Accelerated Reliability and Durability Testing Technology

421 Pages·2012·3.183 MB·English

by  Lev M. Klyatis

ACCELERATED RELIABILITY
AND DURABILITY
TESTING TECHNOLOGY
WILEY SERIES IN SYSTEMS ENGINEERING AND
MANAGEMENT
Andrew P. Sage, Editor
A complete list of the titles in this series appears at the end of this volume.
ACCELERATED RELIABILITY
AND DURABILITY
TESTING TECHNOLOGY
LEV M. KLYATIS
Professor Emeritus
Habilitated Dr.-Ing., Dr. of Technical Sciences, Ph.D.
A JOHN WILEY & SONS, INC., PUBLICATION
Copyright © 2012 by John Wiley & Sons, Inc. All rights reserved.
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Library of Congress Cataloging-in-Publication Data:
Klyatis, Lev M.
Accelerated reliability and durability testing technology / Lev M. Klyatis.
p. cm. – (Wiley series in systems engineering and management)
ISBN 978-0-470-45465-7 (cloth)
1. Reliability (Engineering) 2. Accelerated life testing. I. Title.
TS173.K63 2009
620'.00452–dc22
2009017252
Printed in Singapore.
10 9 8 7 6 5 4 3 2 1
To My Wife Nellya Klyatis
Contents
Preface xi
About the Author xvii
1 Introduction 1
1.1 The Purpose of Accelerated Testing (AT) 1
1.2 The Current Situation in AT 2
1.3 Financial Assessment of the Risks Involved in Creating
a Testing Program 23
1.4 Common Principles of ART and ADT 26
1.5 The Level of Usefulness of ART and ADT 32
Exercises 40
2 Accelerated Reliability Testing as a Component of an
Interdisciplinary System of Systems Approach 43
2.1 Current Practice in Reliability, Maintainability,
and Quality 43
2.2 A Description of the Product/Process Reliability and Durability
as the Components of the Interdisciplinary SoS Approach 48
2.3 The Collection and Analysis of Failure and Usage
Data from the Field 51
2.4 Field Input Infl uences 57
2.5 Safety Problems as a Component of the Field Situation 58
2.6 Human Factors as a Component of the Field Situation 60
2.7 The Interconnection of Quality and Reliability 67
vii
viii CONTENTS
2.8 The Strategy to Integrate Quality with Reliability 69
2.9 The Place of ART/ADT in High Quality, Reliability,
Maintainability, and Durability 75
Exercises 77
3 The Basic Concepts of Accelerated Reliability
and Durability Testing 81
3.1 Developing an Accurate Simulation of the Field Situation
as the Basic Component of Successful Accelerated Reliability
Testing (ART) and Accelerated Durability Testing (ADT) 81
3.2 Conceptual Methodology for the Substantiation of a
Representative Region for an Accurate Simulation of
the Field Conditions 91
3.3 Basic Procedures of ART and ADT 97
3.4 ART and LCC 115
Exercises 122
4 Accelerated Reliability and Durability Testing Methodology 125
4.1 Analysis of the Current Situation 125
4.2 Philosophy of ART/ADT 131
4.3 ART/ADT Methodology as a Combination of
Different Types of Testing 134
4.4 Accelerated Multiple Environmental Testing 141
4.5 Accelerated Corrosion Testing 149
4.6 Technology of Advanced Vibration Testing 185
4.7 Field Reliability Testing 191
4.8 Trends in the Development of ART/ADT Technology 191
Exercises 195
5 Equipment for Accelerated Reliability (Durability)
Testing Technology 199
5.1 Analysis of the Current Situation with Equipment
for Accelerated Reliability (Durability) Testing 199
5.2 Combined Equipment for ART/ADT as a Combination
(Integration) of Equipment for Different Types of Testing 207
5.3 Consideration of Components for ART/ADT and Combined
(Integrated) Equipment Testing 209
5.4 Equipment for Mechanical Testing 231
5.5 Equipment for Multi-environmental Testing
and Its Components 264
CONTENTS ix
5.6 Equipment for Electrical Testing 315
Exercises 316
6 Accelerated Reliability and Durability Testing as a Source of Initial
Information for Accurate Quality, Reliability, Maintainability, and
Durability Prediction and Accelerated Product Development 321
6.1 About Accurate Prediction of Quality, Reliability,
Durability and Maintainability 321
6.2 The Strategy for Accurate Prediction of Reliability, Durability,
Maintainability and Quality, and Accelerated Product
Development 323
6.3 The Role of ART and ADT in the Accurate Prediction
and Accelerated Development of Quality, Reliability,
Maintainability, and Durability 349
Exercises 350
7 The Financial and Design Advantages of Using Accelerated
Reliability/Durability Testing 353
Exercises 357
8 Accelerated Reliability Testing Standardization 359
8.1 Overview and Analysis 359
8.2 IEC Standards 362
8.3 ISO Standards 367
8.4 Military Reliability Testing Standards and
Appropriate Documents 367
8.5 Standardization in Reliability (Durability) Testing
by Societies 370
Conclusions 373
Common Conclusions 373
Specifi c Conclusions 373
