Browse Topic: Reliability

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Accelerating Product Development Life Cycle through Digitalization of Fatigue Life for Structural Components2026-26-0496To be published on 01/16/2026
In today’s competitive market, accelerating product development without compromising durability is critical. Durability is a key benchmark for assessing the quality and reliability of automotive products. To meet rising customer expectations and regulatory demands, the industry must develop vehicles that offer high performance and reduced weight while ensuring safety. A well-engineered vehicle must retain structural integrity and functionality under normal operating conditions and withstand extreme load events without critical failure. Achieving this requires effective Road Load Data Acquisition (RLDA), integrated with robust design practices and efficient validation processes. However, physical RLDA is time-consuming and costly, as it depends on prototype vehicles that are often available only in the later development stages. Failures identified during these late-stage tests can delay the product launch significantly. To address these challenges, this paper introduces a digital
Kokare, Sanjay, Dwivedi, Sushil, Siddiqui, Arshad, Iqbal, Shoaib
Design Robustness of Electronic Locking Differential for enhanced off-road performance2026-26-0502To be published on 01/16/2026
The Electronic Locking Differential (ELD) is a critical component for enhancing off-road vehicle performance by ensuring optimal traction in challenging terrains. This paper addresses intermittent engagement issues observed in the ELD system during off-road trials, which impacted its reliability and functionality. It presents a comprehensive study of design robustness improvements implemented to resolve these concerns and optimize the ELD’s performance, ensuring enhanced customer satisfaction in demanding off-road environments. The analysis begins with identifying factors contributing to the intermittent engagement and disengagement of the ELD system upon actuation. These factors include residual magnetism, material properties, temperature effects, and the stack-up characteristics of transfer path components under various boundary conditions. To address these challenges, three key design modifications were introduced: (1) reduction of residual magnetism through an increased air gap
S, Mohd Imtiaz, AP, Baaheedharan, Ghumare, Dheeraj, Kanagaraj, Pothiraj, Jain, Saurabh Kumar
UNIQUE HYBRID PANORAMIC HEADLINER CLIP WITH HIGH TOLERANCE TO REPLACE DUAL LOCK FASTENERS2026-26-0299To be published on 01/16/2026
Mounting strategies for vehicles with panoramic sunroofs remains a challenge owing to its high complexity to balance cost, performance and assembly efficiency. Achieving efficient and reliable headliner mounting solutions is one of the conundrums where cost optimization must go together with uncompromised performance. Traditional methods like Dual Lock Fasteners (DLFs), have set high benchmarks for robustness but at the cost of increased manufacturing complexity and expense. In pursuit of a more economical and production-friendly alternative, various plastic clip designs were explored. However, these solutions posed significant challenges during validation due to the stringent requirements for mounting feasibility, tolerance management, and long-term durability This paper introduces a novel hybrid plastic-metal clip solution that addresses those challenges comprehensively. The new design achieves precise tolerance control, ensuring reliable headliner installation under varying Body-in
D, GOWTHAM, Kumarasamy, Raj Ganesh, Shoeb, Mohd, Chauhan, Aarti
Resilient Design Strategies for Wireless Charger ECUs: A Proactive Threat Analysis and Risk Assessment Framework for Ensuring Cybersecurity in EV Charging Ecosystems2026-26-0173To be published on 01/16/2026
The goal of Automotive cybersecurity is safety, reliability, confidentiality and authenticity. As the automotive industry grows smarter, so too do the cybersecurity protocols used to protect vehicles from malicious actors. Automotive cybersecurity secures communication networks, electronic systems, software and data collected by the new wave of intelligent cars The paper describes the cyber security threats its analysis ion wireless charging
Uthaman, Sreekumar, Mulay, Abhijit B, Gadekar, Pundlik
Digital Control of Synchronous Rectification and Dead Time Configuration for Improving Efficiency and Longevity of DC Motors2026-26-0089To be published on 01/16/2026
Abstract: - This paper elucidates the implementation of software-controlled synchronous rectification and dead time configuration for bi-directional controlled DC motors. These motors are extensively utilized in applications such as robotics and automotive systems to prolong their operational lifespan. Synchronous rectification mitigates large current spikes in the H-bridge, reducing conduction losses and improving efficiency [1]. Dead time configuration prevents shoot-through conditions, enhancing motor efficiency and longevity. Experimental results demonstrate significant improvements in motor performance, including reduced thermal stress, decreased power consumption, and increased reliability [2]. The reduction in power consumption helps to minimize thermal stress, thereby enhancing the overall efficiency and longevity of the motor.
