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Reliability Approach Mecharonics
Reliability Approach Mecharonics
Reliability Approach Mecharonics
MCTR 701_1
Master Advanced Mechatronics
Lecturers : Luc Marechal, Christine Barthod, Georges Habchi
Mechatronics
common framework
Lecture 2 1
Mechatronics common framework Luc Marechal
MCTR 701_1 | 2021
Lecture 2 2
Contents
Lecture 2
PROCESS
Application to the two industrial
examples previously described
Contents
• Objectives
• Issues
• Preliminary steps to the implementation of the approach
• Mechatronic system
• Bibliographic review (state of the art)
• Conclusions
• Improvement areas
Mechatronics common framework Luc Marechal
MCTR 701_1 | 2021
Lecture 2 4
Definitions
• ISO 9004:2008
• Total Quality Management (TQM)
• Statistical
• Process control
• Six Sigma
• Quality Function Deployment (QFD)
• Quality Circle,
• Taguchi method
• ….
Mechatronics common framework Luc Marechal
MCTR 701_1 | 2021
Lecture 2 5
Definitions
Definitions
• Corrective Maintenance: carried out after fault recognition to put an entity into a state in which it can
perform a required function.
• Preventive Maintenance: carried out at predetermined intervals or according to prescribed criteria and
intended to reduce the probability of failure or the degradation of the functioning of an entity.
Definitions
Uptime depends on reliability of the system where as downtime depends on maintainability of the system.
Definitions
Failures
Failure is inevitable for engineering systems.
Impact of failures :
• minor inconvenience and costs
• personal injury
• significant economic loss
Fukushima
• environmental impact Space X
• deaths Chernobyl accident
Bhopal gas tragedy
space shuttle Columbia disaster
Cause of failure :
• bad engineering design
• faulty manufacturing
• inadequate testing
• human error
• poor maintenance
• lack of protection against excessive stress
Mechatronics common framework Luc Marechal
MCTR 701_1 | 2021
Lecture 2 G. Habchi
/ 10
Classification of failures
It is essential :
• to understand ‘why’ and ‘how’ failures occur to minimize them
• to know how often such failures may occur
Markov
• Neither different functioning phasis, nor the mission profile and the
influent factors are taken into account
• The physical and functional interactions created between the
different technological parts are not studied
• No estimation of the global reliability
Mechatronics common framework Luc Marechal
MCTR 701_1 | 2021
Lecture 2 15
Design
Complete specifications
Reliability objectives
Reliability data concerning the components of the system and that are
not available in database
Example to illustrate
Smart actuator
Specifications
In addition to be a classical actuator, the smart actuator assume additional
functions such as operating, monitoring, communicating, data processing, etc.
Overall plan
Physical implementation
of the circuit board
Mechatronics common framework Luc Marechal
MCTR 701_1 | 2021
Lecture 2 20
specification
• Objectives
Describes:
• Mission profile
The expected funtion for each phasis of the profile
The reactive functions to take into account the environment
1. External The contraints imposed by the users
Functional
Analysis To write the Functional Specification
constraints
• Interactions between
the system and its
environment
Mechatronics common framework Luc Marechal
MCTR 701_1 | 2021
Lecture 2 21
Mission profile
Mission profile
temperature (°C)
100
temperate, hot 60
40
20
cold
0
1 an
0 5 10 15 20 25 2 ans 30
CF3
Electric power Standard
Function Criteria/Target Value/Information
Average number of opening/closing cycles before Legislation
10 million of cycles
the occurrence of a first failure (MTTF)
Desired lifetime 10 years
MF Intermittent operation
Electric power: 1 slot ON-OFF/60 ms
Operating information Duration of an opening/closing cycle: 40 ms
Time between two cycles: 1.67 s MF: Allows wagon shutter opening when the
Operation time 20 h/24, 6 days/7 wagon arrives at the unloading station,
Temperature and duration of the hot phase 120°C for 2/12 of cycles
CF1 Temperature and duration of the cold phase 5°C for 4/12 of cycles CF1: Withstands the thermal environment,
Temperature and duration of the temperate phase 70°C for 2 times 3/12 of cycles
CF2 Electric power and voltage 10 W and 24 V +/- 5% CF2: Works with the installed electrical power,
Low Voltage Directive: NSC 20-030
CF3 Meet the legislation requirements Directive clean machine (Example: Noise CF3: Meets the requirements of legislation,
emitted by equipment NFEN 11201)
Degree of electrical protection: NFEN60529 CF4: Meets the normative standards requirements,
CF4 Meet the normative standard requirements
Noise emitted by equipment: NFEN 11201
Working order TOR function (1) CF5: Allows the master system to order operating
CF5
Stop order TOR function (0)
(ON/OFF).
