Search Results (15)

This paper presents an extended, accelerated reliability evaluation of forty microinverters, module-level power electronic (MLPE) units for photovoltaic (PV) modules. The forty microinverters were stressed at two static temperatures (65 °C and 75 °C) with two input power profiles (fixed and cyclic power). These power profiles were employed to replicate field-use conditions closely. The accelerated testing was performed for an extended duration (over a period of 15,000 h) to determine the acceleration factor and estimate the service life of microinverters in field-use conditions. Electrical performance and thermal data were continuously monitored during the experiment for all the microinverters. The accelerated stress testing had no failures even after 15,000 h of operation. Using the Arrhenius life-stress model along with average field-measured temperature and military handbook-based analysis, it was estimated that the microinverters should be able to survive for 24–48 years during their service life in field conditions, with a reliability of 74%, having a lower one-sided confidence bound of 95%, obtained using the classical success run approach. Moreover, the lifetime of microinverters was statistically analyzed using a Weibull distribution model. Weibull slope factors were used to estimate a range of characteristic lifetime periods and the reliability of the microinverters with a 95% lower one-sided confidence limit, demonstrating a similar or even exceeding the lifetime of the associated PV modules of 25 years. Full article

This paper proposes a novel, degradation-sensitive, adaptive SST controller for cascode GaN-FETs. Unlike in traditional transformers, a semiconductor switch’s degradation and failure can compromise its robustness and integrity. It is vital to continuously monitor a switch’s health condition to adapt it to mission-critical applications. The current state-of-the-art degradation monitoring methods for power electronics systems are computationally intensive, have limited capacity to accurately identify the severity of degradation, and can be challenging to implement in real time. These methods primarily focus on conducting accelerated life testing (ALT) of individual switches and are not typically implemented for online monitoring. The proposed controller uses accelerated life testing (ALT)-based switch degradation mapping for degradation severity assessment. This controller intelligently derates the SST to (1) ensure robust operation over the SST’s lifetime and (2) achieve the optimal degradation-sensitive function. Additionally, a fast behavioral switch loss model for cascode GaN-FETs is used. This proposed fast model estimates the loss accurately without proprietary switch parasitic information. Finally, the proposed method is experimentally validated using a 5 kW cascode GaN-FET-based SST platform. Full article

To prolong the fatigue life of a product handled by machines such as refrigerators and agricultural machinery, parametric accelerated life testing (ALT) is recommended as a systemized approach to detect design inadequacies and reduce fatigue. It demands (1) an ALT strategy, (2) a fatigue type, (3) parametric ALTs with change, and (4) an estimate of whether the present product completes the BX lifetime. The utilization of a quantum-transported life-stress type and a sample size are advocated. The enhancements in the lifetime of a refrigerator ice-maker, containing an auger motor with bearings, were employed as a case study. In the 1st ALT, a steel rolling bearing cracked due to repeated loading under cold conditions (below −20 °C) in the freezer compartment. The bearing material was changed from an AISI 52100 Alloy Steel with 1.30–1.60% chromium to a lubricated sliding bearing with sintered and hardened steel (FLC 4608-110HT) because of its high fatigue strength at lower temperatures. In the 2nd ALT, a helix made of polycarbonates (PCs) fractured. In the redesign, a reinforced rib of the helix was thickened. Because no troubles in the 3rd ALT happened, the life of an ice-maker was proven to have a B1 life 10 years. Full article

In medicals sciences and reliability engineering, the failure of individuals or units (I/Us) occurs due to independent causes of failure. In general, the symmetry between dependent and independent causes of failure is essential to the nature of the problem at hand. In this study, we considered the accelerated dependent competing risks model when the lifetime of I/Us was modeled using a generalized half-logistic distribution. The data were obtained with respect to constant stress accelerated life tests (ALTs) with a type-II progressive censoring scheme. The dependence structure was formulated using the copula approach (symmetric Archimedean copula). The model parameters were estimated with the maximum likelihood method; only two dependent causes of failure and bivariate Pareto copula functions were proposed. The approximate confidence intervals were constructed using both the asymptotic normality distribution of MLEs and bootstrap techniques. Additionally, an estimator of the reliability of the system under a normal stress level was constructed. The results from the estimation methods were tested by performing a Monte Carlo simulation study. Finally, an analysis of data sets from two stress levels was performed for illustrative purposes. Full article