Patil, Vinod, Kulkarni, Malhar, Soni, Asheesh Kumar
Comparative Analysis and Implementation of data streaming methodologies for Vehicle Navigation Mode for Electric Trucks2026-26-0692To be published on 01/16/2026
In the realm of electric truck logistics, optimizing route planning is essential. This paper presents a key navigation feature for analyzing such optimized routes. Integrating map features into the drive mode improves user experience by offering real-time navigation and dynamic route adjustments based on traffic updates, road closures, and vehicle coordinates. This study compares the performance of Server sent events(SSE), web sockets and API polling methodologies, focusing on metrics such as data transmission efficiency, latency, resource utilization, scalability, and reliability. Our findings demonstrate the advantages and limitations of each method, providing insights into their suitability for real-time route optimization in electric truck logistics. The results highlight the potential of SSE in achieving efficient and timely data updates, contributing to more effective route planning and resource management. Additionally, we discuss how API Polling, Web sockets, and SSE each make
Bhandari, Mehul, Kaur, Prabhjot, DADOO, VISHAL, Mahendrakar, Shrinidhi, Ramanaiah, Rachala
A Machine Learning Approach to Early-Stage Failure Prediction in Traction Motor Manufacturing2026-26-0281To be published on 01/16/2026
Traction motors technology has, driving the EV industry forward with more efficient, lightweight, and durable solutions. However, despite these advancements, noise testing at the end of the production line remains a critical stage for identifying manufacturing defects in traction motors. Hence early fault detection in traction motors is crucial to ensure safety and reliability of EV. This research contributes a solution that predicts early-fault detection, supporting improved reliability, reduced material cost and minimizing process time in the series production line. To identify the root cause of this problem, historical quality data has been acquired from manufacturing plants to enable efficient analysis. Feature selection was then carried out using embedded and wrapper methods to identify the most important features. These selected features were subsequently used as input for ML models. The best accuracy was achieved using SVC model for early-stage motor failure prediction.
Gaikwad, Pooja, Nangare, Kapilraj, Suryawanshi, Chaitanya
Durability Validation of Full Vehicle Structures Using Strain Correlation and RLDA-Based Simulations2026-26-0523To be published on 01/16/2026
Durability validation of full vehicle structures is crucial to ensure long-term performance and structural integrity under real-world loading conditions. Accurate strain correlation between physical testing and finite element (FE) simulations plays a key role in the validation, ensuring reliable predictions of vehicle durability. In this paper, a comprehensive methodology for strain correlation on a full vehicle subjected to torture track testing is implemented. Strategic placement of strain gauges is determined through a combination of static analysis, modal analysis, and identification of critical stress regions in the FE model. Strain gauges were installed on key structural locations of a prototype to capture strain responses under severe loading environments. Simultaneously, vehicle wheel loads were recorded on the torture track to build a detailed Road Load Data Acquisition (RLDA) dataset at critical hard points, Loads measured in terms of wheel loads (WFT) are fed to MBD model to
JAJU, MAYUR, Dokhale, Sandeep, Gadre, Nilesh, Patil, Sanjay
Lightweight AI Deployment for Legacy Automotive ECUs: A Practical Optimization Approach2026-26-0663To be published on 01/16/2026
Automotive systems are increasing adopting data-driven and intelligent functionality in the areas of predictive maintenance, virtual sensors and diagnostics. This has led to a need for the AI models to be directly run on vehicle ECUs. However, most of these ECUs – especially those in cost-sensitive or legacy platforms lack the computational capacity and parallel processing support required for standard AI implementations. Given the stringent real-time and reliability requirements in automotive environments, deploying such models presents a unique challenge. This paper proposes a practical methodology to optimize both the training and deployment phases of AI models for low-computation ECUs that operate without parallelism. Designing lightweight model architectures, using pruning and quantization techniques to minimize resource utilization, and putting in place a strategy appropriate for single-threaded execution are the three main objectives of the developed approach. The goal is to
Sharma, Sahil, Mathew, Melvin
Enhanced Methodologies for predicting Automotive Wheel Bearing life and damage using RLDA2026-26-0482To be published on 01/16/2026
The durability of wheel bearings is assessed in terms of raceway life and flange life. Raceway life focuses on the performance and damage tolerance of rolling elements, while flange life evaluates the structural integrity of wheel flanges under operational stresses. Traditionally, durability predictions relied on conventional design methods and analytic formulas for raceway spalling, as well as static load assumptions for flange fatigue analysis. Recently, integrating design of experiments (DOE) with traditional approaches has enhanced these methods, enabling systematic evaluation of design variables and loading conditions. This paper introduces a methodology for analysing raceway life and damage in automotive wheel bearings using RLDA (Road Load Data Acquisition) data. The process involves acquiring raw deterministic load data, filtering it to preserve high-peaked signals, and transforming the filtered data into block cycles derived from load time histories. Each block cycle contains
