CN114880839A - Method for analyzing difficult and complicated faults of automobile parts - Google Patents
Method for analyzing difficult and complicated faults of automobile parts Download PDFInfo
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Abstract
A method for analyzing difficult and complicated faults of automobile parts comprises the following steps: the method comprises the following steps: and (3) preliminary analysis of the faults, namely, on the premise that the conventional detection of parts meets the requirements of drawings and design, aiming at the difficult faults of which the general quality detection method can not detect the fault reasons, respectively using the following steps: analyzing the dynamic thinking in the running process and the third step: analyzing the dynamic thinking in the aging process to analyze faults; step four: and (5) drawing a conclusion that: the main cause of the problematic fault is obtained through analysis, and the fault is eliminated through design. The design not only utilizes the dynamic thinking to analyze the faults, but also provides a standardized analysis idea for more difficult problems.
Description
Technical Field
The invention relates to a difficult and complicated fault analysis method for automobile parts, which is particularly suitable for analyzing difficult and complicated faults of which the fault reasons cannot be detected by a conventional fault analysis method.
Background
Currently, in the industry, for analyzing faults, the most used method is fta (fault Tree analysis) fault Tree analysis, which is a "top-down" method for identifying which part of the system is related to a specific failure, and is used to identify design problems in a complex system, and the final result is a graph graphically displaying combinations of events that can identify system faults under a fault mode;
however, the FTA analysis method still only originates from analyzing the "dead" data of the given design, measurement and statistical data, and if all the factor analysis results are determined as "non-factors" and the problem is not solved, the problem will be impartial at this time, and the problem becomes a difficult and complicated disease;
in essence, "dead" data are all "live," whether they are "dead" or "live"
This involves a dynamic thinking in quality work: the data are always 'live', and the 'dead' data are also 'live' to enable the user to perform silk drawing and cocoon peeling in quality work and find a true cause, so that the quality problem is thoroughly eliminated. This is really a common complaint that currently all mass analysis efforts are not concerned with.
Disclosure of Invention
The invention aims to solve the problem that the fault reason can not be found out in partial faults in the prior art, and provides a method for analyzing difficult faults of automobile parts in a dynamic process.
In order to achieve the above purpose, the technical solution of the invention is as follows:
a method for analyzing difficult and complicated faults of automobile parts comprises the following steps:
the method comprises the following steps: a preliminary analysis of the fault is carried out,
on the premise that the conventional detection of parts meets the requirements of drawings and design, the method respectively uses the following steps for difficult and complicated faults of which the general quality detection method can not detect the fault reason: analyzing the dynamic thinking in the running process and the third step: analyzing the dynamic thinking in the aging process to analyze faults;
step two: analyzing dynamic thinking in the running process, knowing the material and the matching relation of the fault parts, analyzing changes of working environments of the fault parts and related parts in the running state of the automobile, analyzing main causes of faults, and then performing simulation test to reproduce the faults, wherein if the faults are reproduced, the faults are judged to be influenced by the environmental factors corresponding to the test; if all the tests can not reproduce the fault, judging that the main cause of the fault cannot be found out by the dynamic thinking analysis in the running process;
step three: analyzing the dynamic thinking of the aging process, judging whether the fault part has an easily-aged part, and if not, eliminating the aging factor of the main cause of the fault of the part; if so, carrying out a fault aging analysis test: firstly, judging the influence of aging on the matching relationship of parts, if the matching relationship is changed, measuring the size difference and the performance difference of the aged parts by taking the life cycle of the parts multiplied by a coefficient of 0.4 as a reference to redesign the parts, and testing the newly designed parts, wherein the newly designed parts need to be redesigned and tested if the fault reappears, and the parts for solving the existing aging fault are successfully designed if the fault does not reappear.
Step four: to draw a conclusion
Through the second step: analyzing the dynamic thinking in the running process and the third step: the failure analysis of dynamic thinking analysis in the aging process can obtain the main cause of difficult failures, and the failures are eliminated through design; step two: analyzing the dynamic thinking in the running process and the third step: and (4) judging that the method cannot analyze the difficult fault if the fault principal factor cannot be obtained by the fault analysis of the dynamic thinking analysis in the aging process.
The second step is as follows: the dynamic thinking analysis of the operation process comprises the following steps:
s2.1, judging whether parts with different materials are matched at a fault part, and recording the materials of the matched parts and the corresponding physical and chemical property parameters;
s2.2, analyzing changes of working environments of fault parts and related parts of the fault parts in the parking flameout state and the running process of the automobile, and specifically considering that: temperature, vibration, sealing failure caused by reassembly after sealing, and electromagnetic compatibility;
s2.3, respectively analyzing the influence of the changed environmental factors on the fault spare part and the related spare parts thereof, preliminarily judging whether the influence possibly generated by the influence is possible to cause the corresponding fault, if so, preliminarily judging that the influence is the possible main cause of the fault, and if not, eliminating the influence as the possible main cause of the fault;
s2.4, respectively carrying out test simulation on possible main factors, and finding out the main factors influenced by the environmental factors:
assembling new spare and accessory parts on the whole vehicle or a test bench, simulating the working environment of one possible main cause of preliminary judgment, judging whether the fault can reappear, if so, judging that the fault is influenced by the environmental factors corresponding to the test, and if not, performing the next group of tests;
if all the tests can not reproduce the fault, judging that the main cause of the fault cannot be found by the dynamic thinking analysis in the running process.