To lengthen the life of a mechanical system, parametric accelerated life testing (ALT) is recommended as an established way to help identify structural imperfections and reduce fatigue-related failures. It involves (1) a parametric ALT scheme, (2) fatigue design, (3) ALTs with alterations, and (4) an estimate of whether design(s) achieve the BX lifetime. The application of a quantum-transported time to failure prototype and a sample size expression is also suggested. The improvements in the reliability of a water dispenser made of stainless steel or polypropylene (PP) in a bottom-mount domestic refrigerator was used as a case study. In the first ALT, the hinge and front corner of the dispensing system was cracked. The water dispenser lever was altered by increasing the thickness of its ribs and fillets. In the second ALT, the altered dispensing lever system cracked because there was an insufficient thickness in its front corner for impact loading. The critical design factors for improving reliability were corner fillet rounding and rib thickening in a dispenser lever. As there were no difficulties in the third ALT, the dispenser life was verified to have a B1 life of 10 years. Full article

This investigation practically explains the implementation of parametric accelerated life testing (ALT) as an algorithm to recognize design imperfection and rectify it in creating a reliable quantitative (RQ) statement by sample size equation. It covers: (1) a module BX life that X% of a collection of system items is unsuccessful with an ALT plan, (2) design for fatigue, (3) ALTs with alterations, and (4) discernment as to if the final design(s) obtains the targeted BX lifetime. A (generalized) life–stress formulation by the linear transport process is recommended for the mathematical work of the parametric model. As a case study, an ice-maker including gear system in a refrigerator was utilized. The gear teeth made of cast iron (carbon, 3 wt% and silicon, 2 wt%) was fracturing in a refrigerator ice-maker. To reproduce the field failure and rectify the problematic designs in the marketplace, a parametric ALT was carried out. At the first ALT, the gear teeth made of cast iron partly cracked and fractured under severe cold conditions (below −20 °C) in the freezer. It was modified by changing the material from cast iron to a sinter-hardened powder metallurgy nickel steel because high fatigue strength in the low temperature was required. At the second ALT, we discovered the fractured helix made of polycarbonates (PC). As a modification, strengthened rib on the front and side of the helix the thickness of gear teeth was attached. At the third ALT, there was no concern, and the life of the auger motor including gear system was manifested to have a B1 life 10 years. Full article

Accelerated life testing (ALT) is a time-saving technology used in a variety of fields to obtain failure time data for test units in a fraction of the time required to test them under normal operating conditions. This study investigated progressive-stress ALT with progressive type II filtering with the lifetime of test units following a Nadarajah–Haghighi (NH) distribution. It is assumed that the scale parameter of the distribution obeys the inverse power law. The maximum likelihood estimates and estimated confidence intervals for the model parameters were obtained first. The Metropolis–Hastings (MH) algorithm was then used to build Bayes estimators for various squared error loss functions. We also computed the highest posterior density (HPD) credible ranges for the model parameters. Monte Carlo simulations were used to compare the outcomes of the various estimation methods proposed. Finally, one data set was analyzed for validation purposes. Full article

To extend the life of a mechanical system, parametric Accelerated Life Testing (ALT) is proposed as a procedure to identify design faults and reduce fatigue failure. It includes a derivation of generalized time to failure model by linear transport process and a sample size equation for the ALT. A refrigerator drawer was used as an example. After loading, the rail rollers broke and the center support was bent. Ribs were added to the center support and the rail roller support was extended. At the first ALT, the box cover failed near the intersection between the cover and body. The box was then modified by increasing the rib and fillet. At the second ALT, the rails and center support fractured. They were altered by increasing the rib and corner rounding. After the third ALT, there were no issues. The drawer lifetime was ensured to be B1 life 10 years. Full article

This study demonstrates the application of parametric accelerated life testing (ALT) as a procedure to identify design deficiencies and correct them in generating a reliable quantitative (RQ) specification. It includes: (1) a system BX lifetime that X% of a product population fails with a parametric ALT scheme, (2) fatigue design, (3) ALTs with alternations, and (4) judgement as to whether the design(s) secures the desired BX lifetime. A (generalized) life–stress model through the linear transport process and a sample size formulation are suggested. A pneumatic cylinder in a machine tool was used as a case study. The cylinder was failing in a flexible manufacturing system. To reproduce the failure and modify the design, a parametric ALT was performed. At the first ALT, the metal seal made of nickel-iron alloy (36% Ni) partially cracked and chipped and had a crisp metal sound. It was modified by changing the seal from a metal to a polymer (silicone rubber). At the second ALT, the piston seal leaked due to seal hardening and wear. The failure modes of the silicone seal in the laboratory tests were similar to those returned from the field. For the third ALT, the seal material was changed from silicone rubber to (thermoset) polyurethane. There were no concerns during the third ALT and the lifetime of the pneumatic cylinder was shown to have a B1 life of 10 years. Full article