Narendra, Vishwanath, Mane, Yogiraj, Paua, Ketan, Singh, Ram Krishnan, Vellandi, Vikraman
Reliability of Rubber Grommets by Stochastic Analysis of Geometric Tolerances2026-26-0501To be published on 01/16/2026
Manufacturing tolerances pose considerable challenges in the production of rubber-based components, often leading to dimensional variations that can compromise overall product reliability. These inconsistencies may result in a range of functional issues, including poor sealing, excessive wear, misfit during assembly, and premature failure. Among these components, grommets are especially sensitive due to the complex, non-linear behavior of rubber materials, making precise dimensional control critical to ensure consistent and dependable performance. Even minor deviations in grommet geometry can trigger substantial assembly difficulties. Issues such as misalignment, buckling, insertion challenges, and potential damage to neighboring parts are commonly encountered. These complications typically require multiple rounds of design revisions and physical testing, which extend development timelines and significantly increase production costs. Real-world observations from various automotive
Beesetti, Siva, Hattarke, Mallikarjun, James Aricatt, John, PATHAN, ERAM
Short-Term Prediction of Highway Visibility Level Based on Attention Mechanism LSTM2025-01-721202/21/2025
To improve the accuracy and reliability of short-term prediction of highway visibility level in key scenarios such as short duration and fast changing speed, this paper proposes a short-term prediction method for highway visibility level based on attention mechanism LSTM. Firstly, XGBoost and SHAP methods are used to analyze the factors affecting highway visibility, determine the importance ranking of different influencing factors, and select the factors that have a greater impact on visibility as inputs for the visibility level prediction model. Secondly, based on LSTM as the model foundation network and innovative coupling attention mechanism, a visibility level prediction model based on attention mechanism LSTM is constructed, which can dynamically update the correlation between meteorological feature information at each historical time point and the visibility level at the current prediction time, thereby dividing the importance of information and flexibly capturing important
Ding, Shanshan, Xiong, Zhuozhi, Huang, Xu, Li, Yurong
Advancing Implantable Medical Device Reliability with Enhanced Laser Joining TechnologyTBMG-5217712/01/2024
DC-DC Converters for High Reliability eVTOL Auxiliary Power SystemsTBMG-5214712/01/2024
SAE TOMORROW TODAY: What Role Do Electric Utilities Have in the EV Space?1336811/17/2022
As demand for EVs grows, so too does the role of electric utilities. From powering the grid to ensuring the reliability of EV charging stations, the electric utility industry plays a pivotal role in accelerating EV adoption. For more than a century, Duquesne Light Company (DLC) has delivered electricity to more than 600,000 customers in the Pittsburgh region. Currently, there are more than 6,000 EVs in DLC's service territory -- and they expect that number to grow to more than 23,000 by the end of 2025. With this projected growth, DLC is not only providing reliable power, but EV information analysis and incentives like a Community Charging Program and Electric Fleet Advisory Service Program. We sat down with Sarah Olexsak, Senior Manager, Transportation Electrification, to discuss the role of electric utilities and how DLC is supporting EV adoption in Western Pennsylvania.
Hineman, Marcie
Computation integration2022-01-094703/29/2022
This invention combines optical technology of nanotechnology to produce accessible and reliable data processing. The invention increase security by demanding three key chips to access it. The key chips are the central controls and powersouce of the invention. The invention will revolutionize the way computers are used. The technology suggests advancement of previous computer technology to simplicity. It uses wireless technology to provide greater accessibility. The main claim of this invention is to provide simple data processing. Images (2)
Primous, Matthew
Development of a Built-in Type Dashboard Camera with Reliability and Usability 2022-01-012003/29/2022
Dashcam, which is considered essential parts of vehicles in Korea, are installed in most vehicles for reasons such as accidents, evidence of threatened driving of other vehicles, and insurance premiums. Aftermarket dashcam have been developed with many improvements such as higher resolution camera and LCD application, but still have problems in usability and durability. The first problem is a separate device mounted on the top of the windshield, which obstructs the driver's view and may injure the driver due to a collision impact. In addition, the connection of the power supply may cause a vehicle breakdown such as a fire due to a worker's mistake or a product defect. Secondly, in order to view the stored video, it is troublesome to remove the SD card and check it on the computer. Moreover, since the LCD is so small, it is difficult to search and play the desired video from the list in many saved files. The third problem is durability and reliability, when operating in the high
Jeong, DongHyuk
SAE TOMORROW TODAY: Cummins Innovating Engines to Power the Global Food Economy1315407/16/2021
Whether it's gas, electric or hydrogen-fueled, engines serving the agriculture industry are dynamic. Cummins engines power everything from the farm to the field to the future. Ann Schmelzer, General Manager, Global Ag Business for Cummins, is passionate about problem solving through the lens of technology. Building on Cummins' reputation of reliability, Schmelzer is leading the charge to get their engines into the growing demand of autonomous agriculture. Listen as she shares insights on the current economics of agriculture and ways Cummins is stepping up to meet the needs of the global food economy.
