Design method for improving radar reliability based on FMECA

Abstract

The invention discloses a design method for improving radar reliability based on FMECA. The method comprises the steps of dividing a system FMECA agreed level, a fault criterion and a severity level; aiming at antenna transceiving, servo control, information processing, control and display function faults, a scheme is selected to improve the reliability, and an analog simulation test is carried out to verify the effect; radar hardware design key points are determined, and low-power-consumption design and hardware redundancy design measures are adopted; radar software design key points are determined, the problems of deep coupling and large-area crash of software and hardware are solved, and health management software is designed to realize task migration and reconstruction; according to the process FMECA data of the existing product, obtaining the process failure mode, reason, severity grade and detected difficulty information, carrying out a reliability enhancement test, exciting and exposing the process defect in the module processing process, and adopting a corresponding improvement scheme in the processing process; in the testing and using process, FMECA iteration is carried out, and the radar reliability is improved.

Description

Technical Field

[0001] The present invention relates to the technical field of radar design, and particularly to a design method for improving the reliability of a radar based on FMECA. Background Art

[0002] With the continuous improvement of radar performance and the increasing complexity of system composition, especially the application of various microcircuits and software, the reliability of the radar decreases accordingly, which affects the effectiveness of the radar and increases the support cost of the equipment.

[0003] Failure Mode, Effects and Criticality Analysis (FMECA) is the basis for carrying out general quality characteristic design. Through FMECA work, information such as failure modes, failure causes / mechanisms, failure effects, failure occurrence probabilities, failure consequence severities, and criticalities can be obtained. These information provide strong support for the design analysis of reliability, maintainability, testability, supportability, safety, environmental adaptability, etc. By analyzing the reliability weak links of radar functions and hardware through FMECA, combined with the negative list of reliability design, finding the reliability weak links and taking design measures to avoid them, the reliability of the product can be improved; by analyzing the radar maintenance requirements through FMECA and further analyzing the corresponding maintenance processes, and taking corresponding maintainability design measures in the radar structure design, the maintainability of the product can be improved; by analyzing the radar test requirements through FMECA, taking methods such as testability modeling for BIT design and analysis and iteratively improving the radar fault detection and isolation capabilities, the testability of the product can be improved; through RCMA, LORA, and OMTA based on FMECA, weighing the support cost and support effectiveness, the best support plan can be obtained; by analyzing the safety hazards of the radar through FMECA, PHA, and SHA, including various factors such as electrical, structural, use and support, environment, personnel, software, and equipment failures, and proposing corresponding safety design measures to avoid danger or reduce the danger level, the safety of the product can be improved; by carrying out environmental adaptability design in extreme environments such as plateaus, mountains, islands, and deserts through FMECA, other general quality characteristic design requirements, and hardware design requirements, the environmental adaptability of the product can be improved. Summary of the Invention

[0004] Aiming at the problems existing in the prior art, the present invention provides a design method for improving the reliability of a radar based on FMECA, which conducts functional FMECA, hardware FMECA, software FMECA, and process FMECA at different stages of the entire life cycle of the radar, and takes corresponding improvement measures and usage designs for different failure modes, so as to comprehensively ensure the general quality of the radar and have generality and practicability.

[0005] The object of the present invention is achieved through the following technical solutions.

[0006] (10) Conduct preparatory work for FMECA, and divide the system FMECA convention levels, failure criteria, and severity levels.

[0007] (101) Combine with the high-reliability radar development process to formulate an FMECA work plan. Determine to conduct functional FMECA and process FMECA in the demonstration phase, and conduct hardware FMECA and software FMECA in the design phase. Improve and iterate according to the actual usage conditions of the radar in the usage phase.

[0008] (102) Determine the mission profile, and divide the convention levels of the radar functional FMECA. The initial convention level is the radar, and the lowest convention level is the field-replaceable / maintainable unit.

[0009] (103) Determine different severity categories and their failure criteria based on the product's failure repair support practice data, as well as the functional, performance requirements, and usage environment requirements of the high-reliability radar.