The second step is as follows: the dynamic thinking analysis of the operation process also comprises the following steps: the solution for the fault of the operation process comprises the following steps:
if the fault is reproduced, a fault solving flow of the running process is entered:
s2.5, searching whether past design data of a corresponding automobile type carries out checking of an oversize chain according to the actual size of the automobile in dynamic operation, if not, entering S2.6 after the checking of the oversize chain is required to be carried out again, and if so, directly entering S2.6;
s2.6, searching whether the static design size checked by the past design data size chain of the corresponding vehicle type meets the design requirement of the dynamic size chain, and if not, re-designing the static size chain according to the check result of the dynamic size chain;
s2.7, manufacturing a sample piece meeting the design requirement according to the design of the S2.6, assembling the sample piece on the whole vehicle or a test bench, and testing to see whether the fault can reappear, wherein redesigning and testing are needed if the fault reappears; if the failure can not be reproduced, performing an actual vehicle endurance test to see whether the failure is reproduced, and if the failure is reproduced, redesigning and testing are needed; if the reproduction is impossible, the redesign is successful.
The second step is as follows: the dynamic thinking analysis of the operation process also comprises the following steps:
s2.8 normalization of results: aiming at the parts which are successfully designed, the parts are standardized and converted into regular and distributable drawings and other standard documents to be filed.
The third step is that: the dynamic thinking analysis of the aging process comprises the following steps:
s3.1, judging whether the fault component and related parts thereof have parts which are easy to generate light aging or environmental aging, if so, carrying out S3.2, and if not, eliminating the aging factor of the main cause of the fault of the parts;
s3.2, aiming at parts which are easy to age, judging the change of the size and the performance of the parts in the aging process, then judging the influence of the change of the aged size and the aged performance on the matching and the function execution of the original static design, then judging whether the influence changes the matching property of the initial design or manufacture, if so, carrying out S3.3, and if not, eliminating the aging factor of the main cause of the part fault; if the matching property is not changed, the aging factor of the main cause of the part failure is eliminated.
The third step is that: the dynamic thinking analysis of the aging process further comprises: solution to aging process failure:
s3.3, searching the design life cycle of the aged part, multiplying the life cycle by a 0.4 coefficient to be used as a reference to measure the size difference and the performance difference of the aged part, and then comprehensively considering all requirements of dynamic and static sizes according to the dynamic size and the performance state of the 0.4 coefficient and then re-designing a size chain;
s3.4, manufacturing a sample piece meeting the design requirement according to the design of the S3.3, assembling the sample piece on the whole vehicle or a test bench, and testing to see whether the fault can reappear, wherein redesigning and testing are needed if the fault reappears; if the failure can not be reproduced, performing an actual vehicle endurance test to see whether the failure is reproduced, and if the failure is reproduced, redesigning and testing are needed; if the reproduction is not possible, S3.5 is carried out;
the third step is that: the dynamic thinking analysis of the aging process further comprises: checking evaluation for redesigned parts:
s3.5, considering whether the aged part has the influences of factors of sealing failure and electromagnetic compatibility dynamic change caused by vibration, sealing and reassembly after sealing besides the influence on the change of the size matching property and the performance difference, further adjusting the design to perform a test again if the influences exist, identifying and checking all factors which are contrary to the dynamic change and the static design if the influences do not exist, and successfully designing if the checking is completely passed; if the check fails, the design is further adjusted to perform the test again;
the third step is that: the dynamic thinking analysis of the aging process further comprises: s3.6 normalization of results: aiming at the parts which are successfully designed, the parts are standardized and converted into regular and distributable drawings and other standard documents to be filed.
Compared with the prior art, the invention has the beneficial effects that:
1. in the method for analyzing the difficult and complicated faults of the automobile parts, the difficult and complicated faults of which the reasons cannot be detected by the universal quality detection method are analyzed, the faults are analyzed respectively through dynamic thinking analysis in the operation process and dynamic thinking analysis in the aging process, and unreasonable parts for design or manufacture are found out, so that main reasons of partial difficult and complicated faults are found out. Therefore, the design utilizes the dynamic thinking to analyze the faults, and provides a standardized analysis idea for more difficult problems.