Hineman, Marcie
GUIDANCE FOR DISTRIBUTED RADIO ARCHITECTURESARINC678 (Current)07/15/2021
The purpose of this document is to evaluate Communication, Navigation, and Surveillance (CNS) Distributed Radio architectures and the feasibility of distributing the RF and systems processing sections to ensure the following: Reduce cost of equipment Reduce Size, Weight, and Power (SWaP) Ease of aircraft integration Growth capability built into the design Maintain or improve system availability, reliability, and maintainability It provides a framework to determine whether it is feasible to develop ARINC Standards that support CNS distributed radio architectures.
Airlines Electronic Engineering Committee
Validating an Approach to Assess Sensor Perception Reliabilities Without Ground Truth2021-01-008004/06/2021
A reliable environment perception is a requirement for safe automated driving. For evaluating and demonstrating the reliability of the vehicle’s environment perception, field tests offer testing conditions that come closest to the vehicle’s driving environment. However, establishing a reference ground truth in field tests is time-consuming. This motivates the development of a procedure for learning the vehicle’s perception reliability from fleet data without the need for a ground truth, which would allow learning the perception reliability from fleet data. In Berk et al. (2019), a method based on Bayesian inference to determine the perception reliability of individual sensors without the need for a ground truth was proposed. The model utilizes the redundancy of sensors to learn the sensor’s perception reliability. The method was tested with simulated data. In this contribution, we further explore and validate the method by utilizing real data, including ground truth data based on high
Kryda, Marco, Berk, Mario, Buschardt, Boris, Straub, Daniel
Object Detection and Tracking for Autonomous Vehicles in Adverse Weather Conditions2021-01-007904/06/2021
Object detection and tracking is a central aspect of perception for autonomous vehicles. While there has been significant development in this field in recent years, many perception algorithms still struggle to provide reliable information in challenging weather conditions which include night-time, direct sunlight, glare, fog, etc. To achieve full autonomy, there is a need for a robust perception system capable of handling such challenging conditions. In this paper, we attempt to bridge this gap by proposing an algorithm that combines the strength of automotive radars and infra-red thermal cameras. We show that these sensors complement each other well and provide reliable data in poor visibility conditions. We demonstrate the advantages of a thermal camera over a visible-range camera in these situations and employ YOLOv3 for object detection. The proposed system utilizes a modified Track-Oriented Multiple Hypothesis Tracking (MHT) algorithm which uses data from these sensors to keep
Bhadoriya, Abhay Singh, Vegamoor, Vamsi Krishna, Rathinam, Sivakumar
SAE TOMORROW TODAY: Self-Driving For The Long Haul with Kodiak Robotics1293102/19/2021
Kodiak Robotics is delivering more than freight, it's delivering the future. We spoke with Andreas Wendel, Vice President of Engineering at Kodiak Robotics, to discuss how they became a developer of reliable, highway-tested, self-driving long haul trucks and the elements required to create safe vehicles that perform consistently, delivering freight to commercial customers with a 100% on-time delivery record. Discover the difference between range of visibility and range of confidence across cameras, lidar and radar, and why this three-pronged approach allows Kodiak to develop the software and technology that enables zero disengagements across 800 miles.
Hineman, Marcie
New Capabilities for Grasp-Assisting GlovesTBMG-3852202/01/2021
NASA is developing the next generation of spacesuits for future missions including the optimization of spacesuit gloves that, when coupled to a pressurized suit, tend to limit the range of motion of an astronaut’s hand to as little as 20%. Many of NASA’s future missions will be in challenging environments where hand dexterity of the astronaut will be critical for the success of the missions.
Quality and Reliability in the Assembly and Manufacturing of Medical Electronics PCBsTBMG-3807511/01/2020
With COVID-19 continuing to rage across the United States and the world, hospitals and medical centers are relying on their medical electronics equipment, including ventilators, to help improve COVID-19 patients’ health. EMS providers, contract manufacturers (CMs), and printed circuit board (PCB) fabricators are the strongest link in the supply chain critical for building medical electronics equipment, including ventilators. These PCB companies help design, assemble, and manufacture the PCBs that are at the heart of these life-saving medical instruments.
Methodology and Results of Testing an Impact of F-34 Fuel on the Engine Reliability2020-01-213309/15/2020
An application of the new kind of the fuel for the diesel engine requires to conduct the qualification tests of the engines powered by this his fuel which allow assessing an impact of fuel on the engine reliability. Such a qualification test of the piston and turbine engines of the aircraft stationed on the ground and land vehicles is described in the NATO standardisation agreement (STANAG) 4195 as the AEP-5 test. The methodology and selected results of the qualification tests of the SW-680 turbocharged multi-purpose diesel engine fuelled with F-34 fuel have been presented in this paper. A dynamometric stand with the SW-680 engine has been described. Based on the preliminary results of the investigation it has been found that a change in a type of the fuel from IZ-40 diesel fuel into F-34 kerosene-type one has reduced a maximum engine torque by about 4%. This has been primarily due to a lower fuel density of F-34 by about 3%. Finally, it has been found that this does not require any
Walentynowicz, Jerzy
Solenoid Valve Health MonitorTBMG-3700506/01/2020
The Solenoid Valve Health Monitor System (SVHMS) was developed to remotely monitor the health of solenoid valves, lowering operational costs and increasing reliability by predicting valve failures before they occur. The system measures and analyzes steady state and transient components of the magnetic field and indirectly, the electric current in a solenoid valve during normal operation. It enables continuous monitoring of the integrity and operational status of solenoid valves without the need for interrupting their operation to conduct frequent inspections.
