基于失效模式和动态贝叶斯网络的数控机床可靠性分析

doi:10.13229/j.cnki.jdxbgxb.20240052

Abstract

Abstract:

In order to solve the complex problem of reliability analysis of CNC machine tool system， this paper combines the failure mode influence and hazard analysis method with the dynamic Bayesian network to establish a reliability analysis model. Firstly， the failure causes， failure modes and main fault parts of CNC machine tools were analyzed， and the risk assessment of the failure causes was carried out in combination with expert opinions. Then， based on the failure mode table and fault data of the CNC machine tool， the structure and parameters of the dynamic Bayesian network reliability model were constructed. The state change of the system， the importance of the faulty parts， the importance of the subsystem and the state changes of each component are analyzed by the model， and the results of the model analysis are compared with the traditional Monte Carlo method.

Key words: mechanical design, CNC machine tools, reliability analysis, failure mode impact and hazard analysis, dynamic Bayesian networks

CLC Number:

TG659

Xian-zhen HUANG,Chao LI,Chao SUN,Kai-hui QIU. Reliability analysis of CNC machine tools based on failure modes and dynamic bayesian networks[J].Journal of Jilin University(Engineering and Technology Edition), 2025, 55(11): 3534-3543.

Figures/Tables 13

Table 1

Table 2

Failure modes of main parts of CNC machine tools"

编号	故障模式	编号	故障模式	编号	故障模式	编号	故障模式
FM1	床身断裂	FM26	编码器报警	FM51	滚珠丝杠润滑不良	FM76	液压泵泄压
FM2	床身变形	FM27	皮带松动	FM52	滚珠丝杠副噪声	FM77	润滑油泵压力不足
FM3	立柱断裂	FM28	皮带断裂	FM53	滚珠丝杠不灵活	FM78	润滑泵吸油不足
FM4	立柱变形	FM29	皮带磨损	FM54	刀架不出水	FM79	分油环漏油
FM5	底座破裂	FM30	漏油	FM55	刀架漏水	FM80	冷却泵底座漏水
FM6	底座变形	FM31	无法装夹	FM56	刀架冷却漏水	FM81	冷却泵不上水
FM7	导轨松动	FM32	夹紧机构松动	FM57	编码器松动	FM82	冷却水管漏水
FM8	导轨磨损	FM33	夹紧机构磨损	FM58	编码器损坏	FM83	液位报警
FM9	主轴箱铸造缺陷	FM34	锁紧油缸漏油	FM59	刀架不转位	FM84	排屑器不转
FM10	主轴箱刚度不足	FM35	锁紧部位松动	FM60	刀架转不停	FM85	排屑器卡死
FM11	主轴箱定位孔精度低	FM36	卡盘无动作	FM61	刀架转不到位	FM86	接屑车漏水
FM12	主轴定位故障	FM37	卡盘无法夹紧	FM62	刀架锁不紧	FM87	电机烧坏
FM13	主轴发热过大	FM38	卡盘无动作	FM63	换刀卡住	FM88	电机运转不稳
FM14	主轴噪声过大	FM39	卡盘压力无法调节	FM64	刀具交换时掉刀	FM89	显示器无图像
FM15	主轴停转	FM40	电机损坏	FM65	刀架报警	FM90	显示器无响应
FM16	主轴无变速	FM41	电机线路故障	FM66	刀架不反转只正转	FM91	元件松动
FM17	轴承磨损	FM42	液压套筒无动作	FM67	刀架不定位	FM92	线路、电路短路
FM18	轴承过度发热	FM43	顶尖顶不紧	FM68	电气控制箱故障	FM93	线路接错
FM19	轴承零件损坏	FM44	台尾油路漏油	FM69	线路断开或松脱	FM94	防护门紧
FM20	密封圈腐蚀	FM45	压力不稳定	FM70	滑阀卡住	FM95	防护门卡死
FM21	密封圈磨损	FM46	电机噪声大	FM71	电磁铁故障	FM96	防护门合不上
FM22	密封圈物理失效	FM47	同步带轮裂纹	FM72	电磁铁响声大	FM97	防护罩脱落
FM23	锁紧螺母断裂	FM48	工件出现波纹	FM73	游标漏油	FM98	防护罩漏水
FM24	锁紧螺母腐蚀	FM49	工件加工误差大	FM74	液压油泄露
FM25	锁紧螺母疲劳	FM50	加工工件粗糙度高	FM75	异常噪声、振动

Table 2

Fig.1

Fig.2

Fig.3

Fig.4

Fig.5

Fig. 6

Fig.7

Fig.8

Table 3

Fig.9

Table 4

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系统		零部件
代码	名称	代码	名称	代码	名称	代码	名称	代码	名称
JCS	基础系统	CS	床身	LZ	立柱	DZ	底座	DG	导轨
ZS	主传动系统	ZZX	主轴箱	ZZ	主轴	ZC	滚动轴承	MFQ	密封圈
		SJ	锁紧螺母	GZC	钢栅尺	PD	皮带	DJ1	电机
		YG	油管	LM	螺帽	LG	拉杆	YGT	油缸
		KP	卡盘
TYS	台尾系统	TWY	台尾液压组件	TT	套筒	DJ	顶尖
JJS	进给系统	SF	伺服电机	DL	同步带轮	ZC	轴承	SG	丝杠
DJS	刀架系统	LQG	冷却管路	GJT	管接头	BMQ	编码器	SFDJ	伺服刀架
DJS	刀架系统	DCF	电磁阀
DQS	电气系统	DC	电气控制箱	XL	线路
YYS	液压系统	YDCF	电磁阀	YB	游标	YYB	液压泵
RHS	润滑系统	FYH	分油环	RHB	润滑泵
LQS	冷却系统	YWJ	液位计	LQSG	冷却水管	LQB	冷却水泵
PXS	排屑系统	PXQ	排屑器	JXC	接屑车	DDJ	电动机
SKS	数控系统	XSZ	显示装置	DB	底板	DYB	电源板	ZXB	总线板
FHS	防护系统	FHM	防护门	FHZ	防护罩

可靠度	MC方法	FMECA-DBN	相对误差/%
R（0）	1	1	0.00
R（1）	0.803 922	0.803 848 8	0.01
R（2）	0.601 295	0.600 746 1	0.09
R（3）	0.429 012	0.429 308 2	0.07
R（4）	0.295 428	0.295 915 0	0.16
R（5）	0.197 395	0.197 676 7	0.14
R（6）	0.128 258	0.128 378 4	0.09
R（7）	0.081 126	0.081 236 8	0.14
R（8）	0.050 201	0.050 174 5	0.05
R（9）	0.030 408	0.030 288 4	0.39

系统名称	DBN方法	排序	Birnbaum	排序
基础系统	0.085 158	4	0.820 053	4
主传动系统	0.343 620	1	0.861 945	1
台尾系统	0.035 229	9	0.809 442	9
进给系统	0.048 344	8	0.811 545	8
刀架系统	0.188 817	2	0.834 766	2
电气系统	0.004 209	12	0.804 513	12
液压系统	0.151 712	3	0.828 504	3
润滑系统	0.052 487	7	0.812 211	7
冷却系统	0.028 983	10	0.808 445	10
排屑系统	0.027 211	11	0.808 162	11
数控系统	0.064 734	5	0.814 187	5
防护系统	0.062 316	6	0.813 796	6

Reliability analysis of CNC machine tools based on failure modes and dynamic bayesian networks

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