[0010] (20) In the demonstration phase, conduct functional FMECA. For the weak links of functions such as antenna transceiver, servo control, information processing, control and display, weigh and adopt high-reliability solutions, and conduct simulation tests to verify the effects.

[0011] (201) Conduct functional FMECA, analyze the product design and historical failure data, statistically calculate the product failure occurrence probability, determine the list of severity class I and II functional failure modes, and identify the key functional items of the radar.

[0012] (202) For the failure of the array cooling function, adopt the natural heat dissipation scheme, and improve the stability of the array heat dissipation capacity from the perspective of structural design.

[0013] (203) For the failure of the servo control function, adopt the dual-channel hot standby scheme, upgrade the shielding measures against electromagnetic interference, and overall improve the reliability of the servo control task.

[0014] (204) For the failure of the radar communication function, use the high-speed network communication protocol and the dual-chassis redundant hot standby scheme to overall improve the reliability of the information processing task.

[0015] (205) For the failure of the control and display function, adopt the two-way interconnected link design scheme with the same function, and multiple integrated display and control sub-units are in hot standby to overall improve the reliability of the terminal task.

[0016] (206) Conduct simulation experiments to verify the improvement effect of the equipment. Conduct thermal analysis on the main heat-generating components such as transmit-receive chips, power supply chips, and ASIC chips, and conduct temperature simulation of the key modules.

[0017] (30) Conduct hardware FMECA, determine the key points of high-reliability radar hardware design, and weigh measures such as low-power design and hardware redundancy design. While ensuring the completion of tasks, improve the long-term stable operation ability of the radar.

[0018] (301) Conduct hardware FMECA, calculate the failure rate of failure modes, determine the list of single-point failure modes of severity categories I and II, and identify the key and important modules of the radar.

[0019] (302) In the design of environmental adaptability and testability, the array comprehensively adopts natural heat dissipation with metal heat dissipation fins, as well as low-power design and air duct design for sub-arrays, and installs temperature sensors to solve the problem of array cooling.

[0020] (303) In the design of reliability and safety, by using an optical fiber loop to replace the traditional control loop and optimizing the power loop structure, solve the problem of servo control failure caused by brush wear during long-term operation resulting in the failure of the power loop and control loop.

[0021] (304) In the design of reliability and environmental adaptability, improve the processing ability of the processor, the communication ability of the switching module, the storage space of the storage module, the power supply ability of the power supply module, and the heat dissipation ability of the fan, and reduce the working stress of the devices, thereby reducing the failure rate of information processing devices.

[0022] (305) In the design of reliability, maintainability, and supportability, integrally and collaboratively design multiple integrated display and control sub-units with exactly the same functions, performance, structure, and interfaces to overall improve the mission reliability of the terminal.

[0023] (40) Conduct software FMECA, determine the key points of high-reliability radar software design, and solve the problems of deep coupling between software and hardware and large-area crashes through fully interconnected polling design. Design health management software to achieve task migration and reconstruction.

[0024] (401) Based on the full interconnection of redundant hardware platforms, the radar information processing adopts a polling mechanism. The same software is deployed for each module to independently process one frame of data. The software framework dynamically distributes the echo data to each module for operation by frame through status query, greatly improving software reliability.

[0025] (402) Based on software FMECA and a software fault diagnosis knowledge base, establish a health management system to monitor, detect errors, correct errors, and reconstruct software components. By monitoring and predicting the status and performance of software and network communication and designing corresponding disposal strategies, reduce the impact of problems such as software crashes and network interruptions on system effectiveness.

[0026] (50) Conduct process FMECA. Based on the process FMECA data of existing products, obtain information such as process failure modes, causes, severity levels, and detection difficulties. Conduct reliability enhancement tests to stimulate and expose process defects during module processing, and adopt corresponding improvement plans during the processing to improve the reliability level of critical modules.

[0027] (60) During the test and use process, conduct evaluations on reliability, maintainability, testability, supportability, safety, and environmental adaptability, and perform FMECA iteration to further improve the radar reliability.

