Reliability Engineering (eBook)
XVII, 651 Seiten
Springer Berlin Heidelberg (Verlag)
978-3-662-54209-5 (ISBN)
This book shows how to build in and assess reliability, availability, maintainability, and safety (RAMS) of components, equipment, and systems. It presents the state of the art of reliability (RAMS) engineering, in theory & practice, and is based on over 30 years author's experience in this field, half in industry and half as Professor of Reliability Engineering at the ETH, Zurich. The book structure allows rapid access to practical results. Methods & tools are given in a way that they can be tailored to cover different RAMS requirement levels. Thanks to Appendices A6 - A8 the book is mathematically self-contained, and can be used as a textbook or as a desktop reference with a large number of tables (60), figures (210), and examples / exercises^ 10,000 per year since 2013) were the motivation for this final edition, the 13th since 1985, including German editions. Extended and carefully reviewed to improve accuracy, it represents the continuous improvement effort to satisfy reader's needs and confidence. New are an introduction to risk management with structurally new models based on semi-Markov processes & to the concept of mean time to accident, reliability & availability of a k-out-of-n redundancy with arbitrary repair rate for n - k=2, 10 new homework problems, and refinements, in particular, on multiple failure mechanisms, approximate expressions, incomplete coverage, data analysis, and comments on ë, MTBF, MTTF, MTTR, R, PA.
Preface to the 8 th Edition 6
Contents 9
1 Basic Concepts, Quality & Reliability (RAMS) Assurance of Complex Equipment &
1.1 Introduction 16
1.2 Basic Concepts 17
1.2.1 Reliability 17
1.2.2 Failure 18
1.2.3 Failure Rate, MTTF, MTBF 19
1.2.4 Maintenance, Maintainability 23
1.2.5 Logistic Support 23
1.2.6 Availability 24
1.2.7 Safety, Risk, Risk Acceptance 24
1.2.8 Quality 26
1.2.9 Cost and System Effectiveness 26
1.2.10 Product Liability 30
1.2.11 Historical Development 31
1.3 Basic Tasks & Rules for Quality and Reliability (RAMS) Assurance of Complex Equip. &
1.3.1 Quality and Reliability (RAMS) Assurance Tasks 32
1.3.2 Basic Quality and Reliability (RAMS) Assurance Rules 34
1.3.3 Elements of a Quality Assurance System 36
1.3.4 Motivation and Training 39
2 Reliability Analysis During the Design Phase 40
2.1 Introduction 40
2.2 Predicted Reliability of Equipment and Systems with Simple Structure 43
2.2.1 Required Function 43
2.2.2 Reliability Block Diagram 43
2.2.3 Operating Conditions at Component Level, Stress Factors 48
2.2.4 Failure Rate of Electronic Components 50
2.2.5 Reliability of One-Item Structures 54
2.2.6 Reliability of Series Parallel Structures with Independent Elements 56
2.2.6.1 Systems without Redundancy (series models) 56
2.2.6.2 Concept of Redundancy 57
2.2.6.3 Parallel Models 58
2.2.6.4 Series Parallel Structures with Independent Elements 60
2.2.6.5 Majority Redundancy 64
2.2.7 Part Count Method 66
2.3 Reliability of Systems with Complex Structure 67
2.3.1 Key Item Method 67
2.3.1.1 Bridge Structure 68
2.3.1.2 Reliability Block Diagram in Which at Least One Element Appears More than Once 69
2.3.2 Successful Path Method 70
2.3.3 State Space Method 71
2.3.4 Boolean Function Method 72
2.3.5 Parallel Models with Const. Failure Rates & Load Sharing
2.3.6 Elements with more than one Failure Mechanism or one Failure Mode 79
2.3.7 Basic Considerations on Fault Tolerant Structures 81
2.4 Reliability Allocation and Optimization 82
2.5 Mechanical Reliability, Drift Failures 83
2.6 Failure Modes Analyses 87
2.7 Reliability Aspects in Design Reviews 92
3 Qualification Tests for Components and Assemblies 96
3.1 Basic Selection Criteria for Electronic Components 96