Mechatronics common framework Luc Marechal
MCTR 701_1 | 2021
Lecture 2 24
F1: Supply F2: Supply F3: Control the movement of the spindle,
electric energy controlled voltage Diagnosis the operating state of the actuator
3. Organic Analysis
INPUTS
components,
• Interactions between the
components, Interfaces
Mechatronics common framework Luc Marechal
MCTR 701_1 | 2021
Lecture 2 27
Master system
sub1
Controlled Smart Actuator
Electric Micro-
Electric
Power controller
Power
Spring
Sub3= conditioning circuit board
sub2 Actuator body
Mechatronics common framework Luc Marechal
MCTR 701_1 | 2021
Lecture 2 28
4. Physical Implementation
• Sub-systems
INPUTS
• Components
• Interactions Innovative
Supplementary step proposed compared to
• Interfaces approach
a conventional design approach
5. Dysfonctional Analysis
• Specifications
• Failure history Identifies failure modes and rank them according to
INPUTS
FMEA is a widely used method for analyzing the reliability of engineering systems
Description
• describes inherent causes of events that lead to system failure,
• determines their consequences
• formulates methods to minimize their occurrence or recurrence.
• allows identifying the critical elements of security and dormant faults.
Mechatronics common framework Luc Marechal
MCTR 701_1 | 2021
Lecture 2
Interactions matrix
Subsystem 1 Subsystem 2
Acts on Comp 1 Comp 2 Comp 3 Comp i Comp k Comp n
Comp 1 UF BF
Subsystem
Comp 2
1
Comp 3
Comp i UC
Subsystem
Comp k BC UF
2
Comp n
7. Qualitative Modeling
• System internal functions
ENTREES • Interactions between the system
and its environment Models the functional and dysfunctional behavior
• System architecture
• FMEA
of the system and its components, taking into
account the interactions
7. Qualitative modeling
Modeling of both componants: guide bearing / coil
- Bearing wear
- Collateral interaction linked to the physical implementation guide bearing / coil
First failure mode, Second failure mode,
progressive and sudden and complete
Operating complete First failure mode,
bearing First failure mode, Operating sudden and
progressive and coil complete
partial
• Components
• Interactions between components
and between functions
• Interactions between the system and
its environment Gather the reliability data available on components
(database, experiment, simulation, expertise...)
• Parameters value
• Evolution laws of parameters vs
influence factors
• Evolution laws of parameters vs
interactions
Mechatronics common framework Luc Marechal
MCTR 701_1 | 2021
Lecture 2
Reliability
Technology Comments distribution and FIDES 2009
parameters (reliability database for
Known distribution and Exponential : electronic components)
Electronics parameters available in MTTF* or
Database l (failure rate)
FIDES database
Manufacturing
Process
Environment
Conditions of use
https://www.fides-reliability.org/
Mechatronics common framework Luc Marechal
MCTR 701_1 | 2021
Lecture 2
time
Youth Maturity Wear/Old age
𝒕−𝜸 𝜷
Weibull Distribution : 𝑹 𝒕 = 𝒆𝒙𝒑 [− ]
𝜼
b : shape parameter ; h : scale parameter ; g : position parameter
Mechatronics common framework Luc Marechal
MCTR 701_1 | 2021
Lecture 2
Reliability estimation
Example of data
Imagine that you have installed 10 identical light bulbs (same brand, same power...)
at the same time and that operate under identical conditions
A life test was performed on a lot of 6 loaded bearings under specific conditions and
the following results were recorded
Bearing N°# 1 2 3 4 5 6
Number of cycles at
400 000 130 000 980 000 270 000 660 000 520 000
break
Mechatronics common framework Luc Marechal
MCTR 701_1 | 2021
Lecture 2
Reliability estimation (8)
Use of Weibull model
Estimated reliability
curve for this type of
bearing
Mechatronics common framework Luc Marechal
MCTR 701_1 | 2021
Lecture 2
Taking into account the influent factors of the mission profile on FIDES
Two influent factors considered:
• Temperature
• Vibration Vibration Temperature (°C)
(Grms) 75 90 120 150 200
0,5
5 15 experiments have to be done Evolution of the failure rate for a measurement circuit
vs temperature and vibration
12
Temperature (°C)
Temperature (°C)
Mechatronics common framework Luc Marechal
MCTR 701_1 | 2021
Lecture 2 45
Cold
used method
• Types of results and desired
shape in terms of reliability for the
components and system
• Results
Pack’Aero Smart Actuator RBD
Advantages
• Simple and logical representation of how a system works
• Taking into account the mission profile in the characteristics of the
component
• Visualization of the mission carried out by the system
• Calculation time
Disadvantages
• Difficulty of taking into account multifunction elements (method must
be carried out in conjunction with an FMEA)
• Need to adapt the tool for a calculation of availability and
maintainability (repair)
Mechatronics common framework Luc Marechal
MCTR 701_1 | 2021
Lecture 2
analysis
• System reliability analysis
• Analysis of the effect of influencing
factors and interactions
• Comparison of objectives and results
• Proposal for improvement actions
Results of reliability
Reliability of the smart actuator and components phase/phase
Reliability of the smart actuator over the different phases of the mission profile / 10 years
Reliability of the smart actuator over the different phases of the mission profile / 10 years
Relevant books
Mechatronics common framework Luc Marechal
MCTR 701_1 | 2021
Lecture 2 57
Contact Information