2. According to the method for analyzing the difficult and complicated faults of the automobile parts, the dynamic thinking analysis in the operation process is performed, the influence of the environmental factor change on the parts in the operation process of the automobile is considered, the reasons of the faults of the parts are judged, and the adverse influence of the dynamic factors on the parts is solved by redesigning a test mode. Therefore, the design not only has comprehensive consideration of problems, but also can eliminate the influence of the existing faults through redesign.
3. According to the method for analyzing the difficult and complicated faults of the automobile parts, the life cycle of the parts is regarded as a whole rather than only taking the initial state as a design standard, the service state of the whole life cycle of the running of the automobile can be optimized through the whole thinking, and the stability of the automobile is improved.
Detailed Description
The present invention will be described in further detail with reference to specific embodiments.
A method for analyzing difficult and complicated faults of automobile parts comprises the following steps:
the method comprises the following steps: a preliminary analysis of the fault is carried out,
on the premise that the conventional detection of parts meets the requirements of drawings and design, the method respectively uses the following steps for difficult and complicated faults of which the general quality detection method can not detect the fault reason: analyzing the dynamic thinking in the running process and the third step: analyzing the dynamic thinking of the aging process to analyze faults;
step two: analyzing dynamic thinking in the running process, knowing the material and the matching relation of the fault parts, analyzing changes of working environments of the fault parts and related parts in the running state of the automobile, analyzing main causes of faults, and then performing simulation test to reproduce the faults, wherein if the faults are reproduced, the faults are judged to be influenced by the environmental factors corresponding to the test; if all the tests can not reproduce the fault, judging that the main cause of the fault cannot be found out by the dynamic thinking analysis in the running process;
step three: analyzing the dynamic thinking of the aging process, judging whether the fault part has an easily-aged part, and if not, eliminating the aging factor of the main cause of the fault of the part; if so, carrying out a fault aging analysis test: firstly, judging the influence of aging on the matching relationship of parts, if the matching relationship is changed, measuring the size difference and the performance difference of the aged parts by taking the life cycle of the parts multiplied by a coefficient of 0.4 as a reference to redesign the parts, and testing the newly designed parts, wherein the newly designed parts need to be redesigned and tested if the fault reappears, and the parts for solving the existing aging fault are successfully designed if the fault does not reappear.
Step four: to draw a conclusion
Through the second step: analyzing the dynamic thinking in the running process and the third step: the failure analysis of dynamic thinking analysis in the aging process can obtain the main cause of difficult failures, and the failures are eliminated through design; step two: analyzing the dynamic thinking in the running process and the third step: and (4) judging that the method cannot analyze the difficult fault if the fault principal factor cannot be obtained by the fault analysis of the dynamic thinking analysis in the aging process.
The second step is as follows: the dynamic thinking analysis of the operation process comprises the following steps:
s2.1, judging whether parts with different materials are matched at a fault part, and recording the materials of the matched parts and the corresponding physical and chemical property parameters;
s2.2, analyzing changes of working environments of fault parts and related parts of the fault parts in the parking flameout state and the running process of the automobile, and specifically considering that: temperature, vibration, sealing failure caused by reassembly after sealing, and electromagnetic compatibility;
s2.3, respectively analyzing the influence of the changed environmental factors on the fault spare part and the related spare parts thereof, preliminarily judging whether the influence possibly generated by the influence is possible to cause the corresponding fault, if so, preliminarily judging that the influence is the possible main cause of the fault, and if not, eliminating the influence as the possible main cause of the fault;
s2.4, respectively carrying out test simulation on possible main factors, and finding out the main factors influenced by the environmental factors:
assembling new spare and accessory parts on the whole vehicle or a test bench, simulating the working environment of one possible main cause of preliminary judgment, judging whether the fault can reappear, if so, judging that the fault is influenced by the environmental factors corresponding to the test, and if not, performing the next group of tests;
if all the tests can not reproduce the fault, judging that the main cause of the fault cannot be found by the dynamic thinking analysis in the running process.
The second step is as follows: the dynamic thinking analysis of the operation process also comprises the following steps: the solution for the fault of the operation process comprises the following steps:
if the fault is reproduced, a fault solving flow of the running process is entered:
s2.5, searching whether past design data of a corresponding automobile type carries out checking of an oversize chain according to the actual size of the automobile in dynamic operation, if not, entering S2.6 after the checking of the oversize chain is required to be carried out again, and if so, directly entering S2.6;
s2.6, searching whether the static design size checked by the past design data size chain of the corresponding vehicle type meets the design requirement of the dynamic size chain, and if not, re-designing the static size chain according to the check result of the dynamic size chain;
s2.7, manufacturing a sample piece meeting the design requirement according to the design of the S2.6, assembling the sample piece on the whole vehicle or a test bench, and testing to see whether the fault can reappear, wherein redesigning and testing are needed if the fault reappears; if the failure can not be reproduced, performing an actual vehicle endurance test to see whether the failure is reproduced, and if the failure is reproduced, redesigning and testing are needed; if the reproduction is impossible, the redesign is successful.