3.1.1 Environment 97
3.1.2 Performance Parameters 99
3.1.3 Technology 99
3.1.4 Manufacturing Quality 101
3.1.5 Long-Term Behavior of Performance Parameters 101
3.1.6 Reliability 101
3.2 Qualification Tests for Complex Electronic Components 102
3.2.1 Electrical Test of Complex ICs 103
3.2.2 Characterization of Complex ICs 105
3.2.3 Environmental and Special Tests of Complex ICs 107
3.2.4 Reliability Tests 116
3.3 Failure Modes, Failure Mechanisms, and Failure Analysis of Electronic Components 116
3.3.1 Failure Modes of Electronic Components 116
3.3.2 Failure Mechanisms of Electronic Components 117
3.3.3 Failure Analysis of Electronic Components 117
3.3.4 Present VLSI Production-Related Reliability Problems 121
3.4 Qualification Tests for Electronic Assemblies 123
4 Maintainability Analysis 127
4.1 Maintenance, Maintainability 127
4.2 Maintenance Concept 130
4.2.1 Equipment and Systems Partitioning 131
4.2.2 Fault Detection (Recognition) and Localization 131
4.2.3 User Documentation 133
4.2.4 Training of Operation and Maintenance Personnel 134
4.2.5 User Logistic Support 134
4.3 Maintainability Aspects in Design Reviews 136
4.4 Predicted Maintainability 136
4.4.1 Calculation of MTTRS & MDTS
4.4.2 Calculation of Mean Time to Preventive Maintenance 140
4.5 Basic Models for Spare Parts Provisioning 140
4.5.1 Centralized Logistic Support, Nonrepairable Spare Parts 140
4.5.2 Decentralized Logistic Support, Nonrepairable Spare Parts 144
4.5.3 Repairable Spare Parts 145
4.6 Maintenance Strategies 149
4.6.1 Complete renewal at each maintenance action 149
4.6.2 Block replacement with minimal repair at failure 153
4.6.3 Further considerations on maintenance strategies 154
4.7 Basic Cost Considerations 157
5 Design Guidelines for Reliability, Maintainability, and Software Quality 159
5.1 Design Guidelines for Reliability 159
5.1.1 Derating 159
5.1.2 Cooling 160
5.1.3 Moisture 162
5.1.4 Electromagnetic Compatibility, ESD Protection 163
5.1.5 Components and Assemblies 165
5.1.5.1 Component Selection 165
5.1.5.2 Component Use 165
5.1.5.3 PCB and Assembly Design 166
5.1.5.4 PCB and Assembly Manufacturing 167
5.1.5.5 Storage and Transportation 168
5.1.6 Particular Guidelines for IC Design and Manufacturing 168
5.2 Design Guidelines for Maintainability 169
5.2.1 General Guidelines 169
5.2.2 Testability 170
5.2.3 Connections, Accessibility, Exchangeability 172
5.2.4 Adjustment 173
5.2.5 Human, Ergonomic, and Safety Aspects 173
5.3 Design Guidelines for Software Quality 174
5.3.1 Guidelines for Software Defect Prevention 177
5.3.2 Configuration Management 180
5.3.3 Guidelines for Software Testing 181
5.3.4 Software Quality Growth Models 181
6 Reliability & Availability of Repairable Systems
6.1 Introduction, General Assumptions, Conclusions 184
6.2 One-Item Structure 190
6.2.1 One-Item Structure New at Time t=0 191
6.2.1.1 Reliability Function 191
6.2.1.2 Point Availability 192
6.2.1.3 Average Availability 193
6.2.1.4 Interval Reliability 194
6.2.1.5 Special Kinds of Availability 195
6.2.2 One-Item Structure New at t=0 with Const. Failure Rate ? 198
6.2.3 One-Item Structure with Arbitrary Conditions at t=0 199
6.2.4 Asymptotic Behavior 200
6.2.5 Steady-State Behavior 202
6.3 Systems without Redundancy 204
6.3.1 Series Structure with Constant Failure and Repair Rates 204
6.3.2 Series Structure with Constant Failure and Arbitrary Repair Rates 207
6.3.3 Series Structure with Arbitrary Failure & Repair Rates
6.4 1-out-of-2 Redundancy (Warm, one Repair Crew) 211
6.4.1 1-out-of-2 Redundancy with Const. Failure & Repair Rates
6.4.2 1-out-of-2 Redundancy with Constant Failure and Arbitrary Repair Rates 219
6.4.3 1-out-of-2 Redundancy with Constant Failure Rate only in the Reserve State, Arbitrary Repair Rates 222
