Reliability of Technical Systems

The design of technical systems and their components with respect to fatigue strength require methods that consider the complete process of development and its aftercare. Most projects originate from the vehicle or supplier industry. In picture: brake disc.

Load Data and Durability

For reliability and durability analysis, we need the properties of the systems and components as well as the load data. Moreover, these data only allow relevant conclusions to be drawn in combination with simulation and testing.

In order to enable a design that meets customer requirements without overdimensioning, we determine the loads that occur in the field and their variance. This is done by a suitable mixture of direct load measurement in selected operating states, general observations of customer behaviour and statistical extrapolation of data.

Collect and Evaluate Data

In order to collect data as efficiently as possible, we plan, execute and evaluate the associated campaigns. In addition, we extrapolate the data to long periods of usage. Geo-referenced data play an important role in planning as well as in evaluation and extrapolation. The approach and methods are described in the application fields Overall Process for Load Analysis.

The main results of the data collection campaign and its evaluation are reference or design loads. These represent customer behavior and are mapped to standard load cases or test tracks in a subsequent step. For road vehicles, for example, this means that the reference load is represented by a mixture of tracks on a proving ground. For an agricultural or construction machine, this is represented by a number of standard applications (ploughing, transport or excavation and truck loading). For this multi-target optimization task we offer the appropriate tools (U·SimOpt).

 

Determine Durability with Statistical Methods

In the area Fatigue Testing and Reliability we implement statistical methods for the planning and evaluation of lifetime tests and warranty data. Here, the tool Jurojin, developed over many years in close cooperation with industry, plays a central role.

 

Data Simulation and Load Tests

Often not all loads required for component evaluation could be measured. Thus, component loads have to be supplemented by simulation. In principle, this step could be performed early in the process, but is often only carried out after mapping to the test tracks or standard load cases in order to save simulation effort.

Before release, components or entire systems are tested and evaluated on the test bench. Especially for components with complex loads (wheel carrier of a passenger car or boom of an excavator), the full number of component loads cannot be realized in the test. Instead, simplified test configurations are sought (fewer cylinders, simpler load signals, etc.) in order to limit the effort. We deal with such questions in the field of Simplified Rig Tests.

Application Fields

 

Overall Process for Load Analysis

Throughout the entire process, our software tools support the load data analysis.

 

General Load Data Analysis

A good understanding of the operating loads is crucial for the development of mechanically stressed systems.

 

Simplified Rig Tests

We develope suitable methods to get an optimal rig configuration without the effort of repeated finite elements computations for different mountings.

Products in the Field of Activity

 

Geo-referenced Load Data Analysis with VMC® GeoLDA

Enrichment of conventionally collected measurement data by mapping onto the road network.

 

Assessment of Customer Usage Profiles with U·Sim

 

Fatigue Testing and Reliability with Jurojin

With our tool JUROJIN we support the planning and evaluation of durability tests.