The second step is as follows: the dynamic thinking analysis of the operation process also comprises the following steps:
s2.8 normalization of results: aiming at the parts which are successfully designed, the parts are standardized and converted into regular and distributable drawings and other standard documents to be filed.
The third step is that: the dynamic thinking analysis of the aging process comprises the following steps:
s3.1, judging whether the fault component and related parts thereof have parts which are easy to generate light aging or environmental aging, if so, carrying out S3.2, and if not, eliminating the aging factor of the main cause of the fault of the parts;
s3.2, aiming at parts which are easy to age, judging the change of the size and the performance of the parts in the aging process, then judging the influence of the change of the aged size and the aged performance on the matching and the function execution of the original static design, then judging whether the influence changes the matching property of the initial design or manufacture, if so, carrying out S3.3, and if not, eliminating the aging factor of the main cause of the part fault; if the matching property is not changed, the aging factor of the main cause of the part failure is eliminated.
The third step is that: the dynamic thinking analysis of the aging process further comprises: solution to aging process failure:
s3.3, searching the design life cycle of the aged part, multiplying the life cycle by a 0.4 coefficient to be used as a reference to measure the size difference and the performance difference of the aged part, and then comprehensively considering all requirements of dynamic and static sizes according to the dynamic size and the performance state of the 0.4 coefficient and then re-designing a size chain;
s3.4, manufacturing a sample piece meeting the design requirement according to the design of the S3.3, assembling the sample piece on the whole vehicle or a test bench, and testing to see whether the fault can reappear, wherein redesigning and testing are needed if the fault reappears; if the failure can not be reproduced, performing an actual vehicle endurance test to see whether the failure is reproduced, and if the failure is reproduced, redesigning and testing are needed; if the reproduction is not possible, S3.5 is carried out;
the third step is that: the dynamic thinking analysis of the aging process further comprises: checking evaluation for redesigned parts:
s3.5, considering whether the aged part has the influences of factors of sealing failure and electromagnetic compatibility dynamic change caused by vibration, sealing and reassembly after sealing besides the influence on the change of the size matching property and the performance difference, further adjusting the design to perform a test again if the influences exist, identifying and checking all factors which are contrary to the dynamic change and the static design if the influences do not exist, and successfully designing if the checking is completely passed; if the check fails, the design is further adjusted to perform the test again;
the third step is that: the dynamic thinking analysis of the aging process further comprises: s3.6 normalization of results: aiming at the parts which are successfully designed, the parts are standardized and converted into regular and distributable drawings and other standard documents to be filed.
The principle of the invention is illustrated as follows:
1. the dynamic thinking module based on the automobile driving process comprises the following steps:
1) the core idea is as follows: whether the design or the manufacture is carried out, the design and the configuration of the size engineering can not only check the rationality in the static state, but also consider the size change trend of various parts made of different materials in the running process of the automobile in advance, follow three major principles of quality work, namely 'three principal meanings', 'data is king' and 'fault reproduction', question the rationality of the design and the manufacture from the source followed by the FTA, thereby showing the seemingly reasonable but unreasonable design and manufacture process and solving the difficult and complicated symptoms which can not be solved by common quality tools.
2) The theoretical points are as follows: the universal quality tool first considers the design to be correct and finds the factors that do not fit the source of the design in the full value chain process. In the dynamic quality management, the accuracy of a source is questioned, and the weakness of the static quality is found from the change of working conditions and parameters in the running process of the vehicle.
2. Dynamic thinking module based on the aging process of automobile parts:
1) the core idea is as follows: the automobile parts are continuously aged, so that the design and the configuration of the size engineering need to consider the fact that the parts are continuously aged in the life cycle, but the quality problem occurring in the aging process cannot be solved by replacing new parts all the time. In this module, it is then always reasonable to consider in advance both the design and the manufacture during the aging of the parts.
2) The theoretical points are as follows: the size engineering design and configuration of a new part can be in a deviation limit state when in use, quality examination looks unreasonable, but as the part ages, the deviation of part matching gradually approaches to a nominal size, the deviation tends to be in normal distribution, and the whole life cycle of the part is more and more reasonable.
3. The dynamic process control module based on the management and control of the special characteristics of the automobile parts comprises the following steps:
1) the core idea is as follows: the special characteristic list is not invariable and is not subjectively determined by which department and file, but is a result of the cooperation of the division of work of different departments according to the current quality situation.
2) The theoretical points are as follows: the generic quality tool, the list of special features, is derived from the design drawings of the research and development department and the process department of the manufacturing plant, and has been determined to be invariant, other full value chain units, and even upstream and downstream customers, can only be implemented. However, the dynamic quality management tool has a unique method of checking the special characteristics, and is dynamic, and changes are made from a program file at any time, and version number management is performed.