6.5 k-out-of-n Redundancy (Warm, Identical Elements, one Repair Crew) 228
6.5.1 k-out-of-n Redundancy with Const. Failure & Repair Rates
6.5.2 k-out-of-n Redundancy with Constant Failure and Arbitrary Repair Rates 233
6.6 Simple Series Parallel Structures (one Repair Crew) 235
6.7 Approximate Expressions for Large Series-Parallel Structures 241
6.7.1 Introduction 241
6.7.2 Application to a Practical Example 245
6.8 Systems with Complex Structure (one Repair Crew) 253
6.8.1 General Considerations 253
6.8.2 Preventive Maintenance 255
6.8.3 Imperfect Switching 258
6.8.4 Incomplete Coverage 264
6.8.5 Elements with more than two States or one Failure Mode 272
6.8.6 Fault Tolerant Reconfigurable Systems 274
6.8.6.1 Ideal Case 274
6.8.6.2 Time Censored Reconfiguration (Phased-Mission Systems) 274
6.8.6.3 Failure Censored Reconfiguration 281
6.8.6.4 Reward and Frequency / Duration Aspects 285
6.8.7 Systems with Common Cause Failures 286
6.8.8 Basic Considerations on Network Reliability 290
6.8.9 General Procedure for Modeling Complex Systems 292
6.9 Alternative Investigation Methods 295
6.9.1 Systems with Totally Independent Elements 295
6.9.2 Static and Dynamic Fault Trees 295
6.9.3 Binary Decision Diagrams 298
6.9.4 Event Trees 301
6.9.5 Petri Nets 302
6.9.6 Numerical Reliability and Availability Computation 304
6.9.6.1 Numerical Computation of System's Reliability and Availability 304
6.9.6.2 Monte Carlo Simulations 305
6.9.7 Approximate Expressions for Large, Complex Systems 308
6.10 Human Reliability 309
6.11 Risk Management for Repairable Systems 314
6.11.1 Introduction 314
6.11.2 Risk Modeling, MTTA, S (t) 316
6.11.3 Risk Avoidance and Risk Mitigation 324
7 Statistical Quality Control & Reliability Tests
7.1 Statistical Quality Control 326
7.1.1 Estimation of a Defective Probability p 327
7.1.2 Simple Two-sided Sampling Plans for the Demonstration of a Defective Probability p 329
7.1.2.1 Simple Two-sided Sampling Plan 330
7.1.2.2 Sequential Test 332
7.1.3 One-sided Sampling Plans for the Demonstration of a Defective Probability p 333
7.2 Statistical Reliability (RAMS) Tests 336
7.2.1 Reliability & Availability Estimation and Demonstration for the Case of a given (fixed) Mission
7.2.2 Availability Estimation & Demonstration for the Case of Continuous Operation (Asymptotic &
7.2.2.1 Availability Estimation (Erlangian Failure-Free and / or Repair Times) 338
7.2.2.2 Availability Demonstration (Erlangian Failure-Free and / or Repair Times) 340
7.2.2.3 Further Availability Evaluation Methods for Continuous Operation 341
7.2.3 Estimation & Demonstration of a Constant Failure Rate ? (or of MTBF for the Case MTBF ? 1/?)
7.2.3.1 Estimation of a Constant Failure Rate ? (or of MTBF for MTBF ? 1/?) 345
7.2.3.2 Simple Two-sided Test for the Demonstration of a Constant Failure Rate ? (or of MTBF for the case MTBF ? 1/?) 347
7.2.3.3 Simple One-sided Test for the Demonstration of a Constant Failure Rate ? (or of MTBF for the case MTBF ?1/?) 351
7.3 Estimation and Demonstration of an MTTR 352
7.3.1 Estimation of an MTTR 352
7.3.2 Demonstration of an MTTR 354
7.4 Accelerated Testing 356
7.5 Goodness-of-fit Tests 361
7.5.1 Kolmogorov-Smirnov Test 361
7.5.2 Chi-square Test 365
7.6 Statistical Analysis of General Reliability Data 368
7.6.1 General considerations 368
7.6.2 Tests for Nonhomogeneous Poisson Processes 370
7.6.3 Trend Tests 372
7.6.3.1 Tests of an HPP versus an NHPP with increasing intensity 372
7.6.3.2 Tests of an HPP versus an NHPP with decreasing intensity 375
7.6.3.3 Heuristic Tests to distinguish between HPP and General Monotonic Trend 376