[0028] Compared with the prior art, the advantages of the present invention are as follows: FMECA is an important link in the reliability design of equipment and is the basis for improving the general quality of the radar. Through FMECA, comprehensively understand the mechanism, impact, and harm degree of fault occurrence, and make improvements in the design of reliability, maintainability, testability, supportability, safety, and environmental adaptability. During the operation process, monitor the status in real time, evaluate the fault consequences, predict the operation trend, and give the best maintenance plan to avoid the occurrence of faults or reduce the possibility of fault occurrence from the root cause, and reduce the impact of faults on the operation tasks, so as to improve the reliability of the radar. Through functional FMECA, hardware FMECA, software FMECA, process FMECA, etc., and their iterations in each stage of the entire life cycle of the radar, specifically formulate high-reliability design schemes and design measures, which can improve the reliability of the radar system. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Figure 1 It is a schematic diagram of the agreed hierarchy division of the radar of the present invention.

[0030] Figure 2 It is a table of severity categories and definitions of high-reliability radar FMECA of the present invention.

[0031] Figure 3 It is a simulation diagram of the temperature of the active subarray of the present invention.

[0032] Figure 4 It is the array surface flow field when the radar of the present invention rotates at a low speed.

[0033] Figure 5 It is a schematic diagram of the fully interconnected polling architecture of the present invention.

[0034] Figure 6 It is a summary table of weak link identification and improvement based on enhancement tests of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0035] The present invention will be described in detail below in conjunction with the accompanying drawings of the specification and specific embodiments.

[0036] A design method for improving the reliability of a radar based on FMECA, the steps include: (10) Conduct the preparatory work for FMECA, and divide the agreed levels, failure criteria, and severity levels of the system FMECA.

[0037] (101) In combination with the high-reliability radar development process, formulate work plans for different types of FMECA to be carried out at different stages of the radar's entire life cycle. Determine to conduct functional FMECA and process FMECA during the demonstration phase, hardware FMECA and software FMECA during the design phase, and improve and iterate according to the actual usage conditions of the radar during the usage phase.

[0038] (102) Determine the mission profile and divide the agreed levels of the radar's functional FMECA. The initial agreed level is the radar, and the lowest agreed level is the field-replaceable / maintainable unit.

[0039] The division of the radar's agreed levels is as Figure 1 shown.

[0040] (103) Define the failure criteria and severity levels. Based on the actual data of the product's failure maintenance support, as well as the functional, performance requirements, and usage environment requirements of the high-reliability radar, determine different severity categories and their failure criteria.

[0041] The severity categories and definitions of the radar's FMECA are as Figure 2 shown.

[0042] (20) During the demonstration phase, conduct functional FMECA. For the reliability weak links such as antenna transceiver, servo control, information processing, control and display, etc., weigh and adopt high-reliability solutions, and conduct simulation tests to verify the effects.

[0043] (201) Conduct functional FMECA, analyze the product design and historical failure data, statistically calculate the product failure occurrence probability, determine the list of severity class Ⅰ and Ⅱ functional failure modes, and identify the key functional items of the radar; (202) For the failure of the array cooling function, adopt a natural heat dissipation antenna array, remove the water-cooled or air-cooled equipment, and improve the stability of the array heat dissipation capacity from the perspective of structural design to effectively reduce the array temperature.

[0044] (203) For the failure of the servo hydraulic control function, adopt a dual-channel hot standby scheme, redundantly design all control drive circuits, and upgrade the shielding measures against electromagnetic interference to overall improve the reliability of the servo control task.

[0045] (204) For the failure of the radar communication function, use a high-speed network communication protocol to improve the reliability of data exchange between chassis. Adopt a dual-chassis redundant hot standby scheme, and use a voting redundancy scheme for key modules to overall improve the reliability of the information processing task.

[0046] For control and display function failures, a two-way interconnected link design scheme with the same functions is adopted to achieve hot redundancy of the control and display data interconnected link. A hot standby scheme of multiple integrated display and control sub-units is adopted to overall improve the mission reliability of the terminal.

[0047] (206)Carry out simulation experiments to verify the improvement effect of the equipment. According to the thermal analysis of the heating components and the cause analysis of historical failures, conduct thermal analysis on the heating components such as the transmitting and receiving chips, power supply chips, and ASIC chips, and carry out temperature simulation of the key modules.

