Function oriented belief reliability design and optimization of new torsion spring electrical connectors
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摘要:
新产品正向设计需综合考虑新结构工艺、多设计变量、复杂工作环境的影响,并合理量化不确定性影响,评估可靠性水平,从而在源头上确保高可靠性。基于确信可靠性理论,研究了基于性能裕量的确信可靠性正向设计优化方法。提出了面向新型扭簧电连接器研发的确信可靠性正向设计优化基本流程,包括设计变量初值优选、性能裕量建模、不确定性量化和确信可靠性分析与优化4部分。以某新型扭簧电连接器的正向设计为例,基于正交实验、响应面建模和模拟退火启发式优化等方法实现了多维离散-连续变量及其不确定性作用下的优化设计。
Abstract:To evaluate reliability of new products, function-oriented design should comprehensively consider the influence of new structure and technology, multiple design variables, and complex working environments, and reasonably quantify uncertainty effects. This will ensure high reliability from the original design. Based on the belief reliability theory, this study investigates a performance margin-based and function-oriented method for belief reliability design and optimization. The basic procedure of the function-oriented reliability design is proposed for the development of new torsion spring electrical connectors, which includes four steps, i.e., initial value selection of design variables, performance margin modeling, uncertainty quantification, and reliability analysis and optimization. This procedure is exemplified in the design and development of a new type of torsion spring electrical connector. The optimal design of multidimensional discrete-continuous variables under the influence of their uncertainties is realized based on orthogonal experiments, response surface modeling, and simulated annealing heuristic optimization.
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表 1 内因变量分析
Table 1. Analysis of endogenous variables
序号 影响因素 变量类型 水平数 水平 1 加工工艺 D 2 工艺A、工艺B 2 粗糙度Ra D 3 0.8、1.6、3.2 3 镀层材料 D 3 金、银、镍 4 插针材料 D 3 T2紫铜、碲铜、H62 5 孔套材料 D 3 T2紫铜、碲铜、H62 6 扭簧材料 D 3 C17410、C17510、QBe2.0 7 扭簧材料厚度δ D 2 0.2 mm、0.25 mm 8 扭转角θ C 3 45°、50°、55° 9 格栅间距s C 3 0.6 mm、0.7 mm、0.8 mm 10 插针外径dp C 3 3.57 mm、3.60 mm、3.63 mm 11 扭簧基圆直径ds C 3 3.75 mm、3.80 mm、3.85 mm 12 孔套内径dh C 3 2δ+{3.75, 3.80, 3.85} mm 13 格栅长度l C 3 7.25 mm、9.25 mm、11.25 mm 表 2 确定最优设计变量初值
Table 2. Determination of optimal initial values
序号 内因变量 数值特征 初步优选水平 是否变更 水平变更 1 加工工艺 D 工艺A √ 工艺B 2 粗糙度Ra D 0.8 3 镀层材料 D 金 4 插针材料 D T2 5 孔套材料 D 碲铜 6 扭簧材料 D C17410 7 扭簧材料厚度δ D 0.2 mm 8 扭转角θ C 55° √ 65 mm 9 格栅间距s C 0.6 mm 10 插针外径dp C 3.63 mm √ 3.57 mm 11 扭簧基圆直径ds C 3.75 mm 12 孔套内径dh C 2δ+3.75 mm √ 4.2 mm 13 格栅长度l C 7.25 mm 表 3 响应面采样点
Table 3. Sampling points of response surface
变量 采样边界 -1 1 扭转角θ/(°) 55 75 格栅间距s/mm 0.5 0.9 插针外径dp/mm 3.57 3.60 扭簧基圆直径ds/mm 3.75 3.80 孔套内径dh/mm 4.2 4.25 格栅长度l/mm 5.25 9.25 电流Ii2/A2 1 600 4 900 环境温度Te/℃ -40 150 表 4 随机变量的分布
Table 4. Distribution of random variables
变量 分布 均值μ 标准差σ 随机扰动ε Φε 0 5.35℃ 扭簧基圆直径ds Φds μds 0.001 mm 扭转角θ Φθ μθ 4° 孔套内径dh Φdp μdp 0.01 mm 格栅间距s Φs μs 0.01 mm 电流Ii ΦI μI 0.05μI/3 A 环境温度Te ΦTe μTe 5/3℃ 温升阈值ΔTth ΦΔTth E[ΔTth(I, Te)] 表 5 确信可靠度优化结果
Table 5. Results of belief reliability optimization
变量 取值范围 正向设计优化 初值X0 优化值Xopt 扭簧基圆直径ds/mm [3.75, 3.80] 3.75 3.773 扭转角θ/(°) [55,75] 65 73.87 孔套内径dh/mm [4.20, 4.25] 4.2 4.202 格栅间距s/mm [0.5, 0.9] 0.6 0.5 确信可靠度理论值R 0.978 5 0.994 7 -
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