This study demonstrates the use of parametric accelerated life testing (ALT) as a way to recognize design defects in mechanical products in creating a reliable quantitative (RQ) specification. It covers: (1) a system BX lifetime that X% of a product population fails, created on the parametric ALT scheme, (2) fatigue and redesign, (3) adapted ALTs with design alternations, and (4) an evaluation of whether the system design(s) acquires the objective BX lifetime. A life-stress model and a sample size formulation, therefore, are suggested. A refrigerator compressor is used to demonstrate this method. Compressors subjected to repetitive impact loading were failing in the field. To analyze the pressure loading of the compressor and carry out parametric ALT, a mass/energy balance on the vapor-compression cycle was examined. At the first ALT, the compressor failed due to a cracked or fractured suction reed valve made of Sandvik 20C carbon steel (1 wt% C, 0.25 wt% Si, 0.45 wt% Mn). The failure modes of the suction reed valves were similar to those valves returned from the field. The fatigue failure of the suction reed valves came from an overlap between the suction reed valve and the valve plate in combination with the repeated pressure loading. The problematic design was modified by the trespan dimensions, tumbling process, a ball peening, and brushing process for the valve plate. At the second ALT, the compressor locked due to the intrusion between the crankshaft and thrust washer. The corrective action plan specified to perform the heat treatment to the exterior of the crankshaft made of cast iron (0.45 wt% C, 0.25 wt% Si, 0.8 wt% Mn, 0.03 wt% P). After these design modifications, there were no troubles during the third ALT. The lifetime of the compressor was secured to have a B1 life of 10 years. Full article

This paper suggests parametric accelerated life testing (ALT) as a systematic reliability technique to generate the reliability quantitative (RQ) specification such as mission cycle for identifying design flaws in mechanical systems as exerting the accelerated load, defined as the reverse of stress ratio, R. Parametric ALT therefore is a procedure to improve the fatigue for mechanical products subjected to repetitive loading. It includes: (1) a system BX lifetime shaped on the parametric ALT plan; (2) a fatigue failure and design; (3) tailored ALTs with alternatives; and (4) an assessment of whether the design(s) of the product attains the targeted BX lifetime. A BX life ideas, a life-stress model, and a sample size formulation for parametric ALT are proposed. A reciprocating compressor in a domestic refrigerator is utilized to explain this methodology. The compressor was subjected to repetitive impact loading due to the pressure difference between condenser and evaporator, which results in the compressor field failure. To analyze and conduct parametric ALTs, as mass/energy balance was utilized on the vapor-compression refrigerating cycle, a simple pressure loading of the compressor in operating the refrigerator was investigated. At the first ALT, the compressor was locked due to the fractured suction reed valve made of Sandvik 20C carbon steel (1 C, 0.25 Si, 0.45 Mn). The dominant failure modes of the suction reed valve in the parametric ALTs were established to be very close to that of the fractured product from the marketplace. The root cause of the fatigue failure of the suction reed valve was an amount of overlap between the suction reed valve and the valve plate in combination of repeated pressure loading in the compressor. To supply sufficient mechanical strength, the design faults were altered by the trespan dimensions tumbling process, a ball peening and brushing process for the valve plate. At the second ALT, a compressor was locked due to the intrusion between the crankshaft and the thrust washer. The corrective action plan was to give heat treat the surface of crankshaft made of cast iron (0.45 C, 0.25 Si, 0.8 Mn, 0.03 P). After these alternations, there were no issues at the third ALT. The lifetime of the compressor was ensured to have B1 life 10 years. Full article