7.7 Reliability Growth 378
8 Quality & Reliability (RAMS) Assurance During the Production Phase (Basic Considerations)
8.1 Basic Activities 384
8.2 Testing and Screening of Electronic Components 385
8.2.1 Testing of Electronic Components 385
8.2.2 Screening of Electronic Components 386
8.3 Testing and Screening of Electronic Assemblies 389
8.4 Test and Screening Strategies, Economic Aspects 391
8.4.1 Basic Considerations 391
8.4.2 Quality Cost Optimization at Incoming Inspection Level 394
8.4.3 Procedure to handle first deliveries 399
A1 Terms and Definitions 400
A2 Quality and Reliability (RAMS) Standards , Story of Reliability Engineering 416
A2.1 Introduction 416
A2.2 General Requirements in the Industrial Field 417
A2.3 Requirements in the Aerospace, Railway, Defense, and Nuclear Fields 419
A2.4 A Skillful , Allegorical Story of Reliability 420
A3 Definition and Realization of Quality & Reliability (RAMS) Requirements
A3.1 Definition of Quality and Reliability (RAMS) Requirements 422
A3.2 Realization of Quality & Reliability (RAMS) Requirements for Complex Equipment &
A3.3 Elements of a Quality and Reliability (RAMS) Assurance Program 429
A3.3.1 Project Organization, Planning, and Scheduling 429
A3.3.2 Quality and Reliability (RAMS) Requirements 430
A3.3.3 Reliability, Maintainability, and Safety Analyses 430
A3.3.4 Selection & Qualification of Components, Materials, and Manufacturing Processes
A3.3.5 Software Quality Assurance 431
A3.3.6 Configuration Management 432
A3.3.7 Quality Tests 433
A3.3.8 Quality Data Reporting System 435
A4 Checklists for Design Reviews 436
A4.1 System Design Review (Table A3.3, p. 419) 436
A4.2 Preliminary Design Reviews (Table A3.3 on p. 419) 437
A4.3 Critical Design Review (System Level, Table A3.3 on p. 419) 440
A5 Requirements for a Quality Data Reporting System 441
A6 Basic Probability Theory 444
A6.1 Field of Events 444
A6.2 Concept of Probability 446
A6.3 Conditional Probability, Independence 449
A6.4 Fundamental Rules of Probability Theory 450
A6.4.1 Addition Theorem for Mutually Exclusive Events 450
A6.4.2 Multiplication Theorem for Two Independent Events 451
A6.4.3 Multiplication Theorem for Arbitrary Events 452
A6.4.4 Addition Theorem for Arbitrary Events 452
A6.4.5 Theorem of Total Probability 453
A6.5 Random Variables, Distribution Functions 454
A6.6 Numerical Parameters of Random Variables 460
A6.6.1 Expected Value (Mean) 460
A6.6.2 Variance 463
A6.6.3 Modal Value, Quantile, Median 465
A6.7 Multidimensional Random Variables, Conditional Distributions 465
A6.8 Numerical Parameters of Random Vectors 467
A6.8.1 Covariance Matrix, Correlation Coefficient 468
A6.8.2 Further Properties of Expected Value and Variance 469
A6.9 Distribution of the Sum of Independent Positive Random Variables and of tmin , tmax 469
A6.10 Distribution Functions used in Reliability Analysis 472
A6.10.1 Exponential Distribution 472
A6.10.2 Weibull Distribution 473
A6.10.3 Gamma Distribution, Erlangian Distribution, and ?²-Distribution 475
A6.10.4 Normal Distribution 477
A6.10.5 Lognormal Distribution 478
A6.10.6 Uniform Distribution 480
A6.10.7 Binomial Distribution 480
A6.10.8 Poisson Distribution 482
A6.10.9 Geometric Distribution 484
A6.10.10 Hypergeometric Distribution 485
A6.11 Limit Theorems 485
A6.11.1 Laws of Large Numbers 486
A6.11.2 Central Limit Theorem 487
A7 Basic Stochastic Processes Theory 491
A7.1 Introduction 491
A7.2 Renewal Processes 494
A7.2.1 Renewal Function, Renewal Density 496
A7.2.2 Recurrence Times 499
A7.2.3 Asymptotic Behavior 500
