Principle and implementation of product system reliability

At the beginning of this year, the General Administration of Quality Supervision, Inspection and Quarantine issued the "Regulations on the Repair, Replacement, and Return of Household Car Products". The majority of automobile companies, auto parts suppliers, and other more mechanical and electronic products companies are once again aware of product quality and reliability. Importance. Product reliability analysis, which was previously optional, is no longer a icing on the cake, and it has become one of the basic conditions for a company's ongoing operations.

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The core components of automobiles and automobiles (such as engines) are a complex system. The stability and reliability of individual components does not mean that the system works stably and reliably. Therefore, in the overall process from research and development to production, it is necessary to continue to pay attention to the improvement of the quality reliability of individual components, and at the same time, it is necessary to pay attention to the quality reliability of the subsystems and even the vehicle system.

The so-called system here refers to a complex that can complete a specific function and consist of several units that are related to each other and can work together. Due to the continuous updating of customer needs and the continuous development of science and technology, many products are becoming more and more complex, and the possibility of product failure is also increasing. Therefore, the reliability engineer needs to study the surface physical relationship and the logic relationship between the various components that make up the system, as well as the law of each component failure and its impact on the system performance, and finally construct the life prediction of the system. model.

The analysis principle of system reliability mainly involves two: Reliability Block Diagram and Reliability Mathematical Model. In general, system reliability analysis models can be divided into three categories: Series System, Parallel System, and Mixed System, as shown in the following figure.

Simple hybrid system and its reliability function diagram

In actual work, the analysis of system reliability is much more complicated than the above description of the principle. Because the object that requires us to study system reliability is often a hybrid system consisting of hundreds of units, and the reliability of each unit in the system is often a reliability that contains many obscure statistical principles. function. This has made many engineers with backgrounds in mechanical engineering and electronic engineering unable to do anything. The work of applying and promoting reliability analysis has become difficult and inefficient, and the value of reliability work cannot be exerted at the implementation level.

The “reliability/survival” module in the professional statistical quality analysis software JMP can make the system reliability analysis extremely simple, and the whole work process is just as easy and pleasant as a child building a high-rise building with Lego bricks. The following is a reliability model analysis case of a more mature aircraft system, which allows us to experience the sense of accomplishment of using advanced analysis tools to improve the efficiency of reliability analysis.

The single-wing propeller aircraft shown below consists of key units such as Engine, Cockpit, Wing, Control Panel, Port, and Starboard. For example, Engine is composed of components such as Motor, Fuel, Cooling, and Propeller. How can I estimate the reliability of this complex system accurately and efficiently?

On the "reliability block diagram" platform of JMP software, the reliability technicians will be very comfortable in implementing this analysis. With a click of the mouse and dragging different design element buttons such as basic, serial, parallel, node, and k out of n, engineers can build a logical model of the many components in minutes. If the system contains multiple levels of subsystems, secondary subsystems, etc., you can also implement multi-level nested design by calling library elements. The figure below is a functional block diagram of the reliability of an aircraft system based on JMP software.

After properly setting up the basic framework of aircraft system reliability, the more important thing is to synthesize all known component reliability distribution quantitative models to make a unified and effective prediction of the reliability of the entire system.

The technical difficulty at this time is mainly reflected in the need to calculate a series of technical parameters through a series of cumbersome reliability mathematical model calculations to reflect the risk of system failure, such as reliability, Cumulative Failure Probability, Failure Probability Density, Hazard Rate, Quartile Lifetime, and Component Importance. The whole process is very complicated. Even if the traditional reliability analysis program is called, it takes a lot of time. Any small negligence will lead to the whole mistake, which makes many people discourage it.

Fortunately, JMP software, which has always advocated "exploratory interactive data discovery," solves problems that have plagued reliability engineers for many years with its unique Prediction Profiler. Because in the predictive profiler, engineers can set the reliability parameters of the components through the menu interface, and the model of system reliability can be presented through a vivid and intuitive graphical interface (see the figure below).

In this graphical interface, we can use the mouse to point to the mountains and rivers, and we can predict the quality performance of the aircraft during the product warranty period. We can experience the impact of the increase and decrease of redundant modules on the aircraft failure rate in an immersive manner. Finding the weaknesses of the aircraft in advance and making up for it can directly compare the different effects of different system designs on the aircraft.

In short, if a worker wants to do something good, he must first sharpen his weapon. With the help of modern information technology (such as JMP software), the analysis and research of product system reliability in the automotive, machinery, electronics and other industries will no longer be a difficult task.

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