Reliability Program Standard for Systems Design, Development, and ManufacturingGEIASTD0009A-TEST-REC (Historical)05/27/2020
This standard requires the developers and customer/users working as a team to plan and implement a reliability program that provides systems/products that satisfy the user’s requirements and expectations. The user’s requirements and needs are expressed in the form of the following four reliability objectives: The developer shall solicit, investigate, analyze, understand and agree to the user’s requirements and product needs. The developer, working with the customer and user, shall include the activities necessary to ensure that the user’s requirements and product needs are fully understood and defined, so that a comprehensive design specification and Reliability Program Plan can be generated. The developer shall use well-defined reliability- and systems-engineering processes to develop, design, and verify that the system/product meets the user’s documented reliability requirements and needs. The developer shall implement a set of engineering activities (included in this standard as
G-41 Reliability
Reliability Program Standard for Systems Design, Development, and ManufacturingGEIASTD0009A (Current)05/27/2020
This standard requires the developers and customer/users working as a team to plan and implement a reliability program that provides systems/products that satisfy the user’s requirements and expectations. The user’s requirements and needs are expressed in the form of the following four reliability objectives: The developer shall solicit, investigate, analyze, understand and agree to the user’s requirements and product needs. The developer, working with the customer and user, shall include the activities necessary to ensure that the user’s requirements and product needs are fully understood and defined, so that a comprehensive design specification and Reliability Program Plan can be generated. The developer shall use well-defined reliability- and systems-engineering processes to develop, design, and verify that the system/product meets the user’s documented reliability requirements and needs. The developer shall implement a set of engineering activities (included in this standard as
G-41 Reliability
Understanding vapor and solution phase corrosion of lubricants used in electrified transmissions2020-01-056104/14/2020
In this study, the corrosion rates of commercially available lubricants that are found in electrified and conventional transmissions are measured in the vapor and solution phase across a range of operating temperatures using the wire corrosion test. The results of this study demonstrate the importance of performing vapor and solution phase corrosion measurements in real time across a range of temperatures and offers an efficient and cost-effective way to screen fluid chemistries over a range of potential corrosion situations. Corrosion measurements such as these, when interpreted correctly provide reliable data on which to base appropriate safety margins during the design phase.
Hunt, Gregory, Prengaman, Christopher
Experimental Study on Stress State of a Car Wheel under Typical Working Conditions2020-01-122904/14/2020
Wheel stress state is one of the important factors determining wheel reliability. The nonlinear influence of the tire on the wheel during actual use makes it difficult to obtain the multi-axial stress of the wheel through simulation calculation. This paper proposes a method based on bench test to study the stress state of car wheels. Firstly, starting from the two typical working condition of straight running and turning, the wheel dangerous point position is obtained. Then strain gauges are attached to the dangerous point of the wheel to analyze the stress changes of it under these two load conditions. The variation rules corresponding to different loading conditions are analyzed. Finally, the load conditions affecting the stress state of the wheel are found through comparative analysis. Through the above research, the measurement method and influencing factors of the stress state of the wheel during use are obtained. It provides guidance for wheel structure optimization and
Cheng, Liu, Zu, Ren, Chao, Cheng, Wei, Liu
Report on Unmanned Ground Vehicle ReliabilityJ2958_202002 (Current)02/24/2020
This information report is applicable to the reliability characteristics of unmanned ground vehicles.