Example 1:
a method for analyzing difficult and complicated faults of automobile parts comprises the following steps:
the method comprises the following steps: a preliminary analysis of the fault is carried out,
on the premise that the conventional detection of parts meets the requirements of drawings and design, the method respectively uses the following steps for difficult and complicated faults of which the general quality detection method can not detect the fault reason: analyzing the dynamic thinking in the running process and the third step: analyzing the dynamic thinking in the aging process to analyze faults;
step two: analyzing dynamic thinking in the running process, knowing the material and the matching relation of the fault parts, analyzing changes of working environments of the fault parts and related parts in the running state of the automobile, analyzing main causes of faults, and then performing simulation test to reproduce the faults, wherein if the faults are reproduced, the faults are judged to be influenced by the environmental factors corresponding to the test; if all the tests can not reproduce the fault, judging that the main cause of the fault cannot be found out by the dynamic thinking analysis in the running process;
step three: analyzing the dynamic thinking of the aging process, judging whether the fault part has an easily-aged part, and if not, eliminating the aging factor of the main cause of the fault of the part; if so, carrying out a fault aging analysis test: firstly, judging the influence of aging on the matching relationship of parts, if the matching relationship is changed, measuring the size difference and the performance difference of the aged parts by taking the life cycle of the parts multiplied by a coefficient of 0.4 as a reference to redesign the parts, and testing the newly designed parts, wherein the newly designed parts need to be redesigned and tested if the fault reappears, and the parts for solving the existing aging fault are successfully designed if the fault does not reappear.
Step four: to draw a conclusion
Through the second step: analyzing the dynamic thinking in the running process and the third step: the failure analysis of dynamic thinking analysis in the aging process can obtain the main cause of difficult failures, and the failures are eliminated through design; step two: analyzing the dynamic thinking in the running process and the third step: and (4) judging that the method cannot analyze the difficult fault if the fault principal factor cannot be obtained by the fault analysis of the dynamic thinking analysis in the aging process.
Example 2:
example 2 is substantially the same as example 1 except that:
the second step is as follows: the dynamic thinking analysis of the operation process comprises the following steps:
s2.1, judging whether parts with different materials are matched at a fault part, and recording the materials of the matched parts and the corresponding physical and chemical property parameters;
s2.2, analyzing changes of working environments of fault parts and related parts of the fault parts in the parking flameout state and the running process of the automobile, and specifically considering that: temperature, vibration, sealing failure caused by reassembly after sealing, and electromagnetic compatibility;
s2.3, respectively analyzing the influence of the changed environmental factors on the fault spare part and the related spare parts thereof, preliminarily judging whether the influence possibly generated by the influence is possible to cause the corresponding fault, if so, preliminarily judging that the influence is the possible main cause of the fault, and if not, eliminating the influence as the possible main cause of the fault;
s2.4, respectively carrying out test simulation on possible main factors, and finding out the main factors influenced by the environmental factors:
assembling new spare and accessory parts on the whole vehicle or a test bench, simulating the working environment of one possible main cause of preliminary judgment, judging whether the fault can reappear, if so, judging that the fault is influenced by the environmental factors corresponding to the test, and if not, performing the next group of tests;
if all the tests can not reproduce the fault, judging that the main cause of the fault cannot be found by the dynamic thinking analysis in the running process.
The second step is as follows: the dynamic thinking analysis of the operation process also comprises the following steps: the solution for the fault of the operation process comprises the following steps:
if the fault is reproduced, a fault solving flow of the running process is entered:
s2.5, searching whether past design data of a corresponding automobile type carries out checking of an oversize chain according to the actual size of the automobile in dynamic operation, if not, entering S2.6 after the checking of the oversize chain is required to be carried out again, and if so, directly entering S2.6;
s2.6, searching whether the static design size checked by the past design data size chain of the corresponding vehicle type meets the design requirement of the dynamic size chain, and if not, re-designing the static size chain according to the check result of the dynamic size chain;
s2.7, manufacturing a sample piece meeting the design requirement according to the design of the S2.6, assembling the sample piece on the whole vehicle or a test bench, and testing to see whether the fault can reappear, wherein redesigning and testing are needed if the fault reappears; if the failure can not be reproduced, performing an actual vehicle endurance test to see whether the failure is reproduced, and if the failure is reproduced, redesigning and testing are needed; if the reproduction is impossible, the redesign is successful.
The second step is as follows: the dynamic thinking analysis of the running process also comprises the following steps:
s2.8 normalization of results: aiming at the parts which are successfully designed, the parts are standardized and converted into regular and distributable drawings and other standard documents to be filed.
