使用故障分析来管理运行中的故障

In-service occurrences have the potential to cause millions of pounds worth of damage to an organization in terms of not only lost business but also reputation. 在服务中发生事件时, it is therefore vital that the reason behind how and why a material or product has failed is established as quickly as possible, 找到解决方案并立即实施.

失效分析 is not only a critical aspect of product development and system improvement, 防止未来的问题是至关重要的. 找出根本原因, 或原因, 对于这样的事件, 然而, is not an easy process and needs to consider not only all the relevant design information and service life to date but also the type of application as well as any environmental factors that have the potential to either cause or contribute to the occurrence.

劳斯莱斯的方法

Rolls-Royce has its own dedicated team of expert engineers supporting its core businesses with potential in-service occurrences. 在劳斯莱斯位于达勒维茨的尖端测试设施中工作, 德国, 工程师们进行广泛的独特材料测试, 如多轴疲劳能力, 部件振动试验, 以及大规模自旋测试.

通过劳斯莱斯和im体育APP的合作, 劳斯莱斯团队现在正将这一专业知识应用于多个领域, 从能源和农业到汽车, 航空航天, 和运输, providing access to the same high-quality testing capabilities and service that Rolls-Royce uses every day to test its engines, 材料, 和组件.

理解和复制事件 

The first step in managing an in-service occurrence is to take as much information from the customer as possible regarding the problem, 是否为叶片裂纹, 管破裂, 传感器/连接器失败, 或者更不寻常的事情.

劳斯莱斯的工程师们, 每个人都有不同领域的专业知识, 作为一个完全集成的产品团队一起工作, 如果缺乏事件的即时数据, will carry out pre-analysis and pre-measurement to collate the necessary information. This might include analyzing and measuring the 振动 behavior or executing a modal analysis and replicating failure mode.

如果需要, the team has the capability to measure the in-service situation of an accessory or component in mounted condition via Experimental Modal Analysis (EMA).

在这个过程的早期阶段, the key objective is to gain a full understanding of the system in question. This enables the team to move on to analyzing and replicating real boundary conditions in the test setup, carefully reproducing and observing the issue whilst precisely matching the behavior.

对改进的设计进行验证测试

The next stage in the process is to verify the failure mechanism and make recommendations of how to identify resolutions. 此时此刻, the team will start working towards proof testing an improved design to provide a tailored solution that will prevent future in-service failures.

而项目的范围将随着测试的进行而发展, the team always starts at zero and tailors and adapts the testing as it progresses with the aim of producing a solution as quickly as possible.

高度灵活和多方面的方法 

Determining how and why a product or material has failed requires the expert application of a wide variety of analytical methods and tools. 劳斯莱斯广泛的测试设施允许高度灵活的测试, multi-faceted approach in which every potential cause and solution can be fully explored. This involves being able to select from a wide range of testing methods to identify the procedure that will most accurately replicate the environmental conditions and in-field 振动s for the component. 这可能包括冲击测试, 高水平混响噪声测试, linear/angular acceleration testing as well as one or more 振动 test procedures.

将多种测试类型组合到单个测试程序中

The process will often include combining multiple test types into a single testing program to analyze how two or more factors being applied simultaneously may affect the test outcome. For instance, applying 振动 testing and static loading simultaneously.

The team’s expert knowledge of the different methods allows for many of the procedures to be planned and executed in extremely short timeframes. 该团队的压电测试专家, 例如, are able to calculate any frequency and put the system together in 30 minutes to test components, 比如涡轮叶片, 以超高频率.

The team is also experienced at studying the 振动 behavior of highly complex structures with 3D Digital Image Correlation (DIC), 三维全视野, 非接触式光学轮廓测量技术, 变形, 振动, 几乎对任何材料都有张力. 这对于复杂的管道系统非常有用, 减少对多个应变片的需求.

取决于服务中发生的情况, the test program may incorporate additional failure analysis procedures such as: examining the effect of corrosion including residue identification and corrosion prevention; 金相分析 in which the fracture surface is examined to determine the cause of the failure; chemical analysis to understand if the chemical composition of a material or the chemical processes used during manufacture may have contributed to the failure; and residue analysis which can help identify residual deposits on a material and determine whether this is a surface stain or a product of corrosion or material failure.

For more information about managing in-service occurrences and building a robust failure analysis testing program, 请在这里与我们联系.