A7.2.4 Stationary Renewal Processes 502
A7.2.5 Homogeneous Poisson Processes (HPP) 503
A7.3 Alternating Renewal Processes 505
A7.4 Regenerative Processes with a Finite Number of States 509
A7.5 Markov Processes with a Finite Number of States 511
A7.5.1 Markov Chains with a Finite Number of States 511
A7.5.2 Markov Processes with a Finite Number of States 513
A7.5.3 State Probabilities and Stay Times (Sojourn Times) in a Given Class of States 522
A7.5.3.1 Method of Differential Equations 522
A7.5.3.2 Method of Integral Equations 526
A7.5.3.3 Stationary State and Asymptotic Behavior 527
A7.5.4 Frequency / Duration and Reward Aspects 529
A7.5.4.1 Frequency / Duration 529
A7.5.4.2 Reward 531
A7.5.5 Birth and Death Process 532
A7.6 Semi-Markov Processes with a Finite Number of States 536
A7.7 Semi-regenerative Processes with a Finite Number of States 541
A7.8 Nonregenerative Stochastic Processes with a Countable Number of States 546
A7.8.1 General Considerations 546
A7.8.2 Nonhomogeneous Poisson Processes (NHPP) 547
A7.8.3 Superimposed Renewal Processes 551
A7.8.4 Cumulative Processes 552
A7.8.5 General Point Processes 554
A8 Basic Mathematical Statistics 556
A8.1 Empirical Methods 556
A8.1.1 Empirical Distribution Function 557
A8.1.2 Empirical Moments and Quantiles 559
A8.1.3 Further Applications of the Empirical Distribution Function 560
A8.2 Parameter Estimation 564
A8.2.1 Point Estimation 564
A8.2.2 Interval Estimation 569
A8.2.2.1 Estimation of an Unknown Probability p 569
A8.2.2.2 Estimation of the Parameter ? for an Exponential Distribution: Fixed Test Duration (Time Censoring), Instantaneous Replacement 573
A8.2.2.3 Estimation of the Parameter ? for an Exponential Distribution: Fixed Number n of Failures (Failure Censoring), no Replacement 574
A8.2.2.4 Availability Estimation (Erlangian Failure-Free and / or Repair Times) 576
A8.3 Testing Statistical Hypotheses 578
A8.3.1 Testing an Unknown Probability p 579
A8.3.1.1 Simple Two-sided Sampling Plan 580
A8.3.1.2 Sequential Test 581
A8.3.1.3 Simple One-sided Sampling Plan 582
A8.3.1.4 Availability Demonstration (Erlangian Failure-Free and/or Repair Times) 584
A8.3.2 Goodness-of-fit Tests for Completely Specified F?(t) 586
A8.3.3 Goodness-of-fit Tests for a Distribution F?(t) with Unknown Parameters 589
A9 Tables and Charts 592
A9.1 Standard Normal Distribution 592
A9.2 ?²-Distribution (Chi Square Distribution) 593
A9.3 t-Distribution (Student Distribution) 594
A9.4 F-Distribution (Fisher Distribution) 595
A9.5 Table for the Kolmogorov Smirnov Test 596
A9.6 Gamma Function 597
A9.7 Laplace Transform 598
A9.8 Probability Charts 600
A9.8.1 Lognormal Probability Chart 600
A9.8.2 Weibull Probability Chart 601
A9.8.3 Normal Probability Chart 602
A10 Basic Technological Component's Properties 603
A11 Problems for Homework 607
Acronyms 615
References 616
Index 642
| Erscheint lt. Verlag | 19.5.2017 |
|---|---|
| Zusatzinfo | 650 p. |
| Verlagsort | Berlin |
| Sprache | englisch |
| Themenwelt | Naturwissenschaften ► Physik / Astronomie |
| Technik ► Elektrotechnik / Energietechnik | |
| Technik ► Maschinenbau | |
| Wirtschaft ► Betriebswirtschaft / Management ► Unternehmensführung / Management | |
| Schlagworte | Aerospace • Chemical Manufacturing • Energy, Utilities and Environment • Materials and Steel • Oil, Gas and Geosciences • Quality Control, Reliability, Safety and Risk |
| ISBN-10 | 3-662-54209-9 / 3662542099 |
| ISBN-13 | 978-3-662-54209-5 / 9783662542095 |
| Haben Sie eine Frage zum Produkt? |
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