硕士论文-六西格玛设计方法在发动机悬置系统开发中的应用研究

上海交通大学硕士学位论文六西格玛设计方法在发动机悬置系统开发中的应用研究姓名：俞斌申请学位级别：硕士专业：项目管理指导教师：明新国;刘拥军20090301I//IITHEENGINEMOUNTSYSTEMDEVELOPMENTSTUDYWITHDESIGNFORSIXSIGMAABSTRACTDesignforSixSigma(DFSS)isamethodicalapproachtorobustdesign.Itdoesnotonlyfocusonimprovingtheexistingdesignorprocess.DFSSconcentratesitseffortsoncreatinganewandimproveddesignorprocess.Itrequiresapplyingresourcestofindoutwhatcustomers’realneedsare,andthendevotestheentireprojecttomeetthosecustomers’demandwithincostconstraint.ThisdissertationwillintroducetheenginemountsystemstiffnessoptimizationwiththeDFSSmethodology.Itincludeshowtocollectthevoiceofcustomers,howtotransferitintoengineeringtargetwithHOQ,howtodeveloptheconceptofsettingupthecontrolfactorandnoisefactor,howtooptimizethesystemparameter,andhowtomakethedesigninsensitivetothenoisefactor.Thedesignresultcanbeverifiedinvehicleintheend.KEYWORDS:DFSS,RobustDesign,EngineMount,SystemStiffnessOptimization11.1(DFSSDesignForSixSigma)209021[7]:;;;;DFSS2006IDDOV5IDDOVIdentifyopportunity(Developrequirement)DevelopconceptOptimizedesign(Verify)1.21.2.16902198768.26%3399.73%661~3.4PPM399.73%0.27%12763.4PPM3.4684%1998[2]1995GE61.73.87530666[2]66666666[2]1.2.2DMAIC666DMAICDMAIC6PDCA3D(define)M(measure)A(analyze)I(improve)C(control)DMAICPDCA()[8]6DMAIC6(Y)(X)661-1[8]1-16DMAICTable1-1Contentandtoolsof6DMAICDM///DPMO/RTY/DPU(FMEA)A(ProcessMap)tF(FTA)I(DOE)CSPC41.2.3DMAIC80%DMAIC()[1](DFSS)DMAIC///DMAIC1-1[14]1-1Figure1-1DFSS&DMAIC//[1]//1-226215[14]1-2Figure1-2RobustDesign/[1]2070209021RobustDesign[1](DFSS)DFSS61-3[14]1-3Figure1-3DesignTarget(DFSS)DFSS1-3DFSS1.31.3.11-4:(1)(2)(3)(4)(5)71-4Figure1-4PowertrainMountSystemNVH(NoiseVibrationandHarshness)[16][17](1)(2)(3)(4)(1)—(2)8(3)1.3.2CAE1-51-5Figure1-5DesignProcessofmountsystem1-291-2Table1-2ParameterofPowertrain(rpm)KCAE45~7mmZ1-6101-6Figure1-6MountPosition&TorqueAxleZXYX/Y/Z1.3ADMAS61-71-7Figure1-7rigidbodymode&decoupling11MOUNTDESIGN-ADMAS281-81-8Figure1-8Force-DeflectioncurveofmountCAEUG28ADMAS121.3.3NVHDFSS1.3.2IDDOV1.4DFSSDFSS13DFSS1.5IDDOV142.12.1.170DFSSQCDFSS80DFSSDFSSDFSS[5]207080-90[5]WTO15[4]:DMAICDesignForSixSigmaDFSSDFSS[4]::DMAICDFSS[4][4]2.1.2[3](DFSS)DFSS[3]DMAICDFSSDFSSIDDOV()ICOV()DFSS2-1[3]162-1Table2-1DescriptionofDFSSASIIDDOVIDDOV2.217+/-15%NVHNVH2.3GE212003DFSSIDDOVDTR,Paulstra,Tokai[7]2.4DFSSDFSSIDDOV18193.1(IDDOV)3-13-1Figure3-1ProcessofDFSS(IDDOV)1.3.320(IDDOV)DFSSDFSSDFSSS.M.A.R.TS(Specific)M(Measurable)A(Actionable)R(relevant)T(timeBound)DFSSDFSSDFSSDFSS:21DFSS(VoiceofCustomVOC)VOCVOCVOCDFSSTRIZ22DFSSDFSSDFSSDFSSDFSSIDDOV3.2IDDOV234.1(IdentifyOpportunity)(IDDOV)DFSSS.M.A.R.TS(Specific)M(Measurable)A(Actionable)R(relevant)T(timeBound)DFSSSMARTNVHNVHNVHNVH4.2DFSS24IDDOVDFSS84-1DFSSFigure4-1DFSSProjectTiming200724710108NVH1.3.1CAE255.1(DefineRequirements)IDDOVHOQ(HouseOfQuality)5-15-1Figure5-1ProcessofHOQdevelopment(HOQ)QFD2060TQCQFDQFDQFD26QFDQFDQFDQFDHOQHouseofQuality(QFD),QFDHOQHouseofQualityHOQQFD5.25-2275-2Figure5-2VoiceofCustomerTVS5-3155T,S,V1535-3Figure5-3CompetitionAssessmentofVOCNVH,GCAVOC285.3“”75-45-4Figure5-4CompetitionAssessmentofEngineeringTarget5.4“”295-65-6()Figure5-6LossFunctionofengineeringtarget(StaticStiffness)”5-75-7()Figure5-7LossFunctionofengineeringtarget(PitchMode)5.5811Hz3011Hz18Hz100%5-810Hz12Hz8Hz5-8Figure5-8CustomerDissatisfiedcurveofpitchmode5-95-9Figure5-9EngineeringTarget315.6,5-1045-10Figure5-10HouseofQuality326.1(IDDOV)(DevelopConcept)6-16-1Figure6-1DistributionofHOQ6-2336-2Figure6-2CreativeCriteria6.26.2.1—6-36(Fore/Aft)(Lateral)Bounce(Pitch)(Roll)(Yaw)[16]346-3/6Figure6-3PowertrainMountsystem6}{}]{[}]{[FXKXM=+&&(6-1)[M][K]{X}γβα,,,,,zyx6{F}66600}]{[}]{[=+XKXM&&(6-2))sin(}{}{φω+=tQXii(6-3)(6-3)(6-2)}{}]{[][21iiiQQKMω=−(6-4)2iω(i=1~6)662625242322210ωωωωωω……352iω(6-4){Qi}66[16]—6.2.2[16]6-436Ixx=8.60N.m.sec2Iyy=15.73N.m.sec2Izz=14.41N.m.sec26-4Figure6-4TypicalPowertrainTorqueiαcosiβcosiγcos0.8463-0.1259-0.5176-0.05000.9489-0.31250.53030.29030.7965iαiβiγαβγ)0(998.0373.05303.0)032.0()0500.0(8463.0coscoscoscoscoscoscoscos1331221ozzxxyyxxIIII≈=×+−×−+=++=ααααααααα(6-5))8.92(048.0373.02903.0)032.0(9489.01259.0coscoscoscoscoscoscoscos1331221ozzxxyyxxIIII≈−=×+−×+−=++=βααβααβββ(6-6))2.102(2105.0373.07965.0)032.0()3125.0()5176.0(coscoscoscoscoscoscoscos1331221ozzxxyyxxIIII≈−=×+−×−+−=++=γααααααγγ(6-7)37X=32.50cmcmXRRX53.32998.0/50.32cos/cos===⇒=αα(6-8)cmRY56.1)048.0(53.32cos−=−×==β(6-9)cmRZ55.6)2105.0(53.32cos−=−×==γ(6-10)XYZ[16]6.2.3[18][18]6-1386-1Table6-1Powertrainmountsystemrigidbodymodewhenidle(%)(%)(Bounce)8-9Hz90%1Hz(Fore/Aft)7-9Hz60%1Hz(Lateral)7-9Hz80%1Hz(Pitch)10.5-11.5Hz90%1Hz(Roll)13Hz60%1Hz(Yaw)13Hz60%1Hz6.2.416-56-5Figure6-5TransverseHighTorqueaxis26-6SUV396-6Figure6-6TransverseLowTorqueAxis36-766-7Figure6-7Transverse3loadbearingmounttocradle46-86-8Figure6-8Longitudinal3loadbearingmount6.340zzzzzzzz–90%z–10Hz8-10Hzz6-56-96-9Figure6-9ThreePointPendularsystem417.1IDDOVOptimizeDesign66.26(Fore/Aft)(Lateral)Bounce(Pitch)(Roll)(Yaw)7-17-1Table7-1SystemOptimizationTargetBounce81090%Fore/Aft71385%Lateral71585%P