
4. The blower product FMEA data processing method as claimed in any one of claims 1-3, wherein: the fault and status information in step S1 includes: product position number, product material code, fault and corresponding code, problem and corresponding code, reason analysis and corresponding code, processing measure and corresponding code, and effective processing measure times.
5. The blower product FMEA data processing method of claim 4, wherein:
the product position number comprises a product position and a function number;
the product material code comprises product technical parameter requirements; the parameter technical parameter requirements comprise model, function and requirement;
the fault and the corresponding codes comprise machine types, fault classification, system classification and fault codes;
the problem and corresponding codes comprise problem flow codes, product materials and position code information of problem parts and product problem description.
6. The blower product FMEA data processing method of claim 5, wherein: the effective treatment measure times are calculated according to the times of the faults which occur again in a preset period after the faults occur; if the fault does not occur in the preset period, the number of effective treatment measures is 1, otherwise, the number of effective treatment measures is the ratio of the number of occurrences to the base number corresponding to the preset period.
7. The utility model provides a fan product FMEA data processing system which characterized in that: the system comprises a work order module, a data analysis processing module and a database;
the work order module is used for acquiring fault and state information of the fan according to a preset work order;
the data analysis processing module is used for organizing the fault and state information into structured field data and storing the structured field data into a database;
the data analysis processing module is also used for determining a fault mode and influence information by analyzing the fault and state information, perfecting the field data, and storing the field data in the database to obtain fault mode and fault influence analysis data.
8. The blower product FMEA data processing system of claim 7, wherein: the device also comprises a synchronous processing module; and the synchronous processing module is used for synchronously adjusting the data information of the preset work order according to the fault mode and the fault influence analysis data.
9. The blower product FMEA data processing system of claim 8, wherein: the device also comprises a feedback processing module; and the feedback processing module is used for improving the design of the fan product according to the fault mode and the fault influence analysis data and perfecting the fault mode and the fault influence analysis data according to improved feedback information.
10. A blower product, FMEA, data processing system as claimed in any of claims 7 to 9, wherein: the fault and state information in the work order module comprises: product position number, product material code, fault and corresponding code, problem and corresponding code, reason analysis and corresponding code, processing measure and corresponding code, and effective processing measure times.
11. The blower product FMEA data processing system of claim 10, wherein:
the product position number comprises a product position and a function number;
the product material code comprises product technical parameter requirements; the parameter technical parameter requirements comprise model, function and requirement;
the fault and the corresponding codes comprise machine types, fault classification, system classification and fault codes;
the problem and corresponding codes comprise problem flow codes, product materials and position code information of problem parts and product problem description.
12. The blower product FMEA data processing system of claim 11, wherein: the effective treatment measure times are calculated according to the times of the faults which occur again in a preset period after the faults occur; if the fault does not occur in the preset period, the number of effective treatment measures is 1, otherwise, the number of effective treatment measures is the ratio of the number of occurrences to the base number corresponding to the preset period.
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Application publication date: 20200124 |