2016 ARS Europe · PDF file2016 ARS Europe Green Room, Session 7 ... Valeo / PSA Field FTA update PV / DV data gathering Supplier Involvement Warranty Return analysis Analysis Protocol

2016 ARS EuropeGreen Room, Session 7

Test Tailoring Application for a Car Interior Electronic Module : Design of a New Durability Test Sequence for Sliding Contacts

Corrosion Based on Field Data

Jorge-Filipe Carvalho, Fabrice Blasenhauer

Begins at 10:30 AM, Tuesday, April 5th

PRESENTATION SLIDESThe following presentation was delivered at the:

International Applied Reliability Symposium, EuropeApril 4 - 6, 2016: Munich, Germanyhttp://www.arsymposium.org/europe/2016/

The International Applied Reliability Symposium (ARS) is intended to be a forum for reliability and maintainability practitioners within industry and government to discuss their success stories and lessons learned regarding

the application of reliability techniques to meet real world challenges. Each year, the ARS issues an open"Call for Presentations" at http://www.ARSymposium.org/europe/presenters/index.htm and the presentations

delivered at the Symposium are selected on the basis of the presentation proposals received.

Although the ARS may edit the presentation materials as needed to make them ready to print, the content of the presentation is solely the responsibility of the author. Publication of these presentation materials in the

ARS Proceedings does not imply that the information and methods described in the presentation have been verified or endorsed by the ARS and/or its organizers.

The publication of these materials in the ARS presentation format is Copyright © 2016 by the ARS, All Rights Reserved.

Fabrice Blasenhauer, Valeo / Jorge-Filipe Carvalho, PSA Slide Number: 2Session 7Green Room App

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Abstract

Test Tailoring Application for a Car Interior Electronic Module : Design of a New Durability Test Sequence for Sliding Contacts Corrosion Based on Field DataField data gathering in the automotive industry is usually made via specific fleets analysis: taxis, prototypes,

selected users with dedicated data recorders. The new approach selected by PSA Peugeot Citroën on top column modules (electronic stalk switches) using the Valeo interface is to directly embed recording of main functions in the end-user units. It allows real data collection and analysis. This tool has the potential to provide updates on mission profiles (number of actuations) and better failure mechanism understanding.

Using this feature on top column modules, this two-year collaborative study between Valeo and PSA Peugeot Citroën has set a new basis for reliability testing in the domain. The classical approach of test tailoring has been deployed leading to change the mission profiles and failure mechanisms accordingly. As a consequence, the durability test has changed to cope with the new stresses identified.

Valeo uses an improved version of PSA Peugeot Citroën's internal procedure by being focused on data gathering and failure mechanism reproduction in laboratories. Those actions, in parallel with parametric testing and accelerated tests, had made possible an update to the Failure Tree Analysis of the loss of electrical signal for low current sliding contacts due to corrosion. As a result, this project provides an updated durability test sequence. It will be deployed in laboratories during design validation phases using a systematic description of the failure mechanism and using state-of-the-art accelerated models to describe the field equivalency.

Key Words: Data Gathering, Field Data, Durability Test Sequence


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Introduction

Jorge-Filipe CARVALHO, Mechatronic Expert of CommutationDRD/DSEE/MCSI/EMCDElectronics Modules of Controls and Displays

Fabrice BLASENHAUER, Validation Métier - Reliability Manager ExpertProduct Group : Comfort & Interior Controls


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Agenda

Aiming and BackgroundProcess Field data Mission Profile FTA and Accelerated TestsTest SequencingSummary

Questions


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AIMING and Background

Valeo and PSA share a common approach to setting up a low current contact reliability protocol at 15 years of vehicle life or 240 000 km or 10,000 operating hours.

Items targeted Failure Mode update Reliability targets (probability of failures) demonstration Mission profiles update Methodology

Aiming of this presentation : Method deployed

Return of Experience on Car Manufacturer and OEM collaboration Come back on Technical choices and issues

Jorge Filipe Carvalho


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INTRODUCTION - Vocabulary DV : Design Validation

Tests sequences that demonstrates the design quality and durability PV : Product / Process Validation

Test sequences that demonstrates the process and product stability in term of quality and durability

EDL : Embedded data Logger EOLT : End Of Line Tester TCM : Top Column Module / Stalk Switch with integrated electronics that

commands the beam, wipers, cruise controls …


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INTRODUCTION : Top Column Module

TCM Functions and perimeter


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Product Commutation Metallic Blades scratching on PCB actuated

by the lever (here TURN Signal function)

Lubricated and Electrically conducting Pads

PCB wired to microcontroller


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Process and Animation Mode

Failure ReproductionWR Analysis

New parts Kill Test2nd Step : Benchmark

WR PSA TCMField (High Km)

Valeo / PSA Field

PV / DV data gatheringSupplier InvolvementWarranty Return analysisFTA definitionAnalysis Protocol

