Browse Topic: Reliability

Items (3,418)
Mechanical component failure often heralds superficial damage indicators such as color alteration due to overheating, texture degradation like rusting or false brinelling, spalling, and crack propagation. Conventional damage assessment relies heavily on visual inspections performed by technicians, a practice bogged down by time constraints and the subjective nature of human error. This research paper delves into the integration of deep learning methodologies to revolutionize surface damage evaluation, addressing significant bottlenecks in diagnostic precision and processing efficiency. We detail the end-to-end process of developing an intelligent inspection system: selecting appropriate deep learning architectures, annotating datasets, implementing data augmentation, optimizing hyperparameters, and deploying the model for widespread user accessibility. Specifically, the paper highlights the customization and assessment of state-of-the-art models, including EfficientNet B7 for
Cury, RudonielGioria, GustavoChandrasekaran, Balaji
Traditional vehicle diagnostics often rely on manual inspections and diagnostic tools, which can be time-consuming, inconsistent, and prone to human error. As vehicle technology evolves, there is a growing need for more efficient and reliable diagnostic methods. This paper introduces an innovative AI-based diagnostic system utilizing Artificial Intelligence (AI) to provide expert-level analysis and solutions for automotive issues. By inputting various details such as the vehicle’s make, model, year, mileage, problem description, and symptoms, the AI system generates comprehensive diagnostics, identifies potential causes, suggests step-by-step repair solutions, and offers maintenance tips. The proposed system aims to enhance diagnostic accuracy and efficiency, ultimately benefiting mechanics and vehicle owners. The system’s effectiveness is evaluated through various experiments and case studies, showcasing its potential to revolutionize vehicle diagnostics
Sasikala, T.Swathi, B.Raj, J. Joshua DanielShetty, G. ShreyasDidagur, Darshan
The increase in vehicular traffic on Indian roads has led to a significant rise in the frequency of horn usage, particularly in city driving conditions and during peak traffic hours. Existing electro-mechanical horns are designed to have a mission life of 100,000 cycles according to Indian standards IS 1884 [1]. However, the intensified usage patterns have prompted a re-evaluation of the efficacy of these requirements. Studies reveal that the average horn blow frequency for normal usage vehicles is approximately three times per kilometer. When extrapolated to various usage categories, such as public transport and privately owned vehicles, observed increase in average horn blowing frequency per kilometer. When extrapolated, this corresponds to more than 4 lakhs cycles for a vehicle mission life of 2.5 lakhs kilometers. This insight drives the need to review and update validation test specifications to better align with customer usage patterns, thereby enhancing component reliability. By
Joshi, Vivek S.Jape, Akshay
Increased use of advanced composite structural materials on aircraft has resulted in the need to address the more demanding quality and nondestructive testing procedures. Accordingly, increased utilization of solid laminate composites is driving changes to airline NDI/NDT training requirements and greater emphasis on the application of accurate NDI/NDT methods for composite structures. Teaching modules, including an introduction to composite materials, composite NDI/NDT theory and practice, special cases and lessons learned, are included in this document as well as various hands-on NDI/NDT exercises. A set of proficiency specimens containing realistic composite structures and representative damage are available to reinforce teaching points and evaluate inspector’s proficiency. Extensive details of the guidance modules, hands-on exercises, and proficiency specimens are all presented in this document. This document does not replace OEM guidance as may be specific to material, process
AMS CACRC Commercial Aircraft Composite Repair Committee
ABSTRACT The main goal of this paper is to report recent progress on two example projects supported within the Ground Robotics Reliability Center (GRRC), a TARDEC supported research center headquartered at the University of Michigan. In the first project, the concept of Velocity Occupancy Space (VOS), a new navigation algorithm that allows a robot to operate using only a range finding sensor in an unknown environment was developed. This method helps a mobile robot to avoid stationary and moving obstacles while navigating towards a target. The second project highlighted is related to energy and power requirement of mobile robots. Hazardous terrains pose challenges to the operation of mobile robots. To enable their safe and efficient operations, it is necessary to detect the terrain type and to modify operation and control strategies in real-time. A research project supported by GRRC has developed a closed-form wheel-soil model. Computational efficiency of this model is improved by
Peng, HueiUlsoy, A. Galip
ABSTRACT Accurate reliability assessment requires accurate output distribution. To obtain correct output distribution, a very large number of output physical test data is required, which is prohibitively expensive. Regarding this, simulation-based methods have been developed under the assumption that: (1) accurate input distribution models obtained from large number of input test data; and (2) accurate simulation model (including surrogate model if utilized) that correctly represents physical phenomena. However, in real application, only limited numbers of input test data are available. Thus, input distribution models are uncertain. In addition, the simulation model could be biased due to assumptions and idealizations. Furthermore, only a limited number of physical output test data is available. As a result, a target output distribution to which simulation model can be validated is uncertain and the corresponding reliability is also uncertain. This paper proposes a confidence-based
Choi, K.K.Cho, HyunkyooMoon, Min-yeongGaul, NicholasLamb, DavidGorsich, David
ABSTRACT Leader-follower autonomous vehicle systems have a vast range of applications which can increase efficiency, reliability, and safety by only requiring one manned-vehicle to lead a fleet of unmanned followers. The proper estimation and duplication of a manned-vehicle’s path is a critical component of the ongoing development of convoying systems. Auburn University’s GAVLAB has developed a UWB-ranging based leader-follower GNC system which does not require an external GPS reference or communication between the vehicles in the convoy. Experimental results have shown path-duplication accuracy between 1-5 meters for following distances of 10 to 50 meters. Citation: K. Thompson, B. Jones, S. Martin, and D. Bevly, “GPS-Independent Autonomous Vehicle Convoying with UWB Ranging and Vehicle Models,” In Proceedings of the Ground Vehicle Systems Engineering and Technology Symposium (GVSETS), NDIA, Novi, MI, Aug. 16-18, 2022
Thompson, KyleJones, BenMartin, ScottBevly, David
ABSTRACT A toolchain must be functionally cohesive with a business process, especially in technical domains such as complex systems engineering. Despite the industry-wide shift towards model-based digitization within engineering organizations, there is a lack of development in implementing model-based RAMS (Reliability, Availability, Maintenance, Safety) processes. This results in a missed opportunity to create value throughout the entire system lifecycle, from conceptual design to operations. This paper proposes some reasons for this and outlines a framework for evaluating model-based toolchains in the context of the entire Engineering cycle. A model-based architecture for RAMS is proposed and contrastively evaluated with respect to SysML. Key use cases are identified, and benefits are demonstrated using Maintenance Aware Design Environment Software. Citation: J. Langton, S. Hilton, “Iterative Co-Design Of Organizational Processes and Toolchains For Model-Based Reliability
Langton, JakeHilton, Sam
ABSTRACT This research paper addresses the ground vehicle reliability prediction process based on a new integrated reliability prediction framework. The paper is an extension of the paper presented last year at the GVSETS symposium. The integrated stochastic framework combines the computational physics-based predictions with experimental testing information for assessing vehicle reliability. The integrated reliability prediction approach incorporates the following computational steps: i) simulation of stochastic operational environment, ii) vehicle multi-body dynamics analysis, iii) stress prediction in subsystems and components, iv) stochastic progressive damage analysis, and v) component life prediction, including the effects of maintenance and, finally, iv) reliability prediction at component and system level. To solve efficiently and accurately the challenges coming from large-size computational mechanics models and high-dimensional stochastic spaces, a HPC simulation-based
Ghiocel, Dan M.Negrut, DanLamb, DavidGorsich, David
ABSTRACT Significant Design for Reliability (DfR) methodology challenges are created with the integration of autonomous vehicle technologies via applique systems in a ground military vehicle domain. Voice of the customer data indicates current passenger vehicle usage cycles are typically 5% or less (approximately 72 minutes of use in a twenty-four hour period) [2]. The time during which vehicles currently lay dormant due to drivers being otherwise occupied could change with autonomous vehicles. Within the context of the fully mature autonomous military vehicle environment, the daily vehicle usage rate could grow to 95% or more. Due to this potential increase in the duty or usage cycle of an autonomous military vehicle by an order of magnitude, several issues which impact reliability are worth exploring. Citation: M. Majcher, J. Wasiloff, “New Design for Reliability (DfR) Needs and Strategies for Emerging Autonomous Ground Vehicles”, In Proceedings of the Ground Vehicle Systems
Majcher, MonicaWasiloff, James
Abstract This paper presents a fault-tolerant powertrain topology for series hybrid electric vehicles (SHEVs). The introduction of a redundant phase leg that is shared by three converters in a standard SHEV drive system allows to maximize the reliability improvement with minimal part-count increase. The new topology features fast response in fault detection and isolation, and post-fault operation at rated power throughput. The operating principle, control strategy, and fault diagnostic methods are elaborated. The substantially improved reliability over the standard topology is verified by the Markov reliability model. Time-domain simulation based on a Saber model has been conducted and the results have verified the feasibility and performance of the proposed SHEV drive system with fault-tolerant capability. The experimental results from a prototype have further validated the robust fault detection scheme and excellent post-fault performance
Song, YantaoWang, Bingsen
ABSTRACT The durability and reliability of military vehicle systems are traditionally tested at Aberdeen Proving Ground by driving vehicles on a set of paved roads, secondary roads, trails, and cross-country terrains. However, driving mile-for-mile over the proving ground test courses is very time-consuming and costly. The U.S. Army Aberdeen Test Center (ATC) has recently conducted accelerated durability tests of wheeled vehicles using two different methods: accelerated hardware-in-the-loop simulation and accelerated field testing. This paper discusses the methods used to date and associated technical details to highlight options for future accelerated testing
Ramsey, GregSchultz, GregClerkin, James
ABSTRACT The increasing application of sensors, actuators, and complex algorithms for delivering artificial intelligence and connectivity in products and product-systems will drive an unprecedented growth in design complexity and software content, making it increasingly more difficult to ensure dependability in an economical manner. Much learning about the dependability of such new and innovative products is likely to happen as they are conceived and designed. Consequently, accelerated verification and validation iterations supported by easy and rapid storage and retrieval of failure knowledge must be enabled. No single software solutions provider effectively covers all three critical areas required for developing and delivering dependable smart connected products, namely, reliability engineering, systems engineering, and failure knowledge management. This paper mainly presents a potential map of the commonly used reliability engineering tools overlaid on the systems engineering
Agaram, Venkatesh
ABSTRACT Value Engineering (VE) is an organized effort directed at analyzing the function of a product, service, or process to achieve the lowest total cost of effective ownership while meeting the customer’s needs. A comparison as to how VE is applied and to what extent is made between the automotive industry and the Government using the Program Executive Office Ground Combat Systems (PEO GCS) as a standard. Both the automotive industry and the Government use common VE techniques to conduct VE studies. Both use VE to manage functionality to yield value to the customer. Neither the Government nor the automotive industry sacrifices the quality of the product or its reliability in the name of cost. Both the auto industry and the PEO employ a systematic team approach to analyze and improve the value of a product, facility design, system, or service. Applying systems engineering principles helps ensure successful execution of the PEO GCS VE program. The auto industry uses VE more widely
Dmoch, Barbara J.Wiklund, George
ABSTRACT The U.S. Army Tank-Automotive Research, Development and Engineering Center (TARDEC) contracted DornerWorks Ltd. to evaluate Ethernet-based networking protocols for the safety-critical RDECOM Modular Active Protection Systems (MAPS) framework (MAF). The MAF requires a universal and robust high-speed communication network that can transmit heterogeneous data at near gigabit speeds in a deterministic fashion with bounded and predictable latency. The objectives were to evaluate candidate protocols through rigorous stressing scenarios to: 1) assess and estimate upper bound of performance including data throughput and reliability; and, 2) detect and identify causes and conditions of data loss or corruption. We assessed four protocols: SAE AS6802 (TTEthernet; TTE), ARINC664p7 (rate-constrained; RC), COTS UDP integrated with these two protocols (best-effort; BE), and UDP on a COTS network under three levels of network saturation and with varying payload sizes. On an unsaturated
Verbree, David A.Shvartsman, Andrey
ABSTRACT Results are presented from tests on a formulated 15W-40 mil-spec engine/transmission fluid to examine the impact of additives on improving its reliability and durability under extreme tribological conditions. A block-on-ring (BOR) configuration was used to measure the effect of five additives (an emulsion-based boric acid, tricresyl phosphate, particulate-based boron nitride, particulate-based MoS2, and particulate-based graphite) on the critical scuffing load as a function of additive concentration and time to scuff during oil-off tests (starved lubrication). A four-ball configuration was used to evaluate the impact of simulated engine grit/sand on the abrasive wear of steel as a function of grit size and loading. The results demonstrated that the additives increased the load for scuffing by 50 to 100% for the formulated oil and by 50 to 150% for the unformulated base fluid used in the formulated oil. Two of the additives (emulsion-based boric acid and tricresyl phosphate
Fenske, G. R.Ajayi, O. O.Erck, R. A.Lorenzo-Martin, C.Masoner, AshleyComfort, A. S.
ABSTRACT The demand for mobile, secure communications has been and will continue to be a fundamental requirement for dismounted, urban and distributed operations in the field. It is imperative that soldiers on the front lines receive actionable information in a timely, secured and uninterrupted manner to increase force protection and effectiveness. In this paper, we describe a novel, high technical maturity (TRL 8+) communications link that offers the mounted and dismounted soldier secure, beyond line of sight, encrypted capability for weapons control and command & control of multiple platforms. An innovative spread spectrum waveform was designed from the ground up to deliver necessary functionality for reliable communications amongst multiple nodes with a data rate and range commensurate with battlefield scenarios
Mehta, Amish A.Cambridge, AndrewGardner, Brian
ABSTRACT Problem: The traditional four (4) methods for improving reliability; 1) High design safety margin, 2) Reduction in component count or system architectural complexity, 3) Redundancy, and 4) Back-up capability, are often ignored or perceived as being excessively costly in weight, space claim as well as money. Solution 1: Discussed here are the practical and very cost effective methods for achieving improved reliability by Functional Interface Stress Hardening (FISHtm or FISHingtm). The Author has been able to apply FISH to eliminate 70-92% of unscheduled equipment downtime, within 30-60 days, for more than 30 of the Fortune 500 and many other large companies which utilize automation controls, computers, power electronics and hydraulic control systems. Solution 2: From Structured Innovation the 33 DFR Methods & R-TRIZ Tool can be used to grow or improve reliability, via rapid innovation. The R-TRIZ tool) is provided so that users can instantly select the best 2, 3 or 4 of these
Cooper, Howard C
ABSTRACT This paper discusses various soft security considerations that should be accounted for in the next generation of advanced military unmanned systems. By modeling unmanned system teams as mobile ad hoc networks, we underscore the different types of information-based security vulnerabilities that motivated adversaries may be able to exploit in unmanned systems. Then we provide an overview of computational trust and show that it can be used to defend against these vulnerabilities by finding the most reliable agents to interact with from a pool of potential agents. Finally, we discuss ongoing work at U.S. Army TARDEC that is applying computational trust within a vehicle controller for autonomous convoy operations
Mikulski, Dariusz
ABSTRACT The design of power distribution systems for modern tanks and fighting vehicles involves a number of challenges, including demands for increasing amounts of electrical power. In response to these needs, Solid State Power Controllers (SSPCs) provide a number of advantages over electromechanical circuit breakers and relays. These include increased reliability, higher volume and weight power densities, lower power dissipation, reduced EMI emissions, very rapid short circuit protection, and precise I2t overload protection. The latter protects wiring, loads and the SSPCs themselves against overheating, while reliably avoiding “nuisance trips” when switching into capacitive or incandescent lamp loads. Further, SSPCs provide capabilities in the area of real time feedback, enabling system-level diagnostics and prognostics, and predictive, condition-based maintenance, thereby providing increased availability and continued mission readiness
Glass, Mike
ABSTRACT As the U.S. Army develops its 30-year science and technology strategy for ground systems, these systems are seen more as mobile power generation systems than just semi-autonomous mobile protection systems. As ground systems continue to have greater levels of electrification, they are perceived as key to providing power not only to the propulsion and mobility systems, but to protection systems, communications, information systems and a complex, ever-increasing suite of auxiliary power systems which are not limited to the vehicle platform itself, but to external systems and platforms. All power systems can be connected wirelessly, or through a microgrid. Therefore, optimizing the overall ground system along with an external suite of loads and sources through a power grid, as a system of systems, becomes crucial in vehicle design. This optimization problem for performance and reliability is complex when considering the outside grid and a mix of other sources and loads with
Skowronska, Annette G.Gorsich, DavidMange, JeremyDunn, AndrewPandey, VijitashwaMourelatos, Zissimos P.
ABSTRACT The functionality of the next-generation Department of Defense platforms, such as the Small Unmanned Ground Vehicles (SUGV) and Small Unmanned Arial Vehicles (SUAV), requires strongly electronics-rich architectures. The reliability of these systems will be dependent on the reliability of the electronics. These electronic systems and the critical components in them can experience extremely harsh thermal and vibrations environments. Therefore, it is imperative to identify the failure mechanisms of these components through experiments and simulation based on physics-of-failure methods. One of the key challenges in recreating life-cycle vibration conditions during design and qualification testing in the lab is the re-creation of simultaneous multi-axial excitation that closely mimics what the product experiences in the field. Currently, there are two common approaches in the industry when testing a prototype or qualifying a product for multi-axial vibration environments. One
Habtour, EdMortin, DavidChoi, CholminDasgupta, Abhijit
Many of the “ilities” (Reliability, Maintainability, etc) are afterthoughts in the creation of a specification, and are often relegated to a set of templated boilerplate requirements, that are largely ignored. The Reliability / Robust Design professionals often use a P-Diagram (Parameter Diagram) as a key part of understanding the system under design. A way of integrating the Reliability effort more into the mainstream of the design activity, and give them a stronger voice, is to put their P-Diagram right into the specification, before it gets released to industry. This paper describes the rationale and the manner in which to do this
Dutcher, Kevin J.
ABSTRACT The concept of Autonomous Vehicles ultimately generating an “order of magnitude” potential increase in the duty or usage cycle of a vehicle needs to be addressed in terms of impact on the reliability domain. Voice of the customer data indicates current passenger vehicle usage cycles are typically very low, 5% or less. Meaning, out of a 24 hour day, perhaps the average vehicle is actually driven only 70 minutes or less. Therefore, approximately 95% of the day, the vehicles lay dormant in an unused state. Within the context of future fully mature Autonomous Vehicle environment involving structured car sharing, the daily vehicle usage rate could grow to 95% or more
Wasiloff, James
ABSTRACT Faster than real-time and real-time vehicle dynamic models run with fixed time step integrators, without accuracy control and usually apply numerous approximations to obtain a stable solution. These models generally provide very good descriptions of the system behavior, capturing the gross motions and character of the response. However, the consequence of approximation and the lack of error control is that the resulting loads cannot be trusted for structural design analysis. Nonetheless, these lightweight faster than real-time models are indispensible in concept development where an unlimited number of designs may be considered in the automated exploration of the design space. This work investigates a novel simulation technique in an attempt to converting the family of real-time vehicle dynamics models into reliable first order structural load predictors. The method applies an error estimator to the real-time fixed step integrator to identify loss of accuracy in stiff models
Critchley, JamesJayakumar, Paramsothy
ABSTRACT This paper describes an approach to aid the many military unmanned ground vehicles which are still teleoperated using a wireless Operator Control Unit (OCU). Our approach provides reliable control over long-distance, highly-latent, low-bandwidth communication links. The innovation in our approach allows refinement of the vehicle’s planned trajectory at any point in time along the path. Our approach uses hand-gestures to provide intuitive fast path editing options, avoiding traditional keyboard/mouse inputs which can be cumbersome for this application. Our local reactive planner is used for vehicle safeguarding. Using this approach, we have performed successful teleoperation nearly 1500 miles away over a cellular-based communications channel. We also discuss results from our user-tests which have evaluated our innovative controller approach with more traditional teleoperation over highly-latent communication links
Baker, Chris LBatavia, Parag
ABSTRACT Modern robotic technologies enable the development of semiautonomous ground robots capable of supporting military field operations. Particular attention has been devoted to the robotic mule concept, which aids soldiers in transporting loads over rugged terrain. While existing mule concepts are promising, current configurations are rated for payloads exceeding 1000 lbs., placing them in the size and weight class of small cars and ATVs. These large robots are conspicuous by nature and may not successfully carry out infantry resupply missions in an active combat zone. Conversations with soldiers and industry professionals have spotlighted a need for a compact, lightweight, and low-cost robotic mule. This platform would ensure reliable last-mile delivery of critical supplies to predetermined rally points. We present a design for such a compact robotic mule, the µSMET. This versatile platform will be integrated with the Squad Multipurpose Equipment Transport (SMET), to ferry
Grenn, KatharinaAdam, CristianKleinow, TimothyMason, BrianSapunkov, OlegMuench, PaulLakshmanan, Sridhar
ABSTRACT For medium sized combat vehicles, the traditional method for auxiliary power is hydraulics, based on proven track record of reliability, high output forces and excellent power density. With the transition to vehicle electrification, emphasis has been placed on the integration of electric motors into the overall architecture of the vehicle. Electric components generally are larger in size and weigh more for the amount of power they deliver compared to hydraulics. This paper will explore the integration of electric motors in a vehicle and the advantages and disadvantages as compared to hydraulic power
Aardema, JimLaboda, Thomas
ABSTRACT The use of lead-free components in electronic modules destined for defense applications requires a deep understanding of the reliability risks involved. In particular, pad cratering, tin whiskers, shock and vibration, thermal cycling and combined environments are among the top risks. Testing and failure analysis of representative assemblies across a number of scenarios, including with and without risk mitigations, were performed to understand reliability of lead-free assembly approaches, in comparison with leaded and mixed solder approaches. The results lead to an understanding of lead-free reliability and how to improve it, when required. This outcome is resulting in user acceptance of lead-free electronics, which is timely given the increasing scope of lead-free legislation
Straznicky, Ivan
ABSTRACT Army vehicles are complex due to various on-board mission critical communication devices. The Army cannot afford unreliable software to interact between the devices. The Army vehicle software’s reliability is influenced by multiple factors during or prior to its development. Using complex statistical and mathematical models, software’s reliability can be predicted, but it is dependent on the accuracy and context of the historical software failure data. The cost of developing such complex models does not yield a good return on investment. The data collection process to use these models is very difficult and time consuming. In this paper, we propose reliability metrics based on the current software development and design process factors. We also propose a fuzzy logic based software reliability prediction algorithm using the proposed reliability metrics
Dattathreya, Macam S.Singh, Harpreet
ABSTRACT The recent U.S. Army TARDEC’s 30-Year Strategy calls for enhancing their skill set in the “ilities,” especially reliability, since this factor directly impacts more than 58% of life cycle costs, according to a DoD study. To support this initiative, this paper presents technology transfer of Iowa developed Reliability-Based Design Optimization (I-RBDO) software by integrating theories and numerical methods that have been developed over a number of years in collaboration with the Automotive Research Center (ARC), which is funded by the U.S. Army TARDEC. Both the sensitivity-based and sampling-based methods for reliability analysis and design optimization methods are integrated in I-RBDO for broader multidisciplinary applications. I-RBDO has very comprehensive capabilities that include modeling of input distributions for both independent and correlated variables; a variable screening method for high dimensional RBDO problems; statistical analysis; reliability analysis; RBDO; and
Choi, K.K.Gaul, Nicholas J.Song, HyeongjinCho, HyunkyooLamb, DavidGorsich, David
ABSTRACT This paper addresses cross-domain optimization of lean technologies developed through motorsports as applied to military vehicle design. Optimization of performance objectives eliminates the reiterative assessments utilized in standard validation and verification of product development. This paper describes the enhancement of overall vehicle reliability, durability, and performance through utilization of front-loaded design, development, engineering, and prototyping activity. Cross-domain optimization, using a Design of Experiments approach (DOE) and the integration of CAE tools, predictably allows for the efficient and accurate solution of challenges prior to full scale prototype build and, congruently, eliminates the necessity for multiple variants often required throughout many testing phases. This paper illustrates, systematically, the reduction of build phases while introducing a new paradigm for military vehicle design
Bishop, Lynn W.Houghton, Kristian
ABSTRACT This paper addresses some aspects of an on-going multiyear research project of GP Technologies for US Army TARDEC. The focus of the research project has been the enhancement of the overall vehicle reliability prediction process. This paper describes briefly few selected aspects of the new integrated reliability prediction approach. The integrated approach uses both computational mechanics predictions and experimental test databases for assessing vehicle system reliability. The integrated reliability prediction approach incorporates the following computational steps: i) simulation of stochastic operational environment, ii) vehicle multi-body dynamics analysis, iii) stress prediction in subsystems and components, iv) stochastic progressive damage analysis, and v) component life prediction, including the effects of maintenance and, finally, iv) reliability prediction at component and system level. To solve efficiently and accurately the challenges coming from large-size
Ghiocel, Dan M.Negrut, DanLamb, DavidGorsich, David
ABSTRACT The current reliability growth planning model used by the US Army, the Planning Model for Projection Methodology (PM2), is insufficient for the needs of the Army. This paper will detail the limitations of PM2 that cause Army programs to develop reliability growth plans that incorporate unrealistic assumptions and often demand that infeasible levels of reliability be achieved. In addition to this, another reliability growth planning model being developed to address some of these limitations, the Bayesian Continuous Planning Model (BCPM), will be discussed along with its own limitations. This paper will also cover a third reliability growth planning model that is being developed which incorporates the advantageous features of PM2 and BCPM but replaces the unrealistic assumptions with more realistic and customizable ones. The internal workings of this new TARDEC developed simulation-based model will be delved into with a focus on the advantages this model holds over PM2 and BCPM
Kosinski, Daniel
ABSTRACT This paper discusses and outlines ideas regarding changes to how testing is performed in response to new policy regarding rapid integration of technology into Army ground vehicle systems. It specifically presents and discusses the ways that systems can begin testing early using laboratory testing. It discusses how testing is currently performed and then leverages best practices from the Automotive Industry to recommend methods to recommend how the Army can adapt these for its testing function. Specifically it discusses how specific test should be selected, how to define the testing environment and how to use the data generated from the lab test. It concludes with an example case study. Citation: B. LaRose, M. Morgan, K. Stark, D. Kosinski, K. Fischer, M. Brudnak, G. Schultz, A. Christino, M. Wayne, I. Baseski, “Testing in a Complex World”, In Proceedings of the Ground Vehicle Systems Engineering and Technology Symposium (GVSETS), NDIA, Novi, MI, Aug. 13-15, 2019
LaRose, BryanMorgan, MelissaStark, KristenKosinski, DanFischer, KenBrudnak, MarkSchultz, GregChristino, AngeloWayne, MartinBaseski, Igor
ABSTRACT Reliability Physics simulations for electronic assemblies has matured to become best practice during specification and design. However, the potential advantages of these simulations to programs and integrators are more far reaching. This paper will explore how the simulations can be used for virtual qualification, reliability assurance, maintenance scheduling and obsolescence management. Citation: Ed Dodd, “Reliability Simulations for Electronic Assemblies: Virtual Qualification, Reliability Assurance, Maintenance Scheduling and Obsolescence Mitigation”, In Proceedings of the Ground Vehicle Systems Engineering and Technology Symposium (GVSETS), NDIA, Novi, MI, Aug. 13-15, 2019
Dodd, Ed
ABSTRACT The M1 Abrams will be the primary heavy combat vehicle for the US military for years to come. Improvements to the M1 that increase reliability and reduce maintenance will have a multi-year payback. The M1 engine intake plenum seal couples the air intake plenum to the turbine inlet, and has opportunities for improvement to reduce leakage and intake of FOD (foreign object debris) into the engine, which causes damage and premature wear of expensive components
Tarnowski, StevePennala, SteveGoryca, MaryKauth, Kevin
ABSTRACT This work investigates the effects of obstacle uncertainty on the speed, distance, and feasibility of a planned traversal path. Simulation results for artificial and real-world environments are used to numerically quantify how geometric uncertainty within a map affects path traversal cost. A significant outcome of this research is the discovery of a relationship between increasing uncertainty and path cost. As obstacle uncertainty increases, previously planned routes can become infeasible as they effectively become blocked off due to uncertainty in the obstacle geometry. This paper illustrates a method that can serve to increase the speed, simplicity, and reliability of path planning, while allowing uncertainty to be included in the mobility analysis. Citation: S. Tau, S. Brennan, K. Reichard, J. Pentzer, D. Gorsich, “The Effects of Obstacle Dimensional Uncertainty on Path Planning in Cluttered Environments”, In Proceedings of the Ground Vehicle Systems Engineering and
Tau, SethBrennan, SeanReichard, KarlPentzer, JesseGorsich, David
ABSTRACT Program offices and the test community all desire to be more efficient with respect to testing but currently lack the analytical tools to help them fit early subsystem level testing into a framework which allows them to perform assessments at the system level. TARDEC initiated a Small Business Innovative Research (SBIR) effort to develop and deploy a system reliability testing and optimization tool that will quantify the value of subsystem level tests in an overall test program and incorporate the results into system level evaluations. The concept software, named the Army Lifecycle Test Optimization (ALTO) tool, provides not only the optimization capability desired, but also other key features to quickly see the current status, metrics, schedule, and reliability plots for the current test plan. As the user makes changes to the test plan, either by running the optimization or adjusting inputs or factors, the impacts on each of these areas is computed and displayed
Luna, JoelSnider, SharonBrudnak, MarkLaRose, BryanMorgan, MelissaKosinski, DanScott, Mike
ABSTRACT Variable displacement pumps have been used in automotive transmissions for decades. L3T had high confidence that a Variable Displacement Oil (VDO) pump would increase overall transmission efficiency. An off-the-shelf (OTS) or OTS modified pump in this pressure and flow range was not found. Therefore, a VDO pump is being developed with the known risk of replacing a highly reliable pump with a new better performing pump of unknown reliability. In this document the development of this VDO pump is discussed. Initial testing of the VDO pump demonstrated an average 25HP savings in pumping losses throughout the transmission operating ranges. At this point, durability testing has not been performed
Bol, Stephen
This paper presents additive Weibull reliability model using customer complaints data and finite element fatigue (FEA) analysis data. Warranty data provides insight into the underlying customer issues. Reliability engineers prepare a prediction model based on this data to forecast the failure rate of components. However, warranty data has certain limitations with respect to prediction modeling. The warranty period covers only the infant mortality and useful life zone of a bathtub curve. Thus, predicting with solely warranty data generally cannot provide results with desired accuracy. The failure rate of wear-out components is driven by random issues initially and wear-out or usage-related issues at the end of the lifetime. For accurate prediction of failure rate, data need to be explored at wear-out zone of a bathtub curve. Higher cost always limits the testing of components until failure, but FEA fatigue analysis can provide the failure rate behavior of a part much beyond the warranty
Koulage, Dasharath BaliramMondal, KanchanManerikar, Dattatray Shriniwas
Advances in IoT and electronic technology are enabling more personalized, continuous medical care. People with medical conditions that require a high degree of monitoring and continuous medication infusion can now take advantage of wearable medicine injection devices to treat their problems. Wireless communication allows medical personnel to monitor and adjust the amount and flow rate of an individual’s medication. The small size of the injectors enables the individual to be active and not be burdened or limited by a line-powered instrument (see Figure 1
Just as a business needs an effective and reliable service to deliver its goods to customers, medications need an effective delivery system to get them to the specific area of the body where they can have an impact
As the U.S. military embraces vehicle electrification, high-reliability components are rising to the occasion to support their advanced electrical power systems. In recent years, electronic device designers have started using wide band-gap (WBG) materials like silicon carbide (SiC) and gallium nitride (GaN) to develop the semiconductors required for military device power supplies. These materials can operate at much higher voltages, perform switching at higher frequencies, and feature better thermal characteristics. Compared to silicon, SiC-based semiconductors provide superior performance. The growing availability of these materials, in terms of access and cost, continues to encourage electrification. With the ever-present pressure of size, weight, and power (SWaP) optimization in military applications, and a desire to keep up with the pace of innovation, there's a need for capacitors that can deliver higher power efficiency, switching frequency, and temperature resistance under harsh
American drivers have long been accustomed to quickly filling up at a gas station with plenty of fuel available, and electric vehicle drivers want their pit stops to mimic this experience. Driver uncertainty about access to charging during long trips remains a barrier to broader EV adoption, even as the U.S. strives to combat climate change by converting more drivers
In the rapidly evolving landscape of electronic engineering, the reliability of electronic components under varying thermal conditions has emerged as a paramount concern. This paper presents an integrated approach for the reliability analysis of electronic components, emphasizing thermal impacts. Our methodology synergizes computational thermal analysis, experimental stress testing, and Failure Modes, Effects, and Diagnostic Analysis (FMEDA) to offer a comprehensive framework for assessing and enhancing component reliability, specifically focusing on a case study of motorcycle hand control switches. The approach begins with a detailed thermal simulation to identify potential hot spots and thermal gradients across electronic components under different operational scenarios. For the case study, motorcycle hand control switches a critical interface between the rider and the motorcycle's electrical system were subjected to this analysis to predict thermal behavior under varied
Mote, ShwetaJadhav, ShantaramChaudhari, VijayMhaske, Aashay
For many patients waiting for a donor heart, the only way to live a decent life is with the help of a pump attached directly to their heart. This pump requires about as much power as a TV, which it draws from an external battery via a seven-millimeter-thick cable. The system is handy and reliable, but it has one big flaw: despite medical treatment, the point at which the cable exits the abdomen can be breached by bacteria
As aerospace engineers push the boundaries of new frontiers, the need for advanced materials that can withstand the rigorous demands of these advanced applications is relentless. These materials go beyond functionality; it is about ensuring reliability in the skies, where failure is not an option. Fluorosilicone can help do exactly that. In the 1960s, the U.S. Air Force noticed that conventional silicone-based sealants, coatings, and other components degraded rapidly when exposed to fuels, de-icing fluids, and other hydrocarbon-based solvents. Dimethyl-based silicones are non-polar and easily absorb hydrocarbon-based solvents, which may result in material swelling, mechanical weakening, and ultimately, failure
The aerospace industry heavily relies on NASGRO as a standard method for crack propagation analysis, despite encountering challenges due to variations in stress gradients across flight missions. In response to this issue, this paper introduces a pioneering methodology that integrates stress gradients at each time point throughout a mission, computed cycle by cycle using NASGRO. The study meticulously evaluates the feasibility and efficacy of this approach against established industry-standard procedures, focusing on the critical topic of low cycle fatigue (LCF) and underscoring the significance of damage-tolerant design principles. The methodology encompasses the design of an H-sector in Ansys Workbench, the execution of stress analysis for a typical flight mission profile, and the systematic extraction of stress gradients for each cycle at the pivotal crack nucleation point. Subsequently, NASGRO is employed to estimate life cycles using both industry-standard baseline methodologies
Karandikar, Rishi SuhasKumar, Niraj
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