G-41 Reliability
Analytical Model for Calibration Results Performances Enhancement, Resulting in Automated Prescription for Equipments2019-01-187809/16/2019
Most of the decisions taken every day are based on the results of measurements of all different events that occur around us. The reliability of these measurements depends basically on the environment in which they are carried out, the procedure defined and the equipment used, evaluating their different contributions through the uncertainty of measurement. In the case of the measuring equipment, the calibration process associated with adequate traceability provides part of the information necessary to contribute positively to the generation of reliability. However, the physical nature of the instruments means that all of them have a certain degree of drift in their metrological characteristics, which requires users to establish time intervals to confirm the maintenance of the goodness of measurement of such equipment. In this article, a methodological proposal for the processing of calibration data, which makes it possible to establish a systematic approach for the dynamic and flexible
Contreras, Juan Pablo, García Lasanta, Juan Manuel, Mendez-Huelva, Damian, Garofano, Jose Enrique
Ranking of Thick Ice Shapes Based on Numerical Simulation for Certification2019-01-194406/10/2019
The objective of this paper is to present a numerical method to rank thick ice shapes for aircraft by comparing the ice accretion effects for different icing scenarios in order to determine the more critical ice shape. This ranking allows limiting the demonstration of the aerodynamic characteristics of the aircraft in iced condition during certification to a reduced number of ice shapes. The usage of this numerical method gives more flexibility to the determination of the critical ice shapes, as it is not dependent of the availability of physical test vehicles and/or facilities. The simulation strategy is built on the Lattice Boltzmann Method (LBM) and is validated based on a representative test case, both in terms of aircraft geometry and ice shapes. Validation against existing experimental results shows the method exhibits an adequate level of reliability for the ranking of thick ice shapes.
Barth, Marcus, Degrigny, Johan, Brown, James, Tezok, Fatih, Lewis, Richard, Alegre, Nathalie, Barrios-Garcia, Isaac
Analyzing Field Environments to Understand Product Failure Causes2019-01-147706/05/2019
Product failures often require expensive repairs or replacements. Over-engineering adds to recurring costs and its success is uncertain if the failure’s cause is not understood. Engineers need in-depth knowledge before attempting a re-design. This case study focuses on bus seat failures that occasionally occur in the field but are not predicted by current industry standard tests in the lab. The goal was to collect comprehensive field vibration data and analyze that data to understand the failure’s causes. The study used accelerometers placed at various points in multiple seating configurations and across multiple field environments. Analysis identified transmissibility issues between axes of motion, as well as a seat configuration with higher reliability.
Vande Kamp, Jade
Inter-Vehicular Sliding Friction and Crush Energy Losses in Impulse Momentum Planar Collision2019-01-042204/02/2019
New in this study is the mathematical formula for calculating energy dissipated due to sliding under the action of Coulomb kinetic friction in the context of Impulse Momentum Planar Collision (IMPC) with isotropic restitution. The surface sliding dissipated energy theorem established here is precisely consistent with the laws of physics underlying IMPC. A principal goal of distinguishing between surface sliding energy dissipation and energy dissipation due to vehicle crush is to improve the rational basis for use of crush energy analysis with IMPC. Also new in this study is a consistent interpretation of Newton's, Poisson's and Stronge's restitution hypotheses as they apply to IMPC with Coulomb kinetic friction. While this paper adds to the understanding of energy dissipation, the IMPC method presented here is not new. The IMPC method features a yaw velocity component and two translational velocity components referenced to the dynamic center of mass of each vehicle as well as an
Carpenter, Nicholas, Welcher, Judson
A Methodology of Design for Fatigue Using an Accelerated Life Testing Approach with Saddlepoint Approximation2019-01-015904/02/2019
We present an Accelerated Life Testing (ALT) methodology along with a design for fatigue approach, using Gaussian or non-Gaussian excitations. The accuracy of fatigue life prediction at nominal loading conditions is affected by model and material uncertainty. This uncertainty is reduced by performing tests at a higher loading level, resulting in a reduction in test duration. Based on the data obtained from experiments, we formulate an optimization problem to calculate the Maximum Likelihood Estimator (MLE) values of the uncertain model parameters. In our proposed ALT method, we lift all the assumptions on the type of life distribution or the stress-life relationship and we use Saddlepoint Approximation (SPA) method to calculate the fatigue life Probability Density Functions (PDFs). Finally, a design for fatigue is performed where a Reliability-Based Design Optimization (RBDO) process is developed to optimize the system’s characteristics (model parameters, fatigue and/or material
Tsianika, Vasiliki, Geroulas, Vasileios, Papadimitriou, Dimitrios, Mourelatos, Zissimos, Hu, Zhen, Majcher, Monica
A Process for Delivering Extreme AFP Head Reliability2019-01-134903/19/2019
Every now and then a good idea happens. The Modular head was a great idea and enabled the use of multiple types of AFP heads, ATL, ply cutting, part probing, etc. with the use of a single machine and machining cell. At the time the modular head was developed by Electroimpact circa 2004, the industry assumed (and accepted) that AFP was an unreliable process. It still isn’t as reliable as we’d like. One way of coping with this lack of reliability is to stage more than one head in the AFP cell so that a spare head of the exact same type is ready to jump into action if the head out on the floor has an issue. If the reliability of the AFP process were to increase 10x or 50x, would there still be a business case for the multiple AFP head system? The modular head may still win the day, but the metrics change. For instance, if there was only 20 minutes of down time for every head load, it may no longer be advantageous to have 2 heads of the exact same type in the cell. It is our goal to