The third step is that: the dynamic thinking analysis of the aging process comprises the following steps:
s3.1, judging whether the fault component and related parts thereof have parts which are easy to generate light aging or environmental aging, if so, carrying out S3.2, and if not, eliminating the aging factor of the main cause of the fault of the parts;
s3.2, aiming at parts which are easy to age, judging the change of the size and the performance of the parts in the aging process, then judging the influence of the change of the aged size and the aged performance on the matching and the function execution of the original static design, then judging whether the influence changes the matching property of the initial design or manufacture, if so, carrying out S3.3, and if not, eliminating the aging factor of the main cause of the part fault; if the matching property is not changed, the aging factor of the main cause of the part failure is eliminated.
The third step is that: the dynamic thinking analysis of the aging process further comprises: solution to aging process failure:
s3.3, searching the design life cycle of the aged part, multiplying the life cycle by a 0.4 coefficient to be used as a reference to measure the size difference and the performance difference of the aged part, and then comprehensively considering all requirements of dynamic and static sizes according to the dynamic size and the performance state of the 0.4 coefficient and then re-designing a size chain;
s3.4, manufacturing a sample piece meeting the design requirement according to the design of the S3.3, assembling the sample piece on the whole vehicle or a test bench, and testing to see whether the fault can reappear, wherein redesigning and testing are needed if the fault reappears; if the failure can not be reproduced, performing an actual vehicle endurance test to see whether the failure is reproduced, and if the failure is reproduced, redesigning and testing are needed; if the reproduction is not possible, S3.5 is carried out;
the third step is that: the dynamic thinking analysis of the aging process further comprises: checking evaluation for redesigned parts:
s3.5, considering whether the aged part has the influences of factors of sealing failure and electromagnetic compatibility dynamic change caused by vibration, sealing and reassembly after sealing besides the influence on the change of the size matching property and the performance difference, further adjusting the design to perform a test again if the influences exist, identifying and checking all factors which are contrary to the dynamic change and the static design if the influences do not exist, and successfully designing if the checking is completely passed; if the check fails, the design is further adjusted to perform the test again;
the third step is that: the dynamic thinking analysis of the aging process further comprises: s3.6 normalization of results: aiming at the parts which are successfully designed, the parts are standardized and converted into regular and distributable drawings and other standard documents to be filed.
Example 3:
example 3 is substantially the same as example 2 except that:
step two: and (3) dynamic thinking analysis of the operation process:
water leakage fault of engine thermostat: and (3) a newly developed automobile model is stopped and checked after a driving road test, and water leakage of a water pipe of the engine thermostat is found. According to the "three-cash-point meaning", the test unit collects the departments and units of research and development, purchase, quality insurance, suppliers, etc. to conduct consultation. According to the principle of 'fault reappearance', no water leakage phenomenon exists between a water pipe of the thermostat and the thermostat when idle speed observation is carried out after the on-site cold machine is started.
The size and tolerance of the inner diameter base of the rubber pipe of the thermostat are as follows: the nominal size phi is 16mm (-0.2, -0.8), the actually measured phi of a fault piece is 15.68mm, and the actually measured phi of 10 pieces in the warehouse randomly spot check is 15.2 mm-15.4 mm, so that the drawing requirements are met.
Basic size and tolerance of the outer diameter of the thermostat steel pipe: the nominal size phi 16mm (+ -0.2), the actually measured phi 16.08mm of the fault part, and the actually measured phi 16 mm-phi 16.14mm of 10 parts randomly selected and inspected in the warehouse meet the drawing requirements.
Checking the fit tolerance: the fit clearance between the rubber tube of the thermostat and the steel tube of the thermostat is (0, 1) mm theoretically, is interference fit and is reasonable in a static state.
Dynamic thinking results: the design of the size chain has the risk of gaps between the rubber tube and the steel tube: the drawing requirement of the outer diameter of the steel pipe of the thermostat is phi 16mm (+ -0.2), the drawing requirement of the inner diameter of the rubber pipe of the thermostat is phi 16mm (-0.2, -0.8), when the tolerance of two parts is in a limit state, the interference magnitude between the two parts is 0, and because the rubber pipe receives hot water and the thermal expansion coefficient of the rubber pipe is greater than that of the steel pipe, clearance fit can occur between the rubber pipe of the thermostat and the steel pipe of the thermostat when an engine is heated, and water leakage can not occur due to sealing.
And (3) fault reproduction: a thermostat rubber pipe and a thermostat steel pipe with a limit state tolerance are selected to be assembled on an engine, when the engine runs to the highest water temperature, a water leakage phenomenon occurs, and the fault can be reproduced.
A thermostat rubber pipe and a thermostat steel pipe which are not in a limit state tolerance are selected to be assembled on an engine, and when the engine runs to the highest water temperature, the water leakage phenomenon does not occur. The reason why not every test car leaks here can also be explained.
The problem is solved: and the interference magnitude of the matching between the rubber tube of the thermostat and the steel tube of the thermostat is redesigned and changed from the original (0, 1) mm to (0.4, 0.9) mm.