This paper develops parametric accelerated life testing (ALT) as a systematic reliability method to produce the reliability quantitative (RQ) specifications—mission cycle—for recognizing missing design defects in mechanical products as applying the accelerated load, expressed as the inverse of stress ratio, R. Parametric ALT is a way to enhance the prediction of fatigue failure for mechanical systems subjected to repeated impact loading. It incorporates: (1) A parametric ALT plan formed on the system BX lifetime, (2) a fatigue failure and design, (3) customized ALTs with design alternatives, and (4) an assessment of whether the last design(s) of the system fulfills the objective BX lifetime. A BX life concept with a generalized life-stress model and a sample size equation are suggested. A domestic refrigerator hinge kit system (HKS), which was a newly designed mechanical product, was used to illustrate the methodology. The HKS was subjected to repeated impact loading resulting in failure of the HKS in the field. To conduct ALTs, a force and momentum balance was utilized on the HKS. A straightforward impact loading of the HKS in closing the refrigerator door was examined. At the first ALT, the housing of the HKS failed. As an action plan, the hinge kit housing was modified by attaching inside supporting ribs to the HKS to provide sufficient mechanical strength against its loading. At the second ALT, the torsional shaft in the HKS made with austenitic ductile iron (18 wt% Ni) failed. The cracked torsional shaft for the 2nd ALTs came from its insufficient rounding, which failed due to repeated stress. As an action plan, to have sufficient material strength for the repetitive impact loads, the torsional shaft was reshaped to give it more rounding from R0.5 mm to R2.0 mm. After these modifications, there were no problems at the third ALT. The lifetime of the HKS in the domestic refrigerator was assured to be B1 life 10 years. Full article

The lifetime of ultraviolet high-power light-emitting diodes (UV HP-LEDs) is an open issue due to their high current density, high temperature, and UV radiation. This work presents a reliability study and failure analysis of three high-temperature accelerated life tests (ALTs) for 13,500 h with 3 W commercial UV LEDs of 365 nm at a nominal current in two working conditions: continuous mode and cycled mode (30 s on/30 s off). Arrhenius–Weibull parameters were evaluated, and an equation to evaluate the lifetime (B50) at any junction temperature and other relevant lifetime functions is presented. The Arrhenius activation energy was 0.13 eV for the continuous mode and 0.20 eV for the cycled mode. The lifetime at 50% survival and 30% loss of optical power as a failure definition, working at T_a = 40 °C with a multi-fin heat sink in natural convection, was over 4480 h for the continuous mode and 19,814 h for the cycled mode. The need to add forced convection for HP-LED arrays to achieve these high-reliability values is evidenced. The main source of degradation is the semiconductor device, and the second is the encapsulation silicone break. Full article

In this article, a progressive-stress accelerated life test (ALT) that is based on progressive type-II censoring is studied. The cumulative exposure model is used when the lifetime of test units follows Pareto-IV distribution. Different estimates as the maximum likelihood estimates (MLEs) and Bayes estimates (BEs) for the model parameters are discussed. Bayesian estimates are derived while using the Tierney and Kadane (TK) approximation method and the importance sampling method. The asymptotic and bootstrap confidence intervals (CIs) of the parameters are constructed. A real data set is analyzed in order to clarify the methods proposed through this paper. Two types of the progressive-stress tests, the simple ramp-stress test and multiple ramp-stress test, are compared through the simulation study. Finally, some interesting conclusions are drawn. Full article

The Burr type XII (BurrXII) distribution is very flexible for modeling and has earned much attention in the past few decades. In this study, the maximum likelihood estimation method and two Bayesian estimation procedures are investigated based on constant-stress accelerated life test (ALT) samples, which are obtained from the doubly truncated three-parameter BurrXII distribution. Because computational difficulty occurs for maximum likelihood estimation method, two Bayesian procedures are suggested to estimate model parameters and lifetime quantiles under the normal use condition. A Markov Chain Monte Carlo approach using the Metropolis–Hastings algorithm via Gibbs sampling is built to obtain Bayes estimators of the model parameters and to construct credible intervals. The proposed Bayesian estimation procedures are simple for practical use, and the obtained Bayes estimates are reliable for evaluating the reliability of lifetime products based on ALT samples. Monte Carlo simulations were conducted to evaluate the performance of these two Bayesian estimation procedures. Simulation results show that the second Bayesian estimation procedure outperforms the first Bayesian estimation procedure in terms of bias and mean squared error when users do not have sufficient knowledge to set up hyperparameters in the prior distributions. Finally, a numerical example about oil-well pumps is used for illustration. Full article