PROVIDING KNOWLEDGE AND RESOURCES FOR THE ADVANCEMENT OF DIAGNOSTICS, PROGNOSTICS AND SYSTEM HEALTH MANAGEMENT

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Shenzhen FMMEA for Lithium-ion Batteries HDI Board Microvia Void and Failure Investigation 1 3 3 4 4 The IEEE 2012 Prognostics and System Health Management (PHM-2012) Conference was held on May 23-2,

1 Prognostics PHM NEWSLETTER PROVIDING KNOWLEDGE AND RESOURCES FOR THE ADVANCEMENT OF DIAGNOSTICS, PROGNOSTICS AND SYSTEM HEALTH MANAGEMENT JULY 2012 CALCE Presents at IEEE 2012 Prognostics and System Health Management-Beijing INSIDE THIS ISSUE: CALCE Presents at IEEE 2012 PHM Beijing CALCE Wins IEEE Prognostics Challenge CALCE Presents at IEEE Battery Conf. Shenzhen FMMEA for Lithium-ion Batteries HDI Board Microvia Void and Failure Investigation The IEEE 2012 Prognostics and System Health Management (PHM-2012) Conference was held on May 23-2, 2012, in Beijing, China. The conference, chaired by Prof. Michael Pecht and organized by Beihang University and the China PHM Society, attracted over 20 international experts and representatives from industry, academia, and government agencies. The conference covered PHM theory as well as industrial applications of PHM in batteries, computers, aerospace, power and electronics systems, and health care and medical technologies. Annual Conf. of the PHM Society 4th International Conf. on PHM IEEE Aerospace Conf. Join CALCE PHMC To kick the conference off, Prof. Michael Pecht gave a keynote speech on Advances in PHM for Tomorrow s Industries. Two of the four tutorials at the conference were given by CALCE representatives. (Continued on pg. 2) Prof. Michael Pecht at PHM-2012

He discussed the fundamental algorithms, models, and techniques for each step.

2 PHM NEWSLETTER PAGE 2 CALCE Presents at IEEE 2012 Prognostics and System Health Management-Beijing continued Dr. Chaochao Chen presented on Prognostics and Health Management Fundamentals. His tutorial introduced the five key steps of PHM: data processing, feature extraction, fault diagnostics, failure prognostics, and decision making. He discussed the fundamental algorithms, models, and techniques for each step. He introduced time-domain, frequency-domain, and time-frequency data analyses, and he presented the corresponding feature extraction technologies. He also described model-based and data-driven-based approaches in fault diagnostics and failure prognostics. Finally, he illustrated the decision technologies incorporating prognostics results to optimize maintenance policies and logistics business practices. Mr. Nick Williard gave a tutorial on Advancing Battery Management Systems through PHM Methodologies. This presentation focused on how prognostic methodologies can be applied to a battery management system (BMS) in order to improve the accuracy and performance of the overall battery system. He reviewed and evaluated useful sensors capable of capturing information related to the battery state in the context of specific applications. He then gave the methods by which features are selected from sensor data and used to evaluate battery state and remaining useful performance. He described the pros and cons of utilizing physical models versus data-driven models, and he proposed improved solutions based on the fusion of both approaches. He described the use of model outputs for communicating beneficial performance and maintenance information to the user for different applications. In the case of electric vehicles, the BMS is highly integrated with the dashboard to provide fuel gauge readings and fault messages. Model outputs are also fed back into the BMS to optimize the energy utilization and charging protocol. Mr. Williard also described other BMS functions, such as maintaining safe operational voltage and current levels, performing cell balancing, and controlling active heating and cooling functions. Lastly, he discussed future improvements of BMS technologies through the use of wireless networking to provide GPS positions, weather forecasts, and adaptation based on user driving profiles. Dr. Chaochao Chen at PHM Mr. Nick Williard at PHM Dr. Chaochao Chen and Mr. Wei He presented conference papers on battery prognostics. Their papers addressed the prediction uncertainty problems in determining battery state of health and state of charge from the perspectives of optimal model adaptation and nonlinear filtering. Ms. Preeti Chauhan presented her paper on the use of temperature as a health assessment tool for implementing prognostics and health management in electronic components.

JULY 2012 PAGE 3 CALCE Students Win IEEE Prognostics Challenge A team of eight CALCE students won first place in the Academic Category of the IEEE PHM 2012 Prognostics Challenge.

. Each team was tasked with estimating the remaining useful life of bearings in rotating machines.

3 JULY 2012 PAGE 3 CALCE Students Win IEEE Prognostics Challenge A team of eight CALCE students won first place in the Academic Category of the IEEE PHM 2012 Prognostics Challenge. The competition was open to teams from the top universities in the field of prognostics and was organized by the IEEE Reliability Society and the FEMTO-ST Institute.. Each team was tasked with estimating the remaining useful life of bearings in rotating machines. The prediction of remaining useful life enables forecasted maintenance of systems, increases availability, and reduces the risk of unexpected failures, thus increasing safety. Participating teams were provided with datasets from an experiment that monitored the degradation of bearings under various operating conditions. The CALCE team successfully extracted degradation features from the bearing vibration data and developed fault propagation models using three different methodologies to predict the remaining useful life of the bearings. Method 1 used Moving Average Spectral Kurtosis and Bayesian Monte Carlo. Method 2 used a Soft Computing Model with Support Vector Regressor. Method 3 utilized Vibration Frequency Signature Anomaly Detection and Survival Time Ratio. The CALCE team included Arvind Vasan, Edwin Sutrisno, Hyunseok Oh, Jing Tian, Moon-Hwan Chang, Surya Kunche, Wei He, and Yan Ning. They are the students of Prof. Michael Pecht. Ph.D student Arvind Vasan presented their winning approach at the 2012 IEEE International Conference on Prognostics and Health Management in Denver, Colorado. CALCE Presents at IEEE Conference on Battery Management Systems for High Operational Availability and Safety - Shenzhen, China The Hong Kong Productivity Council and PHM Centre, City University of Hong Kong, along with the IEEE Reliability Society co-organized this conference at Shenzhen, China, on May 21, Nearly 100 industry representatives attended this IEEE event. The conference addressed challenges in battery management systems (BMSs) from the fundamental engineering and chemistry perspectives and focused on finding innovative approaches to achieve high operational availability and safety for BMSs. The CALCE battery team led by Prof. Pecht shared their expertise with Nissan Leaf the audience. Dr. Chaochao Chen gave a talk on an overview of Battery Management Systems in electric vehicles. He reviewed recent research and development in BMSs, discussed prognostics and health monitoring for a variety of battery chemistries, and summarized the techniques, algorithms, and models used for state of charge (SOC) estimation, state of health (SOH) estimation, and remaining useful life (RUL) prediction. Mr. Wei He introduced some key requirements and approaches for battery safety. Mr. Nick Williard presented his work on battery chemistries and degradation mechanisms, showing that an understanding of degradation mechanisms is required to improve battery prognostics and current designs.

The ways that environmental and usage conditions influence individual degradation mechanisms will be studied.

4 PHM NEWSLETTER PAGE 4 Failure Modes, Mechanisms, and Effects Analysis for Lithium-ion ion Batteries CALCE is working to create a failure modes, mechanisms, and effects analysis (FMMEA) for lithium-ion batteries. This project outlines all the failure and degradation modes of a battery and matches them with their underlying physical degradation mechanisms. The ways that environmental and usage conditions influence individual degradation mechanisms will be studied. The existing degradation models and the underlying assumptions behind them New Battery Sudden failure, high temp Low current cyclic testing Failure Analysis: Electrode Material Degradation (i.e., what mechanisms these models are designed to simulate) will be investigated as well. The goal is to identify which failure mechanisms are sensitive to which environmental conditions. At the same time, we also seek to understand how to model each specific failure mechanisms. We will then use FMMEA to weigh the results of the degradation models by monitoring the environmental conditions in-situ through the use of prognostics and health management. For further information, please contact Dr. Chaochao Chen at chaochao@calce.umd.edu. HDI Board Microvia Void and Failure Investigation Driven by portable devices and wireless communications, the electronics industry has incr eased the densit y of I/ Os while decreasing the footprint of components. This drives the need for high density interconnect (HDI) boards, which use finer lines and spaces ( 100µm), and smaller vias ( 10µm). During HDI board fabrication, the electroplating process can create plating voids on copper-filled microvias that can potentially degrade the reliability of a structure. Currently, companies use their own inspection methods and criteria to accept or reject HDI boards, which has led to voided microvias being accepted. There is a need in the PWB industry to establish standard qualification testing for HDI structures and a threshold to reject unreliable microvias. CALCE has been studying the materials and reliability of HDIs for over 17 years. With this expertise, combined with a focus on the underlying physics of failure and state-of-the-art test and analysis facilities, CALCE is capable of helping the PWB industry develop an HDI qualification testing methodology and set up industry criteria for microvia acceptance. This project focuses on 1) determining the effect of voids in microvias on PWB reliability, and whether there is a threshold level of voiding that is detrimental; 2) devising a test to detect microvia voiding and identify the associated failure mode; and 3) assessing the susceptibility to failure of boards with many microvia voids compared to boards with few or no voids. For further information, please contact Dr. Michael Azarian at or mazarian@calce.umd.edu.

5 JULY 2012 PAGE Annual Conference of the PHM Society 2012 The Annual Conference of the Prognostics and Health Management Society 2012 will be held at the Hyatt Regency in Minneapolis, Minnesota, on September 23-27, The conference will bring together the global community of PHM experts from industry, academia, and government in diverse application areas such as energy, aerospace, transportation, automotive, and industrial automation. For more information, visit: 4th International Conference on Prognostics and Health Management There is a growing interest in Prognostics and Health Management (PHM) of structures, systems, and components. Much effort is being devoted to the development of techniques for health monitoring, fault detection, diagnosis, and prognosis with the intent of improving the safety and economic performance of existing and future structures, systems, and components. It is our pleasure to announce the 4th International Conference on Prognostics and System Health Management that will be held on September 8-11, 2013, in Milan, Italy. This conference aims at fostering exchange in state-of-the-art PHM research and application. The presentation of developments in various industrial fields is expected to highlight differences in research challenges and practical needs, while at the same time providing benefits from cross-fertilization of methods and applications. Sponsoring Organizations: Chair on Systems Science and the Energetic Challenge, European Foundation for New Energy-EDF, Ecole Centrale Paris-Supelec, France Laboratory of Signal and Risk Analysis (LASAR) Politecnico di Milano, Italy For more information, visit: IEEE Aerospace Conference Big Sky, Montana, March 2-9, 2013 The 2013 IEEE Aerospace Conference ( is the 34th in a series of annual week-long conferences designed for aerospace experts from industry, government, and academia in a stimulating and thought-provoking environment. The Conference promotes interdisciplinary understanding of aerospace systems, their underlying science and technology, and their applications to government and commercial endeavors. Technical cosponsors include AIAA and the PHM Society. Attendees, over 700 in 2012, will enjoy exceptional access to authors and invited speakers in a unique setting. This will be an excellent forum that will benefit participants, their organizations, and the engineering, scientific, and aerospace communities. ABSTRACT SUBMISSION Abstracts of 00 words or less must be submitted via the Conference Web site by July 30, Accept/reject notices will be ed promptly. Dr. Chaochao Chen of CALCE will chair the session Prognostics for Electronics and Avionic Systems. Interested researchers are welcome to submit their work to this session. For further information, please contact Dr. Chen at chaochao@calce.umd.edu Join the CALCE PHM CONSORTIUM If you are not a member and would like to join the CALCE Prognostics and Health Management Consortium, please Dr. Chaochao Chen (chaochao@calce.umd.edu), and we will provide you with the membership agreement. Upon becoming a member, you will have membership benefits including access to PHMC materials, research projects, education, and cooperative programs.

Reliability, Availability and Maintenance (RAM) & Prognostics and Health Managemenrt (PHM) - 4.0

Reliability, Availability and Maintenance (RAM) & Prognostics and Health Managemenrt (PHM) - 4.0 Enrico Zio Chair on Systems Science and the Energy Challenge CentraleSupelec, Fondation Electricité de France