Browse Topic: Reliability

Items (3,600)
In the process of replacing the rollers of the fabric cart of the tobacco storage cabinet, in order to solve the problems of low replacement efficiency and high safety risk.This article proposes a specialized lifting tool for fabric cart rollers with a self-locking and adopts the screw lifting structure, which facilitates roller maintenance operations, and conducts SolidWorks Simulation calculations and dynamic simulation methods. Jinan Cigarette Factory fine cigarettes special line leaf silk temporary storage cabinet fabric car roller replacement, for example, the results show that: the average operating personnel reduced by 50%, the replacement time from 6.7h to 1.2h, efficiency increased by 458%, This innovation significantly reduces the labor intensity of maintenance personnel and ensures a safe and reliable replacement process.
Zhang, LeiXue, YifeiZhang, GeSun, YanzhaoWang, HongbinCheng, Linfeng
Recent advances in precision motion technology have heightened the requirement for precise stiffness analysis in flexible mechanisms. This paper begins with a theoretical analysis, constructing a mathematical expression for the stiffness of flexible mechanisms, providing a systematic framework for analysis. Subsequently, the study employed finite element analysis on both single and double parallelogram flexible mechanisms to validate the proposed theoretical stiffness formulas. This process not only confirmed the effectiveness of the proposed expressions but also highlighted the influence of different structures on stiffness characteristics. The finite element analysis results validate the proposed theoretical model as an effective and reliable tool for predicting the stiffness of flexible mechanisms. By establishing a reliable predictive model, this research paves the way for the informed design and systematic optimization of next-generation flexible mechanisms in precision motion engineering.
Cai, Dongchen
To address the challenge of accurately assessing the reliability of complex equipment, a reliability evaluation system for a five-axis machining center was developed based on extension theory. By collecting and analyzing the failure modes and data of various subsystems, the strengths of the Fuzzy Analytic Hierarchy Process (FAHP) and the Entropy Weight Method (EWM) were combined to determine the weight of reliability evaluation indicators for both the machining center and its subsystems. A comprehensive assessment of the five-axis machining center's overall reliability was conducted. According to the principle of maximum membership, the reliability grades for the spindle system and the feed system were both rated as “excellent.”
Fei, ShouxiangWang, DechaoPiao, ChengdaoZheng, Shengkui
Reliability evaluation aims to quantify the reliability level of equipment and to verify its compliance with reliability requirements. Existing reliability evaluation methods primarily rely on operational phase data, which means reliability evaluation may lag behind actual needs. In practice, both users and design teams are more concerned with how to estimate CNC machine tools’ reliability before they are put into operation. Moreover, current reliability evaluation methods usually ignore the design team’s influence on CNC machine tool reliability. To overcome these limitations, this study proposes a novel reliability evaluation method that accounts for the influence of the design team on the reliability of CNC machine tools. By analyzing the impact of the design team’s technical capabilities and reliability capabilities on CNC machine tool reliability, a set of quantifiable evaluation indicators was established. Then, the weight coefficients of all indicators were determined using the expert scoring method. Finally, all data were integrated using the vector projection method, which enabled a quantitative reliability evaluation of CNC machine tools from different design teams within the same category. Additionally, the proposed method was applied to conduct practical case studies on multiple CNC external cylindrical grinding machine tools designed by different design teams, thereby validating the feasibility of the proposed method. The reliability evaluation results not only determine the reliability level of each CNC machine tool but also identify the weak points in the technical capabilities and reliability competencies of each design team. This study concludes by discussing the significance of this approach for enhancing the reliability capabilities of design teams and its practical implications for end users.
Sun, DongyangZheng, WeixuChu, HongyanXu, JingjingCheng, Qiang
This study presents a systematic investigation into the assembly stress and fatigue life of 60-series harmonic reducers. A sophisticated finite element simulation model is constructed to precisely simulate the real assembly process and calculate stress distribution in the flexspline under axial assembly errors. In addition, corresponding fatigue life tests are designed to explore the influence of different axial assembly errors on the number of rotation cycles and transmission efficiency of the harmonic reducer. By comparing the predictions of the fatigue life mathematical model with the test data, a reliable fatigue life prediction method is established, providing a solid theoretical basis for the whole-machine assembly process and reliability design of this series of harmonic reducers.
Du, YuefeiQiu, HaodongFan, YongLi, ZiyuanDong, YiZhang, ChiLi, ChenzhengLi, Yuan
With the continuous development of large precision equipment, the reliability requirement for long-distance transportation is also constantly increasing. Large packaging box with sealing and vibration reduction performance is crucial during transportation. This article introduces the sealing measures for large-sized packaging box, as well as the sealing structure design methods for key parts, vibration reduction measures and the selection and design of vibration dampers. The designed packaging box has been used for long-distance transportation of various types of equipment and the reliability of sealing and vibration reduction performance has been verified in practical applications, providing reference for the design of similar packaging boxes.
Zhang, RuoyuJiang, Shouli
Fleet heterogeneity, from manufacturing variations and diverse operating conditions, complicates reliability analysis by obscuring true failure patterns in aero-engines. This is a critical challenge in an industry as inaccurate Mean Time Between Failures (MTBF) estimates threaten safety and inflate operational costs, by forcing a choice between inefficiently conservative maintenance or the risk of in-service failures. Conventional analysis often fails by pooling all fleet data. To address this, our paper presents an analytical framework that improves predictive accuracy by filtering, rather than aggregating statistical noise. The methodology uses a Randomized Block Design (RBD) and ANOVA hypothesis test to screen a diverse dataset and isolate statistically homogeneous subgroups. This filtration identifies a core fleet with a consistent failure signature, providing a purified dataset for modeling. This refined data is then modeled using both Weibull and the Exponentiated Inverse Weibull distributions to ensure the results are robust and not model-dependent. Applying this framework to a 25-engine dataset that experienced 66 failures, we isolated a stable failure pattern, yielding a primary MTBF of 171.16 hours and a cross-validated MTBF of 176.35 hours. The close 3% convergence between these models validates our approach. By providing a dependable MTBF, this work establishes a stronger foundation for data-driven Reliability Centered Maintenance (RCM). It empowers maintenance planners to move toward evidence-based intervals, safely extending engine time-on-wing, optimizing spare parts inventory, and significantly reducing direct operational costs for airlines.
Jubaid, Mayin UddinBebe, GibsonBigyen, Musa PethuelAnik, S M Kullul MehedeeYasmin, AshrafiSahran, Mohamed Sideek Mohamed
In port construction, high-pile wharves—a primary structural form—are constantly exposed to marine environmental erosion, making corrosion a particularly prominent issue. Traditional anode installation typically relies on underwater diving operations, which suffer from low efficiency, high risks, and significant costs. To address these challenges, a novel installation technique requiring no divers has been developed. Through specialized equipment design and optimized construction processes, this technology enables remote, efficient, and safe anode installation. Research focuses on the design of non-diver anode support installation equipment, safety validation, and construction methodologies. Through theoretical analysis, numerical simulation, and field construction trials, this technology significantly enhances construction efficiency while reducing operational risks and costs. It provides a reliable solution for corrosion protection in high-pile wharves and holds significant importance for advancing port construction technology.
Lan, JinpingZhang, Shoulong
Transporting large steel materials for mountain electric towers is challenging due to steep gradients, narrow roadways, and uneven terrain. To address these issues, this study designs an adaptive attitude adjustment mountain transport vehicle. This mountain transport vehicle has a compact structure, measuring 1.4 meters in length and 1.1 meters in width, which enhances its suitability for confined mountainous environments. This vehicle adopts a design scheme that combines hydraulic lateral adjustment, load-bearing platform follow-up adjustment and frame adaptive adjustment mechanisms. The transportation of tower materials, measuring 12 meters in length and 1.2 tons in weight, is accomplished by employing two vehicles working in coordination. The three-dimensional model of the entire vehicle is established by using SolidWorks software. The lateral stability of the mountain vehicle and the limit working conditions of its adjustment mechanism are analyzed through theoretical calculation. The dynamic simulation of the virtual prototype is carried out using Adams software, including the processes of lateral leveling, follow-up adjustment and frame adjustment. The results show that the leveling mechanism can achieve an adjustment range of more than ±25°. The results confirm the vehicle’s excellent stability and adaptability to mountainous conditions. This study provides a more effective and more reliable solution for the construction of mountain electric towers than traditional manual or animal-powered transportation methods.
Zhang, RuiKong, FanfangHe, YulingLv, JiahuiChen, ChanglongZhan, LulinLiang, Ke
Ball screws, as classic high-precision transmission structures, are widely used in various linear motion mechanisms. To meet the needs of space applications, it is necessary to address issues such as microgravity and long lifespan to enhance the in-orbit lifespan and reliability of ball screws. Traditional oil or grease lubrication methods are often unsuitable for space environments due to microgravity and vacuum evaporation problems. This paper conducts relevant research on lubrication design, friction pair design, and friction and wear verification to solve the lubrication and lifespan issues of long-lifespan ball screws for space applications.
Xie, WenZhao, JianGong, KangHu, XiaonanGuo, MengleiJiao, Hanyu
Craters are the primary landmarks used for visual navigation in missions exploring small celestial bodies. However, obtaining high-quality, annotated crater data is often challenging due to limited imaging conditions and strict mission constraints. Conventional semantic segmentation models struggle with limited data and are challenging to train effectively. To overcome this limitation, this study introduces a few-shot segmentation approach for crater detection on small celestial bodies. Our method includes a prototype representation module that constructs class-level prototypes to quickly associate crater regions with their semantic features. This paper also designs an iterative learning module that gradually improves the segmentation output, helping the model better capture detailed edges and structures. Tests on a simulated few-shot dataset demonstrate that our method provides reliable and accurate crater segmentation, achieving a mean intersection-over-union (mIoU) of 88.7, outperforming traditional fully supervised methods.
Li, ShuaiZhu, Shengying
The climb gradient along the takeoff trajectory at each point during takeoff reflects the aircraft’s ability to clear obstacles and reach a safe altitude, ensuring the safety of civil flights. Airworthiness regulations specify certain requirements for the single-engine-out climb gradient. Given that the data used in conventional calculation methods are significantly influenced by the flight status during the process, this paper explores two new climb performance calculation methods based on the existing ones. A set of data was calculated, and the resulting errors were all no more than 10%, indicating that both new calculation methods are effective and reliable. Therefore, they provide a certain reference value for the climb gradient calculation of transport category aircraft.
Jiang, TianjunLiu, Tao
Requirements of Interface for Aircraft/Store Electrical Interconnection System (GJB 1188A-99) is the current standard followed by all types of carrier aircraft and stores. This paper designed a 1553B bus remote terminal mode code configuration method that met the requirements of GJB1188A standard, completing the interrupt initialization and data initialization of compulsory mode codes. These comprehensive test results confirm that the proposed mode code configuration method is both reliable and effective, and provides strong portability, which can be used as a reference for the GJB1188A interface software design of other components
Han, BinZhang, KunLiu, XuhanYe, JinhanLi, Zhengmao
Multi-UAV cooperative localization can utilize information fusion between nodes to improve localization accuracy and performance on the target. Distributed state fusion estimation methods have been heavily studied in recent years, but the final estimates in the research results do not converge towards the global optimum. This paper aims to make the state estimates of each individual in the UAV formation for the target converge and converge to reliable values. In this paper, we study a multi-UAV cooperative tracking method based on adaptive weighted fusion, which first evaluates the importance of each node in the UAV formation and the reliability of the local filtering estimation results, and then assigns the weights according to the reliability of the UAV’s local state estimation of the target in the whole at the current moment. Finally, this paper verifies through simulation experiments that the method can not only accomplish the state tracking of the target, but also that the state estimates of each node in the network converge to more accurate state estimates.
Xia, ShengjiWang, ChangqingLiu, FaleiJia, ZhaoxuanZhao, Quanpu
This document contains information and guidance on assessment of the risk posed by observed tin whiskers for aerospace, defense, and high-performance (ADHP) products or other products that demand high reliability.
G-24 Pb-free Risk Management Committee for ADHP
The magnetic field modeling methodology for ships based on magnetic dipole arrays demonstrates heightened sensitivity to input data. When addressing overdetermined systems characterized by numerous variables and constrained measurement points, the coefficient matrix frequently develops pathological ill-conditioning, leading to solution divergence and compromised result accuracy. This research reformulates the ship magnetic field inversion challenge as a non-convex quadratic programming problem, employing the Successive Convex Approximation (SCA) algorithm as the computational solver. Rigorous comparative validation was performed against conventional stepwise regression algorithms and experimental datasets acquired from scaled ship model measurements. Results substantiate that while the modeling precision of the SCA algorithm remains comparable to that achieved by stepwise regression methods, SCA exhibits demonstrably superior solution stability. This enhanced robustness positions SCA as a more reliable computational framework for critical naval applications, particularly in high-fidelity ship magnetic signature modeling and rapid detection/localization of magnetic targets in marine environments.
Chen, HaoPan, Xun
The reliability of aviation maintenance personnel directly impacts flight safety, yet systematic methodologies for the quantitative prediction of human error probability (HEP) in this domain remain lacking. To address this gap, a novel human factors reliability analysis method for aviation maintenance is proposed, extending the SPAR-H model through Evidential Reasoning (ER). This method is implemented as follows: Maintenance tasks are decomposed into subtasks. Subsequently, the eight types of Performance Shaping Factors (PSFs) for each subtask are evaluated by domain experts according to defined PSF levels. Expert judgments are then aggregated using Evidential Reasoning theory, enabling the calculation of aggregated PSF levels. These aggregated levels are interpolated to determine the corresponding impact multipliers. Finally, the HEP for aviation maintenance operations is calculated by integrating the SPAR-H basic error probability model with task series/parallel logic rules. The proposed methodology is validated using an inspection operation case study. This study establishes a methodological framework for human factors reliability analysis in aviation maintenance, providing a theoretical foundation for developing scientifically grounded prevention and control measures to enhance aviation safety levels.
Meng, MengMa, NingGuan, ZhongqingHan, ZuyangNan, WenxueCai, Hongbin
Vehicle vibrations during precision instrument transport can cause damage and failure. Existing vibration isolators often lack reliability, mass production feasibility, and easy maintenance. In this paper, we design and analyze a quasi-zero-stiffness vehicle-mounted isolator with an inerter, decreasing dynamic stiffness while raising the effective mass. Theoretical, simulation, and experimental results show improved isolation performance, lower isolation frequency, and a broader isolation bandwidth.
Li, KaiLv, SiboSun, NingDai, Shijie
The gearbox is a key component of the mechanical transmission system, and its fault diagnosis is essential to the reliability of the equipment. However, obtaining fault samples under actual working conditions for gearbox fault diagnosis is challenging. In this paper, the rigid-flexible coupling dynamic simulation model of the gearbox is established, and the co-simulation of gear normal, crack, and breakage is carried out in the ADAMS and MATLAB environments. The comparison between the simulated and measured signals shows that the simulation method can accurately reflect the key characteristics, such as rotation frequency and meshing frequency, and verify its reliability and accuracy. The research results can provide effective data support for gearbox fault diagnosis and improve the operational safety of mechanical systems.
Li, DongxiaoZhang, QianqiZhang, ZhongzhengLi, Yongbo
Aiming at the problem of insufficient modeling of spatio-temporal heterogeneity in road traffic accident prediction, a dual task machine learning framework integrating geographical environment, location attributes and time periodicity is proposed. The dataset used in this study was derived from traffic accident records of Nanchang during 2019–2023. Firstly, geographical identifiers are generated by rounding and aggregating latitude and longitude coordinates. At the same time, the location type is processed by a one-hot encoding, so as to carry out spatial clustering analysis of accident hotspots. Compared with the North-South pattern, the contribution of geographical features shows a strong East-West trend. The kernel density heatmap identified Zone A and zone B as dual core high-risk areas. Secondly, the sinusoidal/cosine function is used to encode the time feature circularly, which effectively captures the daily change of the accident. The quantitative analysis of random forest regression model showed that time characteristics accounted for 89.2% of the variance of accident frequency interpretation, significantly exceeding the contribution of geographical factors (10.2%) and location attributes (0.6%). After hyperparameter optimization, the accuracy of XGBoost classifier in predicting serious accidents is 75.97%, and the AUC value is 0.8412, which has strong robustness, and provides reliable support for dynamic risk assessment of traffic management system.
Luo, JiangZhang, YuxinLi, XinWu, Ronghai
To minimize noise caused by interior components rubbing against each other, automotive materials are usually tested in advance with the established stick-slip method according to VDA standard 230-206. This procedure is widely used for soft materials, upholstery and plastics. However, it is limited to constant climatic and selected loading conditions. Contrary, in real application, changing climates and dynamic excitations can nevertheless trigger noise issues even in materials rated as suitable in the prior tests. To address this gap, a new test method has been developed that evaluates the stick-slip behavior of material combinations for a wide range of loading and climatic conditions. Conducted in a climate chamber with a standard stick-slip test bench, the procedure applies sinusoidal excitations, dynamic climatic shifts and advanced data analysis. In addition to the usual results the new method also evaluates realistic scenarios such as starting a vehicle in different seasons or sudden jolting movements with high excitation speeds. The result is a detailed map of stick-slip behavior as a function of excitation speed and climate. While requiring a similar level of effort as the traditional test, this approach delivers far greater insight. It enables a more reliable optimization of materials and facilitates targeted material selection for specific applications. In this manner, it can not only contribute to improve product quality but also to achieve quiet interiors and customer satisfaction.
Fritz, SusanneStrangfeld, Martin
Using vibration data to estimate buckling loads is proven effective for a wide range of structures, including rods, plates, and shells. The Arbelo formulation of the vibration correlation technique improves prediction reliability for cylindrical and spherical shells. In this study, we introduce a simplified variant of the Arbelo approach that provides higher prediction accuracy while requiring significantly lower pre-load levels. We define a new parameter, the Stiffness Decay Index (SDI), to characterize stiffness degradation by normalizing the loaded natural frequency with respect to the unloaded state. This metric enables accurate buckling prediction without causing structural damage or permanent deformation. We evaluate SDI numerically and experimentally for multiple isotropic geometries and demonstrate its advantages over the Arbelo method, particularly for ellipsoidal domes subjected to external pressure. We conduct experiments on rods, plates, oblate shells, and beverage cans to measure frequency shifts under pre-loading. The results show that when load data above 50% of the critical value is available, the SDI approach predicts the buckling load with accuracy exceeding 90%. These findings confirm that SDI, by directly correlating vibration response with stiffness loss, provides superior buckling-load prediction and serves as a reliable, non-destructive alternative to the Arbelo vibration-correlation method.
Rangarajan, GopikrishnaV, VishwajithRaju, GangadharanDinavahi, Ramkrishna
Abstract: This research paper investigates the performance of FKM (Fluorocarbon) seal material when exposed to a 50:50 ethylene glycol-water mixture. The study aims to determine the volume change percentage and Hardness change of FKM elastomers under standardized testing conditions. The experimental approach follows ASTM D471 and ASTM 2240 guidelines, focusing on weight and hardness measurements of the test samples to establish a success criterion. The results provide critical insights into the chemical compatibility and durability of FKM elastomers in Aerospace and industrial applications where ethylene glycol-water mixtures are commonly used. The findings contribute to enhanced material selection and design considerations for sealing applications subjected to glycol-based fluids. Samples of FKM material were immersed in the fluid at controlled temperatures and durations, simulating real-world operational conditions. The primary metric of interest, volume change percentage and Hardness change, were assessed through precision measurement techniques. Weight changes before and after immersion were also recorded to correlate material absorption characteristics with the success criteria. Success thresholds were established based on industry requirements for seal integrity and operational reliability. Preliminary results indicate that FKM exhibits minimal volume expansion and hardness change under specified conditions, aligning with the acceptance criteria. These findings support the suitability of FKM seals for long-term use in coolant systems, with implications for material selection and design in demanding applications. This research contributes to the development of durable sealing solutions, ensuring reliability and safety in systems utilizing ethylene glycol-based coolants. Keywords: FKM, Volume Expansion, ASTM D471
Yarolkar, MakrandPatil, SandipSingh, Tanul
The mechanical performance of short fiber-reinforced plastic (SFRP) components is highly sensitive to fiber orientation, which is significantly influenced by the injection gate location during the molding process. Traditionally, gate placement decisions are driven by warpage minimization strategies, often overlooking mechanical performance under diverse load cases. This research introduces an automated workflow within Digimat-MS that integrates injection gate optimization into the early design phase, leveraging Integrated Computational Materials Engineering (ICME) principles. The proposed methodology enables engineers to upload either Marc, Abaqus or Ansys input decks, select a component of interest, assign material cards, and define gate scenarios. A Design of Experiments (DOE) is then executed locally or remotely, allowing Digimat to evaluate multiple gate configurations. The system aggregates results and identifies optimal gate locations based on the initiation of failure under quasi-static loading conditions, thereby reducing reliance on trial-and-error and expert intuition. This approach not only streamlines the simulation process but also ensures that gate placement decisions are informed by comprehensive mechanical assessments across multiple load cases. The integration of Digimat’s ICME capabilities enhances simulation accuracy, leading to improved reliability and performance of SFRP components.
Kauthale, TanmayMadhavan, VinaySoni, Ganesh
This SAE standard establishes the requirement for suppliers to plan a reliability program that satisfies the following three requirements: a The supplier shall ascertain customer requirements b The supplier shall meet customer requirements c The supplier shall assure that customer requirements have been met
G-41 Reliability
The sag prediction of overhead ground wire is very important, because excessive sag will reduce the safety margin and endanger the transmission reliability, especially under extreme conditions such as heat wave and icing. To solve this problem, we propose a model that combines Exponential Moving Average (EMA) features and monotonic constraints XGBoost. By fusing multi-source meteorological data and sag monitoring data, sag-related features are extracted after outliers elimination and time alignment. Furthermore, EMA features are introduced to capture short-term fluctuations and time dependence. Monotonic constraints encode the physical prior knowledge of “the higher the temperature, the greater the sag”, which improves the physical interpretability. On the measured data, the model’s coefficient of determination is increased from 0.709 to 0.879, indicating that the short-term prediction accuracy is significantly improved. The combined application of EMA features and monotonic constraints can maintain the physical consistency and enhance the time learning ability, which provides a feasible scheme for intelligent sag prediction of transmission lines.
Li, XingyuLin, ShizhongShao, ZhanCui, ShichengChen, RuiduanLuo, He
This study investigates the use of the Overset mesh method for propeller simulations in OpenFOAM and compares it with the Arbitrary Mesh Interface (AMI) approach. While AMI is well validated for rotor aeroacoustics, it is limited in handling large relative motions and complex component interactions. In contrast, the Overset method enables flexible simulation of transition kinematics using overlapping grids, though its aeroacoustic capability in OpenFOAM has not been well established. A comparative analysis was conducted on a Joby-scale five-bladed propeller at an 80° tilt angle without a fairing, representing a transition-flight condition. Aerodynamic and acoustic predictions were obtained using hybrid DDES coupled with the Ffowcs Williams–Hawkings method. Results show that the Overset method provides improved agreement with experimental thrust and torque and captures stronger leading-edge vortices than AMI. Both methods resolve blade-vortex and blade-wake interactions. However, the Overset approach produces higher broadband noise due to stronger vortices and interpolation effects, while AMI yields smoother pressure fields and clearer tonal content. In the far field, AMI better matches experimental SPL trends. Overset shows larger first-BPF SPL errors (up to 22.5 dB vs. 5.7 dB for AMI), though OASPL differences remain small. Overall, Overset is less reliable for noise prediction and more computationally expensive.
Hua, JieMankbadi, Reda R.Lyrintzis, Anastasios S.Golubev, Vladimir
This study highlights that rotor-rotor interactions can significantly modify both tonal and broadband noise characteristics. Continued investigation into these mechanisms is vital to developing reliable noise prediction methodologies and establishing design strategies that balance propulsion efficiency with acoustic acceptability for AAM vehicles. This work sought to answer what physical mechanisms contribute to the increased dominance of broadband noise in eVTOL-scale rotors. By characterizing the tip vortex of a single rotor, it was found that rotor-rotor interaction is highly dependent on two factors: Blade-vortex phasing and interaction duration. Characteristic vortex time scales can be correlated with increased noise. Interactions that generate increased noise have a non-linear relationship with rotor positioning. The interaction-generated noise is highly directive. This work aims to elucidate the dominant source noise mechanisms of rotor-rotor interaction noise by characterizing blade tip vortices using PIV.
Sorensen, PeterSeth, DhureeCuppoletti, Daniel
This document applies to the development of Plans for integrating and managing COTS assemblies in electronic equipment and Systems for the commercial, military, and space markets, as well as other ADHP markets that wish to use this document. For purposes of this document, COTS assemblies are viewed as electronic assemblies such as printed wiring assemblies, disk drives, servers, printers, laptop computers, etc. There are many ways to categorize COTS assemblies1, including the following spectrum: At one end of the spectrum are COTS assemblies whose design, internal parts2, materials, configuration control, traceability, reliability, and qualification methods are at least partially controlled, or influenced, by ADHP customers (either individually or collectively) or by industry standards. An example at this end of the spectrum is a VME circuit card assembly. At the other end of the spectrum are COTS assemblies whose design, internal parts, materials, configuration control, and qualification methods are not controlled, or controllable, in any way by ADHP customers (either individually or collectively) or by industry standards. An example is a disk drive targeted for an industry other than ADHP use. It is critical for the Plan owner to: (1) review and understand the design, internal parts, materials, configuration control, reliability, and qualification methods of all “as-received” COTS assemblies and their capabilities with respect to their application in the intended System and environment; (2) identify risks; and where necessary (3) take additional action to mitigate the risks associated with the performance and reliability of the COTS assembly in the ADHP system.
APMC Avionics Process Management
Why field campaigns in the automotive industry have been going up over the years despite the strong development of technical knowledge, computational design tools and techniques to secure higher reliability standards since early stages of development phases? Uncertainties created by product complexity have been a factor that affects the ability of the manufacturers to prevent design failures before the product launch. Another factor is the shorter product development time, less test time to validate the product means that the new design will not have enough exposure to the real truck application and so some failures may not be able to be detected during the project. To deal effectively with uncertainties this study shows an application of reliability growth techniques in conjunction with DfR- Design for Reliability framework to validate the truck design in the customer application. The Crow - AMSAA method is applied to measure the reliability growth of the complete vehicle in various stages of product development by using the failure rate intensity. By doing that reliability related failures can be found and fixed during the project to secure the required level of failure rate at SOP.A tool developed in excel has the capability to calculate the confidence level and the demonstrable failure rate at any stage of the project to prove statistically the level of certainty of the results to support the decision-making process during project gates.
Coitinho, Marcos
LiDAR (Light Detection and Ranging) systems are essential for autonomous driving (AD) and advanced driver-assistance systems (ADAS), providing accurate 3D perception of the surrounding environment. However, their performance significantly deteriorates under adverse weather conditions such as fog, where laser pulses are scattered by airborne particles, resulting in substantial noise and reduced ranging accuracy. This scattering effect makes it difficult to detect objects within or behind particulate matter, posing a serious challenge for reliable perception in real-world driving scenarios. To address this issue, we propose an algorithm that combines adaptive multi-echo signal processing with a feature-integrated, rule-based denoising framework to enhance LiDAR performance in noisy environments. The multi-echo approach selectively utilizes meaningful signal returns by evaluating both intensity and relative echo positions. Based on predefined rules, the algorithm identifies the echo most likely to represent a real object. The rule-based denoising algorithm dynamically adjusts thresholds by integrating multiple features, including point clouds density, intensity, and echo width. These features are evaluated in conjunction with measured distance to adaptively suppress fog noise and improve signal reliability. This synergistic method enables robust detection of real objects even in low-visibility conditions. Experimental evaluations demonstrate that the proposed algorithm significantly improves effective ranging distance under adverse conditions compared to conventional methods. Furthermore, it eliminates up to approximately 99% of noise induced by airborne particles in foggy scenarios. These results highlight the potential of our approach to enhance LiDAR reliability and safety in real-world automotive applications, contributing to the advancement of autonomous driving technologies under all-weather conditions.
Kaito, SeiyaZheng, ShengchaoFujioka, IbukiBeppu, Taro
The present study investigates optimization of ultimate tensile strength (UTS) in FSW of AA2024-T3 and SS304 in a butt joint configuration. An L18 mixed-level orthogonal array was used to design 18 experiments, varying tool rotational speed (450, 560, and 710 rpm), traverse speed (20, 25, and 40 mm/min), and pin offset (1 and 1.5 mm toward the Al side). The tool rotational speed had the greatest influence on UTS, contributing nearly one-third of the total variance, followed by pin offset and traverse speed. The optimal combination, 450 rpm, 20 mm/min, 1.5 mm offset, yielded a UTS of 344.7 MPa and a joint efficiency of 78.3%. At this setting, peak temperatures reached ~356 °C, ensuring sufficient plasticization and uniform mixing of the Al–SS interface, producing a refined stir zone with an average grain size of 4.2 μm. Fracture analysis revealed ductile failure at the optimal parameters, whereas suboptimal conditions resulted in brittle or mixed fractures due to either insufficient or excessive heat input. These results demonstrate that Taguchi optimization effectively correlates process parameters, thermal profile, material mixing, and mechanical performance, enabling reliable, defect-free dissimilar FSW joints for structural and aerospace applications.
Mir, Fayaz AhmadKhan, Noor ZamanPali, Harveer Singh
Oil churning and windage power losses in dip-lubricated gearboxes can significantly affect overall transmission efficiency, particularly at high rotational speeds. As modern gearbox systems are pushed toward higher efficiency and reliability, understanding and predicting these losses becomes increasingly important. In addition to energy dissipation, the associated multiphase flow phenomena—such as oil splashing, thin film formation along gear surfaces, and aeration of the sump—strongly influence lubrication effectiveness, heat transfer, and component durability. Capturing these effects requires a robust numerical strategy that can resolve both power loss mechanisms and multiphase flow dynamics with sufficient accuracy. In this study, a single spur gear is numerically analyzed under varying oil depths and rotational speeds to quantify total power loss and investigate oil flow patterns. The computational approach employs a volume-of-fluid multiphase framework, and the predictions are systematically validated against experimental data from the OSU Lab. Validation is carried out in two stages: first, by comparing the simulated oil free-surface shapes with experimental flow visualizations for various operating conditions; and second, by comparing total power loss across a range of rotational speeds and immersion depths. The findings confirm that qualitative comparisons of oil behavior show good agreement with experimental observations including splash generation, oil streak formation, and gear surface wetting. Furthermore, predicted power loss trends align with experiments, exhibiting exponential growth with RPM and a transition toward quadratic scaling as oil depth increases. Overall, this work highlights the capability of the numerical framework to predict both churning losses and multiphase flow behavior in gear lubrication systems, providing a foundation for future gearbox design and optimization.
Mahyawansi, Pratik J.Haria, HiralPandey, AshutoshKhajeh Hosseini D, Navvab
Trust calibration is vital for safe human–automation interaction but remains largely qualitative. This study develops multiple quantitative frameworks modeling trust as a function of automation reliability. Four progressive models of binary, linear, triangular, and logistic formalize the calibrated trust zone, defining where human reliance aligns with system performance. The framework corrects major misconceptions: that trust is purely qualitative, that low trust–low reliability states are acceptable, and that overtrust and distrust pose equal risk. It establishes a minimum reliability threshold for meaningful trust and identifies distrust as the safer default in high-risk contexts. A case study on an empirical observation of 32 AI applications plotted in the trust–reliability space confirms the analysis, revealing a consistent distrust tendency where reliability exceeds user confidence and other observations. By quantifying trust through reliability, the study reframes it as a controllable safety variable, enabling predictive calibration and adaptive, trust-aware safety architectures for reliable human–AI collaboration.
Wen, HeMounir, Adil
Patching vulnerabilities in safety-critical domains such as automotive and aerospace is costly and complex. A small code modification can trigger a complete rebuild, producing a binary with widespread changes. This inflates patch size, complicates regression testing, and makes over-the-air (OTA) updates inefficient, as traditional binary patches often replace large portions of the executable. We present a binary rewriting–based experiment that shows the feasibility of a patch that updates only the affected bytes by computing the impact of a code change at the binary level. This produces minimal, localized patches rather than regenerated executables. The preliminary experiment shows that a single source change, which leads to thousands of modified bytes after recompilation, can be captured with only a few bytes using our method. For automotive and aerospace systems, this technique reduces patch size, conserves bandwidth, and minimizes disruption to certified software, offering a promising direction for efficient and reliable vulnerability remediation.
Awadhutkar, PayasSauceda, JeremiasTamrawi, Ahmed
As automotive aerodynamic testing facilities evolve to capture more real-world behavior, updating the correlation between old and new technologies is essential. Recently, the three-member consortium of the United States Council for Automotive Research (USCAR) - General Motors, Ford Motor Company, and FCA US LLC - transitioned from full-size static ground plane facilities to 5-belt moving ground plane wind tunnel facilities. The primary objective of this study was to update the correlation data sets to maintain consistent and robust data sharing among companies, which is the cornerstone of USCAR efforts. To achieve this, a set of updated correlation data sets were calculated to replace the original correlation study results from 2008. Additionally, the methodology for applying correlation equations was revised from using averaged wind tunnel data to employing direct wind tunnel-to-wind tunnel correlation equations. In a two-phase correlation effort conducted in 2022 and 2025, the three companies exchanged and evaluated six vehicles of varying size and proportions across the three rolling road wind tunnels. To ensure the updated correlation data sets capture the bounds of current and future vehicle aerodynamic performance, the tested bandwidth of coefficient of drag area (CDA) data ranged from 0.37 m2 to 1.45 m2 (CD from 0.17 to 0.48). Despite the unique challenges of each wind tunnel project, the outcome of the updated correlation efforts demonstrated excellent correlation (R2 > 99.8%) across direct tunnel-to-tunnel comparisons, mirroring the success of the original 2008 correlation efforts. These findings validate the accuracy and reliability of aerodynamic data collection in each of the three rolling road facilities, thereby supporting consistent and robust data sharing among USCAR partners.
Nastov, AlexanderLounsberry, ToddMadin, TrevorLangmeyer, GregoryFadler, GregorySkinner, ShaunHorton, Damien
High-fidelity 3D reconstruction of large-scale urban scenes is critical for autonomous driving perception and simulation. Existing neural rendering methods, including NeRF and Gaussian-based variants, often face challenges like unstable geometry, noisy motion segmentation, and poor performance under sparse viewpoints or varying illumination. This paper presents a self-supervised Gaussian-based framework to address these challenges, enabling robust static–dynamic decomposition and real-time scene reconstruction. The proposed method introduces three innovations: (1) a semantic–geometric feature fusion module that combines semantic context and geometric cues for reliable motion prior estimation; (2) a cross-sequence geometric consistency constraint that enforces depth and surface continuity across time and viewpoints; (3) an efficient Gaussian parameter optimization strategy that stabilizes geometry by jointly constraining scale and normal updates. Experiments on the Waymo Open Dataset and KITTI benchmarks show that the proposed framework improves PSNR by up to +1.3 dB, SSIM by +0.015, and reduces depth L1 error by over 25%, while achieving real-time rendering speeds exceeding 40 FPS. These results demonstrate that the proposed framework provides a robust, scalable solution for urban scene reconstruction, with practical applications in autonomous driving.
Feng, RunleiWang, NingZhang, Zhihao
Military and aerospace applications have become increasingly complex real-time systems. Multi-core SoCs improve performance but create new challenges in maintaining and verifying deterministic behavior. Connected systems require exceptional security to protect code from external cyberattacks. Evolving functional safety and reliability standards that keep raising the bar mean developers need to begin comprehensive testing sooner if they are going to meet tighter design schedules. Finally, certifying these complex systems has become even more difficult. To help OEMs meet these challenges, the RISC-V architecture has been designed with unique capabilities that support reliability and security in the development of safety-critical applications. With its open instruction set architecture, modularity, and extensibility, RISC-V accelerates the design of functionally safe systems while reducing the complexity, cost, and risk associated with certification to standards like DO-178C and ISO 26262.
Business Reliability Growth for Automotive Engineering, Volume 4R-5522/17/2026
In a world where every business process is under pressure to perform faster, safer, and more reliably, this book delivers a powerful roadmap for sustained operational excellence. Centered on the proven methodology of Design of Experiments (DOE), it shows how organizations can move beyond reactive problem-solving to systematic reliability growth. From well-defined standard operating practices to management-level decision-making, the book connects strategy, data, and execution to create repeatable, measurable results across the enterprise. Readers are guided through practical, real-world applications of DOE, from selecting the right factors and levels to executing robust experiments, analyzing outcomes, validating solutions, and continuously monitoring performance. Each chapter translates complex statistical and engineering concepts into actionable business value, helping teams improve quality, reduce waste, and increase return on investment. Key capabilities explored in this book include: • Holistic reliability across design, manufacturing, supply chain, and marketing. • Advanced experimental designs, including split-plot and fractional factorial methods. • Fault tree analysis (FTA) and FMEA for failure prediction and prevention. • Supply chain optimization through multivariate process control. • Production and field reliability using design for testability and diagnostics. • Electric vehicle system and battery reliability analysis. • Marketing reliability driven by voice of customer and data-based value analysis. This book is an essential resource for engineers, operations leaders, and technical managers who want to build resilient systems, unlock innovation, and achieve long-term competitive advantage through disciplined, data-driven reliability.
Chiang, Young J.
The growing global adoption of electric vehicles (EVs) has resulted in a spike in the number of EV charging stations. As EVs have become more and more popular worldwide, a large number of EV charging stations are opening up to accommodate their demands. During grid failures, an EV charging station can also serve as a flexible load connected to the grid to balance out voltage fluctuations. An EV charging station when powered using a separate source, such as solar or wind, can function as a powerhouse, bringing electricity to the grid when it's needed. Therefore, instead of installing more equipment to sustain voltage, the current EV charging station can be efficiently used to meet the grid's needs during failures. These stations have the potential to be dynamic, grid-connected assets for sustainable cities and communities in addition to their core function of vehicle charging (SDG 11). Because of their dual purpose, they can serve as adaptable loads that reduce voltage variations during grid outages, making it easier for people to obtain dependable electricity (SDG 7). By making use of the current EV infrastructure, a low-carbon energy transition is promoted, and resource efficiency (SDG 13- Climate Action) is supported, while lowering the demand for additional grid-support devices.
R, UthraRangarajan, RaviD, SuchitraD, Anitha
The landing gear, as a crucial component of an aircraft, is pivotal for maintaining the safety and reliability of air travel. This study introduces a data-driven structural optimization method aimed at mitigating the peak strain on the landing gear’s rocker arm. The initial phase involves selecting nine design variables for parametric modeling to generate an initial dataset. Subsequently, the Maximum Information Coefficient (MIC) technique is used to conduct a parameter sensitivity analysis, enabling the identification and elimination of variables with minimal influence. A comparative analysis between the Genetic Algorithm–Backpropagation Neural Network (GA-BPNN) and BPNN reveals that GA-BPNN has a superior fitting capability on the enhanced dataset. By applying Particle Swarm Optimization (PSO), the optimal solution for GA-BPNN is identified. The implementation of this optimized method results in a 38.16% reduction in peak strain, validating its feasibility and reliability in enhancing aircraft safety.
Chen, HuShi, ShiWang, MengFang, XingboWei, XiaohuiNie, Hong
How engineers can ensure safety, reliability and quality in aerospace systems. Courbevoie, Île-de-France In an industry where failure is not an option and precision is paramount, aerospace manufacturers and suppliers are constantly seeking components and system solutions that deliver trusted reliability, performance, and compliance. Industry standards are a key part of achieving these high expectations, bringing together global leaders in the mobility industries to create defined, repeatable methods and consistent processes. One of these aerospace standards is AS1895 developed by SAE International - a critical standard due to the need for durable components that can withstand extreme conditions and offer high performance: high-temperature resistance, pressure sealing, and long service life with a cost-effective installation method. Leading aerospace companies such as Eaton and Honeywell have been manufacturing components that meet this standard for a long period of time.
This paper presents a reinforcement learning (RL)–based outer-loop controller for quadrotor UAV trajectory tracking and its real-world experimental validation. The proposed approach integrates RL into a standard cascaded flight-control architecture by replacing the conventional PID outer loop while retaining the onboard attitude and body-rate PID controllers. This hierarchical design preserves reliable inner-loop stabilization while leveraging RL to address nonlinear dynamics, coupling effects, and modeling uncertainty in translational motion. The controller is trained entirely in a physics-based simulation using Proximal Policy Optimization (PPO) and transferred directly to a Crazyflie quadrotor without additional tuning. Performance is evaluated through real-world figure-8 trajectory tracking experiments with varying time scales to impose increasing dynamic demands. Compared to a conventional PID outer-loop controller operating under identical conditions, the RL-based controller consistently reduces effective phase delay and achieves lower position and velocity tracking errors, particularly for aggressive trajectories. The results demonstrate robust sim-to-real transfer and highlight the potential of learning-based outer-loop control as a drop-in enhancement to classical quadrotor flight controllers.
Saj, VishnuVemuri, SushilKalathil, DileepBenedict, Moble
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, VinodKulkarni, MalharSoni, Asheesh Kumar
In today’s market, faster product development without compromising durability is essential. Durability assessment ensures a vehicle maintains structural integrity under normal and extreme conditions. Achieving this requires effective Road Load Data Acquisition, 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. This study presents a full digital methodology of fatigue life estimation for suspension aggregates. A study has been demonstrated on Rear Twist Beam component of rear suspension. The approach integrates the digital RLDA methodology presented in literature and finite element analysis simulation process, enabling durability assessments entirely within the virtual domain. This approach demonstrates how digital RLDA-derived loads, combined with finite element analysis simulations, can accelerate the product development life cycle by avoiding dependency on physical RLDA loads for durability assessments. This allows for proactive durability assessments without extensive dependency on Rig Level component testing, aggregate level testing, physical prototypes and RLDA loads. The proposed digital framework is validated against experimental results and shows strong correlation with actual fatigue behavior. It provides a reliable and efficient tool for early design phase fatigue assessment, supporting faster design iterations, reducing Computer-Aided Engineering loops and thereby minimizing development time and costs. This paper describes the advantages of a fully digital approach to the product development lifecycle using Digital RLDA and finite element analysis simulations over the traditional approach of vehicle validation.
Kokare, SanjayDwivedi, SushilSiddiqui, ArshadIqbal, Shoaib
Manufacturing tolerances play a critical role in the quality and functionality of components, particularly those made from rubber. Even slight deviations in dimensions can cause significant issues such as improper fit and reduced performance, leading to increased costs and project delays. This is especially true for rubber grommets, which are nonlinear elastic components commonly used as sealants, gaskets, and insulation covers in automotive and industrial applications. Typically manufactured from EPDM rubber with varying Shore hardness, grommets must maintain precise geometry to ensure sealing integrity and protect adjacent parts. Dimensional inaccuracies can result in failures such as buckling or misalignment, compromising both functionality and durability. This study proposes a digital simulation methodology for early-stage evaluation of grommet robustness, reducing reliance on physical prototypes. Using a stochastic design of experiments (DOE) approach, the influence of critical geometric parameters on grommet performance is assessed under variable manufacturing conditions. Buckling, identified as the primary failure mode, along with other functional metrics, is analyzed across a spectrum of dimensional tolerances. These insights support more efficient design workflows and enhance the robustness of rubber grommets in real-world applications.
Beesetti, SivaHattarke, MallikarjunJames Aricatt, JohnPathan, Eram
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 analyzing 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 load values and their frequency of application, providing a structured representation of dynamic loading scenarios. Raceway life evaluation emphasizes the cumulative effects of dynamic loads over time through techniques like load-cycle transformation. By incorporating road load data and equivalent load computations, damage mechanisms can be predicted. Simulating real-world conditions allows for numerical estimation of raceway life, offering insights into bearing longevity and reliability. A formula for calculating the equivalent load (P) is employed, using an exponent (e) to weigh and aggregate load values raised to its power, then normalizing by the total number of cycles. This approach simplifies complex load cases for faster, efficient evaluation. The methodology provides a systematic framework for assessing dynamic load impacts on raceways, aiding in life prediction and durability improvement.
Narendra, VishwanathMane, YogirajPaua, KetanSingh, Ram KrishnanVellandi, Vikraman
Accurate trajectory prediction of traffic agents is critical for enabling safer and more reliable autonomous driving, particularly in urban driving scenarios where close-range interactions are most safety critical. High-definition (HD) and standard-definition (SD) maps play a vital role in this process by providing lane topology and directional cues for forecasting agent movements. However, HD maps are expensive and resource-intensive to create, often requiring specialized sensors, while SD maps lack the precision needed for reliable autonomous navigation. To address this, we propose a novel framework for trajectory prediction that leverages online reconstruction of HD maps using vehicle-mounted cameras, offering a scalable and cost-effective alternative. Our method achieves improvements in predicting accuracy, particularly in close-range scenarios, the most crucial for urban driving, while also performing robustly in settings without pre-built maps. Furthermore, we introduce a new safety-aware evaluation metric that incorporates heuristic weights based on agent relevance and distance, enhancing traditional metrics like Brier-minFDE with a stronger focus on safety-critical scenarios. Extensive experiments demonstrate that our approach outperforms state-of-the-art map-less methods, particularly in close-range prediction, while our proposed metric establishes a more domain-relevant benchmark for assessing trajectory prediction in autonomous driving.
Upreti, MinaliGirijal, RahulB A, NaveenKumarThontepu, PhaniGhosh, ShankhanilChakraborty, BodhisattwaBhardwaj, Ritik
Durability validation of full vehicle structures is crucial to ensure long-term performance and structural integrity under real-world loading conditions. Physical test strain and finite element (FE) strain correlation is vital for accurate fatigue damage predictions. During torture track testing of the prototype vehicle, wheel center loads were measured using wheel force transducers (WFTs). In same prototype strain time histories were recorded at critical structural locations using strain gauges. Preliminary FE analysis was carried out to find out critical stress locations, which provided the basis for placement of strain gauges. Measured loads at wheel centers were then used in Multi Body Dynamics (MBD) simulations to calculate the loads at all suspension mount points on BIW. Using the loads at hard points transient analyses were performed to find out structural stress response. Strain outputs from the FE model were compared with physical measurements. Insights gained from these comparisons were used to update the model to achieve better correlation with test data. The findings of this paper establish a robust methodology for improving vehicle durability assessments by enhancing confidence in fatigue life predictions and structural performance. By integrating physical testing and FE simulations, this approach ensures accurate strain correlation and effective validation of long-term performance. It also provides a scalable framework for validating structural changes, supporting lightweight material integration, and enabling Value Analysis/Value Engineering (VAVE) initiatives to optimize cost-effectiveness and performance. This methodology strengthens simulation-driven durability development, offering valuable insights for future vehicle programs.
Jaju, MayurDokhale, SandeepGadre, NileshPatil, Sanjay
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