[0048] The temperature simulation results of the active subarray are as Figure 3 shown.

[0049] Simulate the rotating working scenario of the radar, simulate the array flow field under the condition of poor heat dissipation performance, and the temperature field simulation is as Figure 4 shown.

[0050] (30)Carry out hardware FMECA to determine the key points of high-reliability radar hardware design, and weigh measures such as low-power design and hardware redundancy design to improve the long-term stable operation ability of the radar while ensuring the completion of the mission.

[0051] (301)Carry out hardware FMECA, calculate the failure rate of failure modes, determine the list of single-point failure modes of severity categories I and II, and identify the key and important modules of the radar.

[0052] (302)In the design of environmental adaptability and testability, the array comprehensively adopts natural heat dissipation of metal heat dissipation fins, as well as low-power design and air duct design of the subarray, and installs temperature sensors to solve the problem of array cooling.

[0053] (303)In the design of reliability and testability, by using an optical fiber loop to replace the traditional control loop and optimizing the power loop structure, solve the problem of servo control failure caused by brush wear during long-term operation resulting in the failure of the power loop and control loop.

[0054] (304)In the design of reliability, environmental adaptability, the maximum processing capacity of the processor is redundant by 20%, the communication capacity of the switching module is redundant by 30%, the storage space of the storage module is redundant by 25%, the power supply capacity of the power supply module is redundant by 40%, and the heat dissipation capacity of the fan is redundant by 50% to reduce the working stress of the components, thereby reducing the failure rate of information processing components.

[0055] (305)In the design of reliability, maintainability, and supportability, integrally and collaboratively design multiple integrated display and control sub-units with exactly the same functions, performance, structure, and interfaces to overall improve the mission reliability of the terminal.

[0056] (40) Conduct software FMECA to determine the key points of high-reliability radar software design. Through the fully interconnected polling design, solve the problems of deep coupling between software and hardware and large-area system crashes, and design a health management software to achieve task migration and reconstruction.

[0057] (401) The information processing software is based on the full interconnection of redundant hardware platforms and adopts a polling mechanism. The same software is deployed for each module to independently process single-frame data, greatly improving software reliability.

[0058] The fully interconnected polling architecture is as Figure 5 shown.

[0059] (402) Based on software FMECA and a software fault diagnosis knowledge base, establish a health management system to monitor, detect errors, correct errors, and reconstruct software components. By monitoring and predicting the software and network communication status and performance and designing corresponding disposal strategies, reduce the impact of software crashes, network interruptions, etc. on system effectiveness.

[0060] (50) Conduct process FMECA. According to the process FMECA data of existing products, obtain information such as process failure modes, causes, severity levels, and detection difficulties, conduct reliability enhancement tests, stimulate and expose process defects in the module processing process, and adopt corresponding improvement plans during the processing process to improve the reliability level of critical modules.

[0061] The weak links and improvement measures of radar processes are as Figure 6 shown.

[0062] (60) During the test and use process, conduct evaluations of reliability, maintainability, testability, supportability, safety, and environmental adaptability, and perform FMECA iteration to further improve radar reliability.

Claims

1. A design method for improving the reliability of a radar based on FMECA, characterized by the steps Including: (10) Conduct preparatory work for FMECA, divide the system FMECA convention levels, failure criteria, and severity levels; (20) During the demonstration phase, conduct functional FMECA. For failures in antenna transceiver, servo control, information processing, control, and display functions, select solutions to improve reliability and conduct simulation tests to verify the effects; (30) Conduct hardware FMECA, determine the key points of radar hardware design, adopt low-power design and hardware redundancy design measures to improve the long-term stable operation ability of the radar while ensuring task completion; (40) Conduct software FMECA, determine the key points of radar software design, solve the problems of deep coupling between software and hardware and large-area crashes through fully interconnected polling design, and design health management software to achieve task migration and reconstruction; (50) Conduct process FMECA. Based on the process FMECA data of existing products, obtain process failure modes, causes, severity levels, and detectability information, conduct reliability enhancement tests to stimulate and expose process defects in the module processing process, and adopt corresponding improvement solutions during the processing process to improve the reliability level of key and critical modules; (60) During the test and use process, conduct evaluations of reliability, maintainability, testability, supportability, safety, and environmental adaptability, and conduct FMECA iteration to further improve the radar reliability.

2. The design method for improving the reliability of a radar based on FMECA according to claim 1, wherein Step (10) is specifically as follows: (101) Combine the radar development process to formulate a FMECA work plan: determine to conduct functional FMECA and process FMECA during the demonstration phase, conduct hardware FMECA and software FMECA during the design phase, and improve and iterate according to the actual usage conditions of the radar during the use phase; (102) Determine the mission profile and divide the convention levels of radar functional FMECA. The initial convention level is the radar, and the lowest convention level is the field-replaceable / maintainable unit; (103) Determine different severity categories and their failure criteria based on the product's failure repair support practice data, as well as the functional, performance requirements, and usage environment requirements of high-reliability radars.

3. A design method for improving the reliability of a radar based on FMECA according to claim 1, characterized in that Step (20) is specifically as follows: (201) Conduct functional FMECA, analyze the product design and historical failure data, statistically calculate the product failure occurrence probability, determine the list of severity class I and II functional failure modes, and identify the key functional items of the radar; (202) For the failure of the array cooling function, adopt a natural heat dissipation solution to improve the stability of the array heat dissipation ability from the perspective of structural design; (203) For the failure of the servo control function, adopt a dual-channel hot standby solution and upgrade the electromagnetic interference shielding measures to overall improve the reliability of the servo control task; (204) For the failure of the radar communication function, use a high-speed network communication protocol and a dual-chassis redundant hot standby solution to overall improve the reliability of the information processing task; (205) For the failure of the control and display function, adopt a two-way interconnected link design solution with the same function and hot standby of multiple integrated display and control sub-units to overall improve the reliability of the terminal task; Carry out simulation experiments to verify the improvement effect of the equipment, conduct thermal analysis on the heating devices, and carry out temperature simulation of the key modules. The heating devices include transmitting and receiving chips, power supply chips, and ASIC chips.

4. A design method for improving the reliability of a radar based on FMECA according to claim 1, characterized in that Step (30) is specifically as follows: (301) Carry out hardware FMECA, calculate the failure rates of failure modes, determine the list of single-point failure modes of severity I and II, and identify the key important modules of the radar; (302) In the design of environmental adaptability and testability, the array comprehensively adopts natural heat dissipation of metal heat dissipation fins, as well as low-power design and air duct design of sub-arrays, and installs temperature sensors to solve the cooling problem of the array; (303) In the design of reliability and safety, by using an optical fiber loop to replace the traditional control loop and optimizing the power loop structure, solve the problem of servo control failure caused by brush wear during long-term operation resulting in the failure of the power loop and control loop; (304) In the design of reliability and environmental adaptability, improve the processing capacity of the processor, the communication capacity of the switching module, the storage space of the storage module, the power supply capacity of the power supply module, and the heat dissipation capacity of the fan, and reduce the working stress of the devices, thereby reducing the failure rate of information processing devices; (305) In the design of reliability, maintainability, and supportability, integrally and collaboratively design multiple integrated display and control sub-units with exactly the same functions, performance, structure, and interfaces to overall improve the mission reliability of the terminal.

5. A design method for improving the reliability of a radar based on FMECA according to claim 1, characterized in that Step (40) is specifically as follows: (401) Based on the full interconnection of the redundant hardware platform, the radar information processing adopts a polling mechanism. The same software is deployed on each module to independently process a frame of data. The software framework dynamically distributes the echo data to each module for calculation according to the frame through status query, improving software reliability; (402) Based on software FMECA and software fault diagnosis knowledge base, establish a health management system to monitor, detect errors, correct errors, and reconstruct software components. By monitoring and predicting the status and performance of software and network communication and designing corresponding handling strategies, reduce the impact of software crashes and network interruptions on the system effectiveness.

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