Rudberg, Todd, Cemenska, Joshua, Sherrard, Ethan
Improvement of Aircraft Availability and Optimization of Component Costs by Pre-Emptive Removal of Targeted Components2019-01-134103/19/2019
Availability of large repairable systems, like aircraft, are critical for commercial operators to generate revenue, and for military organizations to achieve their mission readiness objectives. Of the relatively few studies that deal with improving availability, most have focused on increasing reliability, and not on the biggest driver of low availability - Unscheduled Maintenance Events (UMEs). The cost of maintenance has long been a target of cost-cutting measures, and one common strategy focuses on extracting as much service life as possible out of various non-critical system components by letting those components “run to failure” (as defined in SAE JA1012). However, one of the biggest drawbacks of the “run to failure” approach is that it comes at the cost of lower asset availability because the failure of one of those components will nearly always lead to a UME, typically just when the operator wants to use, or is currently using, that asset. To combat the impact of UMEs, many OEMs
Lesmerises, Alan
Self-Stabilizing, Distributed, Symmetric, Fault-Tolerant SynchronizationTBMG-3392303/01/2019
Distributed systems have become an integral part of safety-critical computing applications, necessitating system designs that incorporate complex fault-tolerant resource management functions to provide globally coordinated operations with ultra-reliability. As a result, robust clock synchronization has become a required fundamental component of fault-tolerant, safety-critical distributed systems. Since physical oscillators are inherently imperfect, local clocks of nodes of a distributed system, driven by these oscillators, do not keep perfect time and can drift with respect to real time and one another. Thus, the local clocks of the nodes must periodically be re-synchronized. As a result, a fault-tolerant system needs a clock synchronization algorithm that tolerates imprecise local clocks and faulty behavior by some processes.
Separable and Standard Monte Carlo Simulation of Linear Dynamic Systems Using Combined Approximations02-12-02-000801/25/2019
Reliability analysis of a large-scale system under random dynamic loads can be a very time-consuming task since it requires repeated studies of the system. In many engineering problems, for example, wave loads on an offshore platform, the excitation loads are defined using a power spectral density (PSD) function. For a given PSD function, one needs to generate many time histories to make sure the excitation load is modeled accurately. Global and local approximation methods are available to predict the system response efficiently. Each way has their advantages and shortcomings. The combined approximations (CA) method is an efficient method, which combines the advantages of local and global approximations. This work demonstrates two methodologies that utilize CA to reduce the cost of crude or separable Monte Carlo simulation (MCS) of linear dynamic systems when the excitation loads are defined using PSD functions. The system response is only calculated at a few frequencies within the
Norouzi, Mahdi, Nikolaidis, Efstratios
Photonic Radiation Sensors Survive Huge Doses UndamagedTBMG-3355801/01/2019
Landmark test results suggest a promising class of sensors can be used in high-radiation environments and to advance important medical, industrial, and research applications.
Reliability Case Analysis of an Autonomous Air Cooling System (AACS) for Aerospace Applications2018-01-191610/30/2018
Current More Electric Aircraft (MEA) utilize Liquid Cooling Systems (LCS) for cooling on-board power electronics. In such LCS, coolant pipes around the structure of the aircraft are used to supply water glycol based coolant to sink heat from power electronics and other heat loads in the electronic bay. The extracted heat is then transferred to ram air through downstream heat exchangers. This paper presents a reliability examination of a proposed alternative Autonomous Air Cooling System (AACS) for a twin engine civil MEA case study. The proposed AACS utilizes cabin air as the coolant which is in turn supplied using the electric Environmental Control System (ECS) within the MEA. The AACS consists of electrical blowers allocated to each heat load which subsequently drive the outflow cabin air through the heat sinks of the power electronics for heat extraction. No additional heat exchanger is required after this stage in which the heated air is directly expelled overboard. One key
Fong, Chung Man, Norman, Patrick, Seki, Naoki
Effects of the Metal Surface Profile to the Sliding Properties between Rubber and Metal and Applying That to Wheel Bearing Seals2018-01-190410/05/2018
Cartridge seals are frequently utilized in wheel bearings where a high level of reliability is required. The cartridge seal combines two components; a seal with flexible rubber lips and a stamped metal slinger that provides a surface for the seal lips to contact without being exposed directly to foreign substances. This paper provides a fundamental evaluation of the sliding properties of rubber seal lips relative to the slinger metal surface profile and evaluates the performance of rotating torque and muddy water endurance from a recommend metal surface profile (developed by advanced fundamental evaluation) of the slinger. Seals with the recommend metal surface profile showed approximately 30% lower torque at the rotating speed from 400 rpm to 800 rpm, which are the speeds representative of automotive city driving. At the same time, the durability performance against muddy water was almost equivalent to the seals without this metal surface.