Through the verification of the real vehicle, the water leakage phenomenon does not occur even in the interference limit state.
To summarize: this case shows that in the quiescent state, it is unreasonable to design what seems reasonable. Through dynamic thinking analysis, it is found that the 'data' in the running process of the vehicle is the data that we should follow in the design, and the 'live change' is seen from the 'dead data', so the quality is designed firstly, and is quite reasonable.
Step three: dynamic thinking analysis of the aging process:
the front axle is filled with the grease nozzle sheath and is easy to fall off: when a newly developed automobile model is checked after a road test, the front axle is slightly pushed by a hand to drop after a grease nozzle sheath is filled. According to the "three-cash-point meaning", the test unit collects the departments and units of research and development, purchase, quality insurance, suppliers, etc. to conduct consultation. According to the principle of 'failure reappearance', the pull-out force is really small from the perspective of sensing the quality by pulling out the grease nipple sheath by hand on site.
And (3) an analysis process:
evaluation results of the quality assurance department: since it was easily pulled out by hand, it was evaluated as being unacceptable in the evaluation of perceived quality by the quality assurance department. However, the sensing quality evaluation is carried out, and the drawing does not have the pulling-out force requirement, so that data support such as listed tolerance fit is not provided.
Dynamic thinking results: since the casing cannot be too tight, and the rubber parts become hard and small in size when they age, it is considered loose in the initial state. The rubber sheath can be tighter and tighter in the aging process, and the rubber sheath is directly broken off in the process of plugging and unplugging after aging, so that the initial plugging force is better.
To summarize: this case shows that in the initial state, it is really reasonable to design what seems unreasonable. Through dynamic thinking analysis, it is found that some parts are continuously aged in the running process of the vehicle, but if the aged parts do not affect the use, the aged parts do not need to be replaced from the aspect of use economy, but the aged parts need to be considered in advance to have dynamic changes in size, and the dynamically changed 'data' is what we should follow. Then, the quality evaluation should also take into account the variation of the dynamic factors.
Claims (8)
1. A method for analyzing difficult and complicated faults of automobile parts is characterized by comprising the following steps:
the fault analysis method comprises the following steps:
the method comprises the following steps: a preliminary analysis of the fault is carried out,
on the premise that the conventional detection of parts meets the requirements of drawings and design, the method respectively uses the following steps for difficult and complicated faults of which the general quality detection method can not detect the fault reason: analyzing the dynamic thinking in the running process and the third step: analyzing the dynamic thinking in the aging process to analyze faults;
step two: analyzing dynamic thinking in the running process, knowing the material and the matching relation of the fault parts, analyzing changes of working environments of the fault parts and related parts in the running state of the automobile, analyzing main causes of faults, and then performing simulation test to reproduce the faults, wherein if the faults are reproduced, the faults are judged to be influenced by the environmental factors corresponding to the test; if all the tests can not reproduce the fault, judging that the main cause of the fault cannot be found out by the dynamic thinking analysis in the running process;
step three: analyzing the dynamic thinking of the aging process, judging whether the fault part has an easily-aged part, and if not, eliminating the aging factor of the main cause of the fault of the part; if so, carrying out a fault aging analysis test: firstly, judging the influence of aging on the matching relation of parts, if the matching relation is changed, measuring the size difference and the performance difference of the aged parts by taking the life cycle of the parts multiplied by a coefficient of 0.4 as a reference to redesign the parts, testing the newly designed parts, if the fault reappears, redesigning and testing the newly designed parts, and if the fault does not reappear, successfully designing the parts for solving the existing aging fault;
step four: to draw a conclusion
Through the second step: analyzing the dynamic thinking in the running process and the third step: the failure analysis of dynamic thinking analysis in the aging process can obtain the main cause of difficult failures, and the failures are eliminated through design; step two: analyzing the dynamic thinking in the running process and the third step: and (4) judging that the method cannot analyze the difficult fault if the fault principal factor cannot be obtained by the fault analysis of the dynamic thinking analysis in the aging process.
2. The method for resolving the problematic fault of the automobile spare and accessory parts according to claim 1, characterized in that:
the second step is as follows: the dynamic thinking analysis of the operation process comprises the following steps:
s2.1, judging whether parts with different materials are matched at a fault part, and recording the materials of the matched parts and the corresponding physical and chemical property parameters;
s2.2, analyzing changes of working environments of fault parts and related parts of the fault parts in the parking flameout state and the running process of the automobile, and specifically considering that: temperature, vibration, sealing failure caused by reassembly after sealing, and electromagnetic compatibility;
s2.3, respectively analyzing the influence of the changed environmental factors on the fault spare part and the related spare parts thereof, preliminarily judging whether the influence possibly generated by the influence is possible to cause the corresponding fault, if so, preliminarily judging that the influence is the possible main cause of the fault, and if not, eliminating the influence as the possible main cause of the fault;
s2.4, respectively carrying out test simulation on possible main factors, and finding out the main factors influenced by the environmental factors:
assembling new spare and accessory parts on the whole vehicle or a test bench, simulating the working environment of one possible main cause of preliminary judgment, judging whether the fault can reappear, if so, judging that the fault is influenced by the environmental factors corresponding to the test, and if not, performing the next group of tests;
if all the tests can not reproduce the fault, judging that the main cause of the fault cannot be found by the dynamic thinking analysis in the running process.
