THE LOAD MATRIX TM METHOD: ADDING STRATEGY TO YOUR DURABILITY TESTING EXPERIENCE

Transcription

1 THE LOAD MATRIX TM METHOD: ADDING STRATEGY TO YOUR DURABILITY TESTING EXPERIENCE Sarah Zitouni AVL List GmbH

2 AN INCREASINGLY COMPLEX WORLD AND VALIDATION PROCESS More innovative and new systems Increasing complexity of electronics & interaction SW/HW Legal requirements Useful life / emission stability More failure modes to be covered by testing LESS DEVELOPMENT & TESTING TIME Future S.Zitouni, C. Velten, J.Wohlfart 26 Nov

3 COMPONENTS OF A COMMON VALIDATION PLAN VALIDATION PLAN DESIGN & ANALYSIS Target: Systematic evaluation of testing status Definition of optimization steps TEST DATA GENERATION Target: Assessment of relevant parameters for validation program and for its improvement ADAPTATION & DESIGN OF DURABILITY TEST CYCLE(S) Target: Systematic improvement of validation activities based on previous results VALIDATION CONTRIBUTION BY TESTING & MONITORING S.Zitouni, C. Velten, J.Wohlfart 26 Nov

4 THE ROLE OF THE LOAD MATRIX METHOD VALIDATION PLAN DESIGN & ANALYSIS LOAD MATRIX Assistance for analysis of test programs for product validation TEST DATA GENERATION Target: Assessment of relevant parameters for validation program REMINDER: improvement Validation can be seen as doing the right thing ADAPTATION & DESIGN Verification can be seen as doing Target: it right OF DURABILITY TEST Systematic improvement of validation activities based on CYCLE(S) previous results VALIDATION CONTRIBUTION BY TESTING & MONITORING S.Zitouni, C. Velten, J.Wohlfart 26 Nov

5 HOW DOES THE LOAD MATRIX METHOD WORK? STEP BY STEP STEP 1: LOAD MATRIX Data Collection SYSTEM ANALYSIS What components need to be tested and how can it fail? APPLICATION AND TARGETS How are the systems used and what are the targets? TEST PROGRAM What is the existing test program? STEP 2: LOAD MATRIX Analysis & Evaluation STEP 3: LOAD MATRIX based improvement EVALUATION What coverage of failure modes do we achieve with the durability test program? What gaps are existing in validation? Do we have to react and how should we improve the program? S.Zitouni, C. Velten, J.Wohlfart 26 Nov

6 HOW DOES THE LOAD MATRIX METHOD WORK? STEP BY STEP SYSTEM INFORMATION STEP 1: LOAD MATRIX Data Collection CUSTOMER USAGE & TARGETS TEST PROGRAM FMEA Failure modes + required operations Lifetime target: 1.5Mkm Experiencebased test program STEP 2: LOAD MATRIX Analysis & Evaluation STEP 3: LOAD MATRIX based improvement EXTENSION OF WORKING AND TESTING ENVIRONMENT TYPE OF TEST CYCLES DURATION AND NUMBER OF TESTS AVL transient test AVL Load cycle test Test Duration Nr Load cycle test 3000h 3 Thermal shock test 1500h 2 Transient test 2000h 2 S.Zitouni, C. Velten, J.Wohlfart 26 Nov

7 THE LOAD MATRIX APPROACH IN MORE DETAILS Main Question: Which kind of durability testing do we need? AVL LOAD MATRIX Methodology Step 1: System analysis Step 2: Application & Targets Step 3: Test program & load analysis Step 4: Evaluation & optimization Failure modes & operating conditions to be covered by durability test program Definition of validation targets to be fulfilled by test program Identification of relevant customer behavior Collection of durability test profiles Definition of damage models for failure modes Calculation of damage and acceleration of test cycles related to customer usage Evaluation of all test contributions and test program status Definition of optimization steps E.g. Wear of Piston ring (High load operation) E.g. Life time target B 10 : 1.5 Mkm / h Customer profile AVL Damage model e.g. wear model AF= D Test D Ref AVL Load cycle test S.Zitouni, C. Velten, J.Wohlfart 26 Nov

8 SUMMARY ON A PROJECT Summary of input data for Load Matrix analysis Target of LM data collection Identification and prioritization of validation relevant failure modes for a hybrid powertrain Collection of validation targets Collection of available customer data and definition of customer reference profiles LM-Step System analysis Application & Targets Results of LM data collection 89 failure modes in LM analysis Failure mode specific targets defined with development team 1 representative customer reference profile defined Compilation of the durability test program for Load Matrix analysis Assessment of failure mode coverage by durability tests Test program & Load analysis 6 test bed cycles and 10 vehicle test cycles were evaluated Damage calculation applied S.Zitouni, C. Velten, J.Wohlfart 26 Nov

9 All All Accumulated durability hours AND THE RELATED RESULTS First analysis of validation program with respect to failure and target coverage Validation Contribution Validation (optimized) contribution Supplier Contribution Validation contribution Supplier Contribution Validation of modified target and additional Tests Validation targetvalidation target Engine Engine + EATS EATS Transmission Transmission Hybrid Hybrid Elements Elements (HV (HV Electrics) Electrics) Drivetrain Drivetrain Low Low voltage voltage electric electric & sensors sensors Visibility over the status of the validation and the existing gaps Identification of validation risks for project team members and management Additional validation contribution by Suppliers Impact of optimization steps on validation status S.Zitouni, C. Velten, J.Wohlfart 26 Nov

10 WHAT DO YOU GAIN FROM USING THE LOAD MATRIX APPROACH? System analysis Identification of components and their failure modes to be covered by testing in one document Link between failure modes and required operation to get maximum damage Application and targets Clear definition of project specific validation targets Alignment of influencing information for validation program Highlight needed missing information Test Program and Load Analysis Determination and quantification of the different test contributions Evaluation and optimization Clear visibility of the validation risks for all relevant components (one graph to see it all!) Integration of new possibilities to generate validation contribution S.Zitouni, C. Velten, J.Wohlfart 26 Nov

11 IN ONE SENTENCE: WHY SHOULD YOU TRY LOAD MATRIX? INCREASED EFFICIENCY OF VALIDATION PROGRAM WITH RESPECT TO YOUR GIVEN BOUNDARY CONDITIONS S.Zitouni, C. Velten, J.Wohlfart 26 Nov