FIELD MISSION PROFIL

1

ENVIRONEMENTAL DAMAGING FACTOR

3

Test (Field / Lab)

ACCELERATING FACTOR

4

4 Steps : 1. Collect data on former projects Field + Validations2. Up-date or/ and creation of Mission Profile3. Identification of the stress factor and failure mode4. Reproduction in Lab conditions of the failure mode

2

Fabrice Blasenhauer


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A new approach for field data measure

Usual procedures to collect field data relies on:

Taxi fleet analysis Prototype vehicles Selected users into selected areas with data loggers

Drawbacks : data volume, assumptions on locations an typical use.ex : 5 vehicles should cover Brasilian Use

Need = increase sampling size and error trackingA new approach using existing electronic components


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New approach for field data gathering

Measuring the current situation in order to Improve the next product generations.

PSA Peugeot Citroen and Valeo set-up Embedded Data Logger(EDL) from PCB lay-out.

First, the EDL was EEPROM component designed to load software parameters in microcontroller at ASSY line.

It is turned into a measurement device to count and save use of the Functions.

EDL count and log errors without adding complexity


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EDL Schematic Embedded Software +

EEPROM

COM card + DIAG PCCAN BUS

ASCII File

POST TREATMENT

History of parts out of a simple process

HW used for download operations


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EDL Life cycles

ASSY of PCB + TCM / EOLT

Load of Software parameters + Setup

Collect and stockpiling

(1 by 1)

Post Treatment

Acquisition phaseDownloading and Analysis

More than 430 parts treated within this projectCross check between field and test allowedField parts tested with “known history”No extra workload for production sites (usual business)Common process of extraction and analysis for Field and Lab Parts

Part Exchange with “history”

Exchanging parts from lab to field is easy and accurate


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Typical analysis on Mission ProfilesDriving patterns update (Eta, Beta) Accurate geographical analysis

MECOSUR market and China vs. Europe…Cross analysis of parameters

Example (diesel vs. gasoline) upon driving patterns …

…

Drawback : Need at least a run within 2 years on the field to reach the highest mileage (typical “taxi” use => 150 000 to 170 000 km in 24 months)

EDL records : S/NActuations by

functionsDate of InitializationLog of errors Calibrations …


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Advantages of EDL

Higher Sampling from multiple Situations

Parts from end-user volunteers (Valeo, PSA) Parts from field (+ warranty returns) No assumption “bias” Cross analysis on parameters (actuations vs. operating hours…)

From Assumptions to Real Data, Mission profile is updated

EDL is only part of a complete and systematic analysis


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Analysis ProtocolField parts and Warranty Return analysis within the same protocol : The analysis protocol aiming is operational (always same analysis, same result

format, same testing procedures) The test protocol is designed to provide ranking in analysis using a synoptic Cost of external analysis are defined

Synoptic Contact Resistance Measurements and FTIR

+ EDL…

Analysis Protocol to master operations is mandatory


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MISSION PROFILES




Valeo / PSA FieldFTA update

PV / DV data gatheringSupplier InvolvementWarranty Return analysisAnalysis Protocol


1


3

Test (Field/Labs)

ACCELERATING FACTOR

4

2

3rd Step : The product life cycle is described and stress identified step by step


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Life cyclesThe product life cycle answers to the time spent for each physical configuration and each condition for each steps of the process.

Stress in situation

Life cycles with the stressful components are identified


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Environmental Damaging Factors

Environmental Damaging Factors are identified using : Warranty returns data (“gate chart” files => statistics) Suppliers feedback about component failure modes Field parts analysis Literature & Experts contribution.

Examples of stress factors selected in usual TCM customer specifications : Vibrations, Thermal cycling, …

Mandatory step to understand the stress applied to products


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FTA as main tool

Fault tree analysis is used as synthesis Drawbacks : Branch often relies on assumptions on failure mechanism The “symptoms” are observed but went hitting depth in the Tree,

root causes need a specific test to validate the hypothesis

FTA is the backbone. Accelerated Test to take over Assumptions


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Preferred Scenarios out of FTABased on the feedback from High Accelerated tests, branches are cut and assumptions re-assessed in order to reach preferred scenarios.

Example of test to validate hypothesis : - High temperature storage :

30% more than usual Validation temperatures - High vibration level :

600 % more than usual Validation accelerations - High pollution level :

New pollution components (particles), up to 20% more than of the usual volume

Salt Spay Machine used in accelerated testing

INCREASE stress LEVEL in order to REDUCE test DURATIONS.


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Accelerated testing LevelsWhich Stress level should be consider in order to validate the assumptions ?

The starting point is into the physics of the Failure and :Suppliers input (data sheet of the component)Bibliography inputs (similar tests in Standards, Car Manufacturers specifications, ASTE