Ishida, Koki, Fujii, Masahiro, Cho, Jun Hwi, Pittel, Kevin
Construction of a Multiple Driving Affective Scale2018-01-188810/05/2018
The authors’ goal is to develop brakes that are more satisfying to users in sensory aspects by explaining the relationship between people’s state of mind and a vehicle’s physical quantities. However, there are no scales to measure such feeling. In this study, a psychological scale was constructed to measure the affective state of general automobile drivers, for the purpose of clarifying the effects of brake characteristics on the affective state. To construct the affective scale, two experiments were conducted. In the first experiment, a comparison of four types of vehicles was performed and then an interview survey was conducted to collect a broad sample of terms used to evaluate the affective state. From the results, it was hypothesized that the evaluation terms were divided into eight categories. For each hypothesized category, ten evaluation terms were selected from the terms obtained in the interviews, the items of the existing psychological evaluation scale, and the synonym
Matsuoka, Masanori, Muramatsu, Keiichi, Kaede, Kazunori, Watanuki, Keiichi, Shiimado, Toshihiro, Nishizawa, Yukio
Calculating System Failure Rates Using Field Return Data. Application of SAE-J3083 for Functional Safety and Beyond2018-01-107404/03/2018
In early design activities (typically before the hardware is built), a reliability prediction is often required for the electronic components and systems in order to assess their future reliability and in many cases to meet customer specifications. These specifications may include the allocated reliability for a particular electronic unit and in the cases of functional safety products to meet the ASIL (Automotive Safety and Integrity Level) requirement specified by the functional safety standard ISO 26262. The standard allows for the use of “statistics based on field returns or tests” as a valid alternative to the handbook-based reliability prediction. This paper presents a newly developed SAE-J3083 standard “Reliability Prediction for Automotive Electronics Based on Field Return Data”, which covers the types of the required data, ways to collect it, and the methodology of how to process this data to calculate the failure rates and meet the expected safety goals.
Kleyner, Andre, Hodgson, Keith
Study on Test Scenarios of Environment Perception System under Rear-End Collision Risk2018-01-107904/03/2018
The foundation of both advanced driving assistance system(ADAS) and automated driving (AD) is an accurate environment perception system(EPS). However, evaluation and test method of EPS are seldom studied. In this paper, naturalistic driving environment was studied and test scenarios for EPS under rear-end collision risk were proposed accordingly. To describe driving environment, a new concept named environment perception element(EPE) was first proposed in this paper, which refers to all the objects that the EPS must perceive during driving. Typical environment perception elements include weather and light conditions, road features, road markings, traffic signs, traffic lights, other vehicles, pedal cyclists and pedestrians and others. Driving behaviors collected in Shanghai, China were classified and rear-end collision risk scenarios were obtained and described using EPEs. Probability distribution of EPEs was therefore obtained. Afterwards, the correlation between EPEs and risk level
Liu, Lin, Zhu, Xichan, Ma, Zhixiong
Safe2Ditch TechnologyTBMG-2871304/01/2018
Highly capable small Unmanned Aerial Vehicles (UAVs) provide substantial business opportunity, especially if allowed to operate in the suburban market. Reliability issues force the use of a safety pilot for each vehicle in operation, which is cost-prohibitive for large-scale commercial applications, and limits the use of these vehicles to line-of-site (LOS) operation. Extending the use of small UAVs to beyond visual line-of-sight (BVLOS) and to fleet operations requires a vehicle system to autonomously perform emergency management activities as a replacement for the human pilot to maintain safety to people and property in populated areas.
High-Power Solid-State Power Amplifier SystemTBMG-2871504/01/2018
NASA Marshall Space Flight Center (MSFC) has developed a High-Power Solid-State Power Amplifier System that combines 1-KW modules (16 amps total) to generate up to 16KW of radio frequency (RF) power from 230 MHz. The NASA device is a first step toward increasing the power of solid-state power amp devices so that they might replace the more cumbersome vacuum tube amps for some applications. Also, when vacuum tube amps fail, a total power failure occurs. Since the NASA device is a system of amplifiers, it enables graceful failure, meaning one or more stages can fail and the system will continue to operate, although at reduced power.
Microwave-Based Test Method for Computer ChipsTBMG-2814101/01/2018
A new approach was developed that overcomes the limitation of conventional chip-testing methods on 3D chips, which include many thin horizontal “floors” connected to one another by vertical pathways called through-substrate vias (TSVs). TSVs help 3D chips do three essential things: speed up, shrink down, and cool off. By allowing elements on different floors to communicate with each other, signals no longer need to travel all the way across a comparatively sprawling 2D chip, meaning calculations go faster and electrons heat up far less conducting material as they move.
Test System Ensures Flawless Performance of Military RF DevicesTBMG-2765510/01/2017
Communication on the battlefield is a life-or-death matter. You can't take chances with RF devices or power units malfunctioning or failing. A soldier's life may depend on how well you designed and tested your product. Will it function in temperature extremes, after physical shocks, and with low battery power? Where will it break or fail, and why? How can that be prevented?
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