Glossary of Terms and Defi nitions 375
References 393
Index 407
Preface
In 2009 – 2010, Toyota experienced an increase in global recalls jumping to
8.5 million cars and trucks [1] . Similar situations have occurred and could
happen again to other automakers as well as to companies in other industries.
Toyota can have similar problems in the future as well. The basic reason behind
many recalls and complaints, as well as higher cost and time for maintenance
and life cycle cost than was predicted during design and manufacturing is the
inaccurate prediction of the product ’ s reliability, durability, and quality during
design and manufacturing. Predictions may be inaccurate due to the lack of
proper accelerated reliability testing (ART) and accelerated durability testing
(ADT) as a source of initial information for the prediction.
The focus of this book is to show multiple applications of the technology
(methodology and equipment) that provide physically ART and ADT of an
actual product in a way that represents the real world ’ s many product infl uenc-
ing interactions.
Integrated global solutions for many engineering problems in quality, safety,
human factors, reliability, maintainability, durability, and serviceability were
not available in the past. One of the basic reasons for this design defi ciency
was the inability to solve a fundamentally important problem — accelerated
reliability (durability) testing. ART and ADT provide an integrated solution
that will positively infl uence product development time, cost, quality, design,
and effective product/process. The context for this treatise is an industrial
product design and development. This approach applies to the development
of a large number of products and processes such as, for example, in the con-
sumer goods, industrial, producer, medical, banking, pharmaceutical, teaching,
and military factors.
The weakness of prior accelerated testing approaches such as vibration
testing, corrosion testing, step - stress testing, thermoshock testing, highly accel-
xi
xii PREFACE
erated life testing ( HALT ), highly accelerated stress screening ( HASS ), accel-
erated aging, mechanical crack propagation and growth, and environmental
stress screening ( ESS ) was the result of inappropriately using only a few of
the infl uencing factors and using these factors in isolation. Such testing
improved the design in a one - dimensional way but failed to provide the
needed global optimum solution formed by combining the many complex
factors in a systematically integrated approach. These types of individually
conducted tests do not provide suffi cient information for the accurate predic-
tion of the interval product/process degradation and failures. The complex
interaction of these factors with the multitude of real - world factors is not
considered.
Hence, the results are potentially (and usually) misleading. Such suboptimal
solutions cannot accurately account for the global impact of complicated
interactions that result in delays in development, time to market, and in
increased costs related to
• Design time and result
• Customer satisfaction and expense
• Maintenance frequency, cost, and access
• Warranty costs and recalls
• Degradation of product/process over time
• Failures during time intervals and warranty periods
• Quality requirements and indices
• Product safety
• Human factors
Many people seek to artifi cially increase the value of limited testing by
including the word “ durability ” in the title (e.g., “ Vibration Durability Testing ” ).
Vibration testing is not suffi cient for the evaluation or prediction of product
durability. Vibration testing is only one of many components of mechanical
testing as a part of complicated durability testing. Vibration testing alone is
not suffi cient for accelerated development predictions for reliability, maintain-
ability, and durability improvement or for solving many other related
problems.
ART or ADT based on a combination of many types of accelerated tests
(fi eld, laboratory, multi - environment, mechanical, electrical, etc.) integrated
with safety and human factors helps to solve the identifi ed problems. ART and
ADT both use an accurate simulation of a fi eld environment. Chapter 1
describes this phenomenon.
What is technology? Technology is often a generic term to encompass all
the technologies people develop and use in their lives. The United Nations
Education, Social and Cultural Organization ( UNESCO ) defi nes technology
as “ . . . the know - how and creative processes that may assist people to utilize
tools, resources and systems to solve problems and to enhance control over