3. The method for resolving the problematic fault of the automobile spare and accessory parts as claimed in claim 2, wherein:
the second step is as follows: the dynamic thinking analysis of the operation process also comprises the following steps: the solution for the fault of the operation process comprises the following steps:
if the fault is reproduced, a fault solving flow of the running process is entered:
s2.5, searching whether past design data of a corresponding automobile type carries out checking of an oversize chain according to the actual size of the automobile in dynamic operation, if not, entering S2.6 after the checking of the oversize chain is required to be carried out again, and if so, directly entering S2.6;
s2.6, searching whether the static design size checked by the past design data size chain of the corresponding vehicle type meets the requirement of the dynamic size chain design, and if not, re-designing the static size chain according to the check result of the dynamic size chain;
s2.7, manufacturing a sample piece meeting the design requirement according to the design of the S2.6, assembling the sample piece on the whole vehicle or a test bench, and testing to see whether the fault can reappear, wherein redesigning and testing are needed if the fault reappears; if the failure can not be reproduced, performing an actual vehicle endurance test to see whether the failure is reproduced, and if the failure is reproduced, redesigning and testing are needed; if the reproduction is impossible, the redesign is successful.
4. The method for resolving the problematic fault of the automobile spare and accessory parts as claimed in claim 3, wherein:
the second step is as follows: the dynamic thinking analysis of the operation process also comprises the following steps:
s2.8 normalization of results: aiming at the parts which are successfully designed, the parts are standardized and converted into regular and distributable drawings and other standard documents to be filed.
5. The method for analyzing the problematic fault of the automobile parts according to any one of claims 1 to 4, wherein:
the third step is that: the dynamic thinking analysis of the aging process comprises the following steps:
s3.1, judging whether the fault component and related parts thereof have parts which are easy to generate light aging or environmental aging, if so, carrying out S3.2, and if not, eliminating the aging factor of the main cause of the fault of the parts;
s3.2, aiming at parts which are easy to age, judging the change of the size and the performance of the parts in the aging process, then judging the influence of the change of the aged size and the aged performance on the matching and the function execution of the original static design, then judging whether the influence changes the matching property of the initial design or manufacture, if so, carrying out S3.3, and if not, eliminating the aging factor of the main cause of the part fault; if the matching property is not changed, the aging factor of the main cause of the part failure is eliminated.
6. The method for resolving the problematic fault of the automobile parts according to claim 5, wherein the method comprises the following steps:
the third step is that: the dynamic thinking analysis of the aging process further comprises: solution to aging process failure:
s3.3, searching the design life cycle of the aged part, multiplying the life cycle by a 0.4 coefficient to be used as a reference to measure the size difference and the performance difference of the aged part, and then comprehensively considering all requirements of dynamic and static sizes according to the dynamic size and the performance state of the 0.4 coefficient and then re-designing a size chain;
s3.4, manufacturing a sample piece meeting the design requirement according to the design of the S3.3, assembling the sample piece on the whole vehicle or a test bench, and testing to see whether the fault can reappear, wherein redesigning and testing are needed if the fault reappears; if the failure can not be reproduced, performing an actual vehicle endurance test to see whether the failure is reproduced, and if the failure is reproduced, redesigning and testing are needed; if the playback is impossible, S3.5 is performed.
7. The method for resolving the problematic fault of the automobile spare and accessory parts as claimed in claim 6, wherein:
the third step is that: the dynamic thinking analysis of the aging process further comprises: checking evaluation for redesigned parts:
s3.5, considering whether the aged part has the influences of factors of sealing failure and electromagnetic compatibility dynamic change caused by vibration, sealing and reassembly after sealing besides the influence on the change of the size matching property and the performance difference, further adjusting the design to perform a test again if the influences exist, identifying and checking all factors which are contrary to the dynamic change and the static design if the influences do not exist, and successfully designing if the checking is completely passed; if the check fails, the design is further adjusted to perform the test again.
8. The method for resolving the problematic fault of the automobile spare and accessory parts as claimed in claim 7, wherein:
the third step is that: the dynamic thinking analysis of the aging process further comprises: s3.6 normalization of results: aiming at the parts which are successfully designed, the parts are standardized and converted into regular and distributable drawings and other standard documents to be filed.
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