Aero-electromechanical equipment reliability design optimization method

Abstract

The present application belongs to the field of aviation electromechanical, and relates to a reliability design optimization method of aviation electromechanical equipment. The present application performs a reliability simulation test through establishing a three-dimensional model, identifies hidden failure modes through the method combining simulation and test, discovers and solves failure modes not considered in the design stage in advance, effectively reduces the research and development cost, identifies and solves equipment design defects as early as possible, can identify the equipment design limit, identify the failure modes of the equipment under the limit state, and effectively improve the reliability of the product through design improvement. Through the method, the reliability of electromechanical product equipment can be effectively improved, and the equipment failure rate and the later maintenance cost can be reduced.

Description

Technical Field

[0001] This invention belongs to the field of aviation electromechanical systems and relates to a method for reliability design optimization of aviation electromechanical equipment. Background Technology

[0002] Aviation electromechanical products are highly coupled products that contain mechanical and electronic components in aviation equipment, primarily used in the main airborne systems of aircraft. The performance and reliability of these products directly affect the flight safety and technical performance of aviation equipment. As the reliability requirements for aviation electromechanical products become increasingly stringent, their lifespan can reach thousands or even tens of thousands of flight hours. Traditional reliability design methods often rely on experience, lack systematic simulation verification, and fail to consider failures of electromechanical products under extreme operating conditions, leading to unforeseen failure modes that may occur during actual operation. Summary of the Invention

[0003] The purpose of this invention is:

[0004] This invention provides a reliability design optimization method for aviation electromechanical equipment. It identifies hidden failure modes by combining simulation and testing, and optimizes the design scheme to ensure high reliability of the equipment.

[0005] The technical solution of this invention is:

[0006] The present invention solves the above problems by means of the following method:

[0007] The reliability design optimization method for aviation electromechanical equipment involves establishing a mechanical 3D model and a hardware 3D model of the equipment after the design scheme is formed during the design phase. These two 3D models are then integrated to form a complete 3D model of the equipment. The 3D model is imported into Ansys software, inputting environmental stresses for both the mechanical and hardware components. Reliability simulation is then performed. If the reliability indicators are not met, design weaknesses are identified based on failure modes, and design improvements are made before further reliability simulation. If the simulation passes, trial production of prototypes is initiated. The produced equipment undergoes high-accelerated life testing and high-accelerated stress testing. If the equipment fails the tests, the design scheme is improved; if it passes the tests, mass production commences.

[0008] The mechanical 3D model includes component material information and mechanical transmission links; the 3D model must be free of defects, continuous and complete, and the assembly relationship of parts must be accurate, without any interference or misalignment of parts. For printed circuit boards with cold plates or reinforcing ribs, the cold plates and reinforcing ribs must be consistent with the actual situation. The component material information must be clearly and accurately established in the 3D model.

[0009] The hardware 3D model includes circuits, solder joints, and electronic components. In the hardware 3D model, the actual geometry and material parameters of the printed circuit board are modeled. Printed circuit boards with local special treatments are consistent with the actual situation. At the same time, the connection features in the printed circuit board are clear, which can simplify it into a uniform solid, and the thermal conductivity is equivalently treated.

[0010] The environmental stresses on the mechanical parts include temperature, humidity, and vibration.

[0011] The environmental stresses on the hardware include temperature, single-particle interference, and heat dissipation environment.

[0012] The reliability simulation includes thermal simulation, vibration simulation, fault prediction simulation, and durability simulation of electromechanical equipment.

[0013] The reliability simulation work requires model verification after the test piece is manufactured to ensure the accuracy of the model, including correction parameters, material parameters, structural parameters, damping parameters, device power consumption, equivalent thermal resistance, and material equivalent thermal conductivity.

[0014] The high-accelerated life test and high-accelerated stress test should gradually apply pressure until the product fails. The failed product should be temporarily modified to repair the fault. Pressure should be gradually applied again until the product fails again. Then the fault should be repaired again. This process of gradually applying pressure-failure-repair should be repeated until the basic operating limit and destructive limit of the product are found.

[0015] The pressure source is the environment and cyclic load.

[0016] The advantages of this invention are:

[0017] 1) By establishing a three-dimensional model and conducting reliability simulation tests, failure modes that were not considered in the design phase can be identified and resolved in advance;

[0018] 2) Effectively reduce R&D costs and identify and resolve equipment design defects as early as possible;

[0019] 3) It can identify the design limits of the equipment and the failure modes of the equipment under extreme conditions, and effectively improve the reliability of the product through design improvements.

[0020] 4) This method can effectively improve the reliability of electromechanical products and equipment, reduce equipment failure rate and subsequent maintenance costs. Attached Figure Description

[0021] Figure 1 Flowchart of reliability design optimization method for aircraft electromechanical equipment. Detailed Implementation

[0022] The present invention will be further described below with reference to the accompanying drawings:

[0023] The reliability design optimization method for aviation electromechanical equipment involves establishing a mechanical 3D model and a hardware 3D model of the equipment after the design scheme is formed during the design phase. These two 3D models are then integrated to form a complete 3D model of the equipment. The 3D model is imported into Ansys software, inputting environmental stresses for both the mechanical and hardware components. Reliability simulation is then performed. If the reliability indicators are not met, design weaknesses are identified based on failure modes, and design improvements are made before further reliability simulation. If the simulation passes, trial production of prototypes is initiated. The produced equipment undergoes high-accelerated life testing and high-accelerated stress testing. If the equipment fails the tests, the design scheme is improved; if it passes the tests, mass production commences.

