某自主化紧急电磁阀可靠性与寿命研究
都占江陶富文
Reliability and Life Research of Certain Autonomous Emergency Solenoid Valve
DU ZhanjiangTAO Fuwen
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作者信息:南京中车浦镇海泰制动设备有限公司， 211800， 南京
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Affiliation:Nanjing CRRC Puzhen Haitai Brake Equipment Co., Ltd., 211800, Nanjing, China
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关键词:
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Key words:
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DOI:10.16037/j.1007－869x.20241549
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中图分类号/CLCN:U270.35
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栏目/Col:车辆制造与列车控制
摘要:
［目的］为实现紧急电磁阀的自主可控与安全应用，针对自主化紧急电磁阀开展可靠性与加速寿命试验研究，通过试验结果与失效分析改进现有设计，并验证其寿命性能。［方法］采用FMMEA（故障模式、机理与影响分析）方法分析电磁阀的失效模式、机理及敏感应力；通过HALT（高加速寿命试验）确定电磁阀的工作极限及与进口件的性能差距；基于Weibull（威布尔）分布和Arrhenius（阿伦尼乌斯）模型的ALT（加速寿命试验）评估电磁阀寿命特征；结合故障件失效分析结果，提出设计改进方案并重新验证寿命特征。［结果及结论］FMMEA分析表明，电磁阀的关键失效部件为止回阀与密封圈，主要敏感应力为温度与电应力；HALT结果显示，自主化电磁阀的高温性能与进口件相当，但低温性能存在差距（极限温度为-40℃ vs. -60℃）；初始ALT试验表明，电磁阀激活能为0.59 eV，等效寿命为5.97年，无法满足动车组要求（7.5年）。通过失效分析发现止回阀硫化橡胶铜粉含量（应由60%降至5%）及工艺缺陷是主要失效原因，改进后再次ALT验证显示，等效寿命提升至10.83年，显著超过地铁（6.0年）与动车组（7.5年）的寿命要求，为自主化电磁阀的工程应用提供了可靠依据。
Abstracts:
［Objective］ To achieve the autonomous control and safe application of emergency solenoid valves, a reliability and accelerated life test research on autonomous emergency solenoid valves is carried out. The existing design is improved through test results and failure analysis, and its life performance is verified. ［Method］ FMMEA (failure mode, mechanism, and effects analysis) method is used to analyze the failure mode, mechanism, and sensitive stress of solenoid valve; Working limits of the solenoid valve and the performance gap with imported parts are determined through HALT (highly accelerated life testing); Life characteristics of the solenoid valve is evaluated based on Weibull distribution and ALT (accelerated life testing) of Arrhenius model; Combined with the failure analysis results of the faulty parts, a design improvement plan is proposed and the life characteristics are re-verified. ［Result & Conclusion］ FMMEA analysis shows that the key failure components of the solenoid valve are the check valve and the sealing ring, and the main sensitive stresses are temperature and electrical stress; HALT results show that the high-temperature performance of the autonomous solenoid valve is comparable to that of imported parts, but there is a gap in low-temperature performance (with a limit temperature of -40 ℃ vs. -60 ℃); The initial ALT test shows that the activation energy of the solenoid valve is 0.59 eV, with an equivalent lifespan of 5.97 years, failing to meet EMU requirements (7.5 years). Through failure analysis, it is found that the content of vulcanized rubber copper powder in the check valve (it should be reduced from 60% to 5%) and process defects are the main causes of failure. After improvement, the re-verification of ALT shows that the equivalent life is increased to 10.83 years, significantly exceeding the life requirements of subway (6.0 years) and EMU (electric multiple units) (7.5 years), this provides a reliable basis for the engineering application of autonomous solenoid valves.
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