【内容简介】
In today’s sophisticated world, reliability stands as the ultimate arbiter of quality. An understanding of reliability and the ultimate compromise of failure is essential for determining the value of most modern products and absolutely critical to others, large or small. Whether lives are dependent on the performance of a heat shield or a chip in a lab, random failure is never an acceptable outcome.
Written for practicing engineers, Practical Reliability Engineering and Analysis for System Design and Life-Cycle Sustainment departs from the mainstream approach for time to failure-based reliability engineering and analysis. The book employs a far more analytical approach than those textbooks that rely on exponential probability distribution to characterize failure. Instead, the author, who has been a reliability engineer since 1970, focuses on those probability distributions that more accurately describe the true behavior of failure. He emphasizes failure that results from wear, while considering systems, the individual components within those systems, and the environmental forces exerted on them. Dependable Products Are No Accident: A Clear Path to the Creation of Consistently Reliable Products
Taking a step-by-step approach that is augmented with current tables to configure wear, load, distribution, and other essential factors, this book explores design elements required for reliability and dependable systems integration and sustainment. It then discusses failure mechanisms, modes, and effects?as well as operator awareness and participation?and also delves into reliability failure modeling based on time-to-failure data considering a variety of approaches.
From there, the text demonstrates and then considers the advantages and disadvantages for the stress-strength analysis approach, including various phases of test simulation. Taking the practical approach still further, the author covers reliability-centered failure analysis, as well as condition-based and time-directed maintenance.
As a science, reliability was once considered the plaything of statisticians reporting on time-to-failure measurements, but in the hands of a practicing engineer, reliability is much more than the measure of an outcome; it is something to be achieved, something to quite purposely build into a system. Reliability analysis of mechanical design for structures and dynamic components demands a thorough field-seasoned approach that first looks to understand why a part fails, then learns how to fix it, and finally learns how to prevent its failing. Ultimately, reliability of mechanical design is based on the relationship between stress and strength over time. This book blends the common sense of lessons learned with mechanical engineering design and systems integration, with an eye toward sustainment. This is the stuff that enables organizations to achieve products valued for their world-class reliability.
【目次】
Preface
The Author
List of Tables
List of Figures
Requirements for Reliability Engineering: Design for Reliability, Reliability Systems Integration, and Reliability-Based System Sustainment
Introduction
Part Reliability
Failure Mechanisms
Failure Modes
Failure Effects?Local Failure Effects?Next Higher Failure Effects?System (End Effect) Failure Modes and Effects Analysis Criticality Analysis System End Effects P?F Interval Operator Awareness of Degradation
Maintainability and Maintainability Engineering
Fault Detection
Fault Isolation
Part Mean Time to Repair
Administrative and Logistical Downtime
Part and System Availability
Reliability in an Organization
The Need for Change in Conventional Organizational Structure
Proposed Organization Structure
Design for Reliability: Reliability Engineering Requirements for Part Design
Design Requirement for a System
Systems Engineering Work Breakdown Structure
Lowest Replaceable Unit, LRU, Reliability Allocations
Conditions of Use, Mission Duration, and Maintainability Allocations
Functional Design Analysis
Functional Reliability Block Diagram
Functional LRU Failure Modes and Effects Analysis
Functional LRU Criticality/Consequences Analysis and Critical Items List
Design Trade Studies
LRU Nondestructive Examination and Math Modeling
Preliminary LRU Failure Mechanisms: Modes and Effects Analysis
Preliminary LRU Criticality/Consequences Analysis and Critical Items List
Preliminary Design Bills of Materials and Drawings
Preliminary Reliability Block Diagram and Math Modeling
Preliminary LRU Reliability, Maintainability, and Availability Estimates
Design Tests and Evaluation
Reliability Experiments and Math Modeling
Design LRU Failure Mechanisms Modes and Effects Analysis
Design LRU Criticality/Consequences Analysis and Critical Items List
Final Design Analysis, Bills of Materials, and Drawings
Final Design Reliability Block Diagram and Math Modeling
Final LRU Failure Mechanisms Modes and Effects Analysis
Design Reviews
Reliability Systems Engineering Requirements for System Integration
Part/LRU-to-Assembly Integration
Part/LRU-to-Assembly Reliability, Maintainability, and Availability Model
Assembly Design Review
Design Modification
Reliability Growth
Assembly-to-Subsystem Integration
Assembly-to-Subsystem Reliability, Maintainability, and Availability Model
Design Review
Design Modification
Reliability Growth
Subsystem-to-System Integration
Subsystem-to-System Reliability, Maintainability, and Availability Model
Design Review
Design Modification
Reliability Growth
System Demonstration
Reliability and Maintainability Demonstration
System Baseline
Configuration Management
Reliability Engineering Requirements for System Sustainment
System Sustainment
Repair Maintenance
Logistical Support
Database Requirements
Notes
Part/LRU Reliability Modeling for Time-to Failure Data
Introduction
Part Candidate for Reliability Engineering and Analysis
Hypothesize Part Failure Mechanisms
Part Failure Modes Analysis
Part Failure Effects Analysis
Critical Items List
Part/LRU Reliability Analysis: Understanding Failure of a Part/LRU
Qualitative Part/LRU Investigation
Part/LRU Design Parameters Fall in One of Three Criteria
Quantitative Part/LRU Investigation
TTF and TTR Frequency Distribution and Probability Density
Function of Part/LRU Failure
Cumulative Frequency Distribution
TTF Survival Function of a Part/LRU
TTF Instantaneous Part/LRU Failure Rate: The Hazard Function.3
TTF Reliability Function of a Part/LRU
Part/LRU Time-to-Failure Characterization of Reliability Parameters
Part/LRU Historical Part Failure Data
Part/LRU Reliability Experiments
Time-Censored Experimental Part/LRU Failure Data
Interval-Censored Experiment
Failure-Censored Experimental Part/LRU Failure Data
Failure-Free Experimental Part Data
Maintainability Analysis Functions of a Part/LRU
Resource Requirements for a Part/LRU
Inherent Availability of a Part/LRU
Notes
Reliability Failure Modeling Based on Time-to-Failure Data
Introduction
Part Reliability Failure Modeling
Candidate for Reliability Engineering and Analysis
Experimental Design for TTF
Exponential Probability Distribution Approach
Spreadsheet Approach
Exponential Distribution: Minitab
Weibull Distribution Approach
Spreadsheet Approach
Weibull Distribution: Minitab
Weibull Distribution: MathCAD Approach
Pump Failure Math Model
Triangular Distribution
Notes
Part Maintainability and Availability
Introduction
Part Mean Time to Repair
Maintenance Experiment
Excel Spreadsheet Approach
Minitab Approach
MathCAD Approach
Empirical Data
Part and System Availability
Inherent Availability
Instantaneous Availability
Operational Availability
Achieved Availability
Notes
Part Reliability Based on Stress-Strength Analysis
Introduction
Part Stress
Part Failure
Time-to-Failure Reliability Functions
Example TTF Reliability Functions for Hex Bolt
Exponential Failure Distribution Approach
Single Failure Mechanism Weibull Model Approach
Multiple Failure Mechanism Weibull Model Approach
Comparative Evaluation of Exponential, Single Weibull, and Multiple Failure Mechanism Weibull Model Approaches Using TTF Data
Part Stress and Strength: Interference Theory
Normal Stress?Normal Strength Normal Stress?Weibull Strength Weibull Stress?Weibull Strength Triangular Stress?Weibull Strength Stress-Strength Reliability of the Bolt in Tension and Shear Nondeterministic, Variable Approach Advantages and Disadvantages for Stress-Strength Analysis Approach
Notes
Reliability Engineering Functions from Stress-Strength Analysis
Introduction
Frequency Distributions of the Mechanisms of Failure
Design for Reliability
Phase I: 1-Operational-Day Test Simulation Period
Phase II: 1-Operational-Year Test Simulation Period
Phase III: 2-Operational-Year Test Simulation Period
Design for Reliability by Analysis
Material in Tension
Notes
Failure Modeling Based on Failure Mechanisms
Introduction
Normal Distribution Stress?Normal Distribution Strength1
Normal Distribution Stress?Weibull Distribution Strength
Weibull Distributed Stress?Weibull Distribution Strength
Triangular Distribution Stress?Triangular Distribution Strength
Notes
Reliability Modeling for Assembly Design Levels
Introduction
Reliability Allocation
Reliability Math Model
Math Modeling for Design Configurations of Assemblies
Series Design Configuration
Parallel Design Configuration
n-Provided, r-Required Redundancy
Standby Redundancy
Equal Reliability: Perfect Switch
Unequal Reliability: Perfect Switch
Equal Reliability: Imperfect Switch
Unequal Reliability: Imperfect Switch
Shared Load Redundancy7
Notes
Reliability Analysis for System of Systems
Introduction
Multiple-Missions System of System
Simple Single-Mission System of Systems
Complex Single-Mission System of Systems
System of Systems Compared
Notes
Reliability-Centered Maintenance
Introduction
Implementation of Reliability-Centered Maintenance
Notes
Reliability-Centered Failure Analysis
Introduction
Nondestructive Examination, Design, and Destruct Limits
Condition-Based Maintenance NDE
Time-Directed Maintenance NDE
Finite Element Math Model, Simulation and Analysis, Design Loads and Material Design Properties, Statistically Significant Failure Mechanisms
No Maintenance Solution
CBM Solution
TDM Solution
Physical Test
Highly Accelerated Life Test
MIL-STD-810
Method 501: High Temperature
Method 502: Low Temperature
Method 503: Temperature Shock
Method 507: Humidity
Method 514: Vibration
Method 520: Combined Environments (Temperature, Vibration, and Humidity)
Accelerated Life Testing
Time Compression Accelerated Life Testing
Life-versus-Stress Analysis Accelerated Life Test
Condition-Based Maintenance
Introduction
CBM Logic
Maintainability Demonstration Test, Validate Part Fault Detection, and P?F Interval
Develop and Implement Maintenance Procedures and Practices.20
Notes
Time-Directed Maintenance
Introduction
Characterize Hazard Function
Define Hazard Threshold
Maintainability Demonstration Test, Validate Hazard Function
Develop and Implement Maintenance Procedures and Practices
Bibliography
Index