[0024] The mechanical 3D model includes component material information and mechanical transmission links; the 3D model must be free of defects, continuous and complete, and the assembly relationship of parts must be accurate, without any interference or misalignment of parts. For printed circuit boards with cold plates or reinforcing ribs, the cold plates and reinforcing ribs must be consistent with the actual situation. The component material information must be clearly and accurately established in the 3D model.

[0025] The hardware 3D model includes circuits, solder joints, and electronic components. In the hardware 3D model, the actual geometry and material parameters of the printed circuit board are modeled. Printed circuit boards with local special treatments are consistent with the actual situation. At the same time, the connection features in the printed circuit board are clear, which can simplify it into a uniform solid, and the thermal conductivity is equivalently treated.

[0026] The environmental stresses on the mechanical parts include temperature, humidity, and vibration.

[0027] The environmental stresses on the hardware include temperature, single-particle interference, and heat dissipation environment.

[0028] The reliability simulation includes thermal simulation, vibration simulation, fault prediction simulation, and durability simulation of electromechanical equipment.

[0029] The reliability simulation needs to be verified after the prototype is manufactured to ensure the accuracy of the model, including correction parameters, material parameters, structural parameters, damping parameters, device power consumption, equivalent thermal resistance, and material equivalent thermal conductivity.

[0030] The high-accelerated life test and high-accelerated stress test should gradually apply pressure sources (environmental, cyclic load) until the product fails. The failed product should be temporarily modified to repair the fault. Pressure should be gradually applied again until the product fails again. Then the fault should be repaired again. This process of gradually applying pressure-failure-repair should be repeated until the basic operating limit and destructive limit of the product are found.

Claims

1. A reliability design optimization method for aircraft electromechanical equipment, characterized in that, After the design scheme is formed during the design phase of aviation electromechanical equipment, a mechanical 3D model and a hardware 3D model of the aviation electromechanical equipment are established based on the design scheme. The two 3D models are then integrated to form a complete 3D model of the electromechanical equipment. The 3D model of the electromechanical equipment is imported into Ansys software, and the environmental stress of the mechanical part and the environmental stress factor of the hardware part are input. Reliability simulation of the electromechanical equipment is performed. If the reliability index is not met, the design weaknesses are identified according to the failure mode, and the design is improved before reliability simulation is performed again. If it passes, trial production of the prototype is carried out. The trial-produced equipment is subjected to high-accelerated life test and high-accelerated stress test. If the equipment fails the test, the design scheme is improved. If it passes the test, mass production is carried out.

2. The reliability design optimization method for aviation electromechanical equipment according to claim 1, characterized in that, The mechanical 3D model includes component material information and mechanical transmission links; the 3D model must be free of defects, continuous and complete, and the assembly relationship of parts must be accurate, without any interference or misalignment of parts. For printed circuit boards with cold plates or reinforcing ribs, the cold plates and reinforcing ribs must be consistent with the actual situation. The component material information must be clearly and accurately established in the 3D model.

3. The reliability design optimization method for aviation electromechanical equipment according to claim 1, characterized in that, The hardware 3D model includes circuits, solder joints, and electronic components. In the hardware 3D model, the actual geometry and material parameters of the printed circuit board are modeled. Printed circuit boards with local special treatments are consistent with the actual situation. At the same time, the connection features in the printed circuit board are clear, which can simplify it into a uniform solid, and the thermal conductivity is equivalently treated.

4. The reliability design optimization method for aviation electromechanical equipment according to claim 1, characterized in that, The environmental stresses on the mechanical parts include temperature, humidity, and vibration.

5. The reliability design optimization method for aviation electromechanical equipment according to claim 1, characterized in that, The environmental stresses on the hardware include temperature, single-particle interference, and heat dissipation environment.

6. The reliability design optimization method for aviation electromechanical equipment according to claim 1, characterized in that, The reliability simulation includes thermal simulation, vibration simulation, fault prediction simulation, and durability simulation of electromechanical equipment.

7. The reliability design optimization method for aircraft electromechanical equipment according to claim 1, characterized in that, The reliability simulation work requires model verification after the test piece is manufactured to ensure the accuracy of the model, including correction parameters, material parameters, structural parameters, damping parameters, device power consumption, equivalent thermal resistance, and material equivalent thermal conductivity.

8. The reliability design optimization method for aircraft electromechanical equipment according to claim 1, characterized in that, The high-accelerated life test and high-accelerated stress test should gradually apply pressure until the product fails. The failed product should be temporarily modified to repair the fault. Pressure should be gradually applied again until the product fails again. Then the fault should be repaired again. This process of gradually applying pressure-failure-repair should be repeated until the basic operating limit and destructive limit of the product are found.

9. The reliability design optimization method for aircraft electromechanical equipment according to claim 8, characterized in that, The pressure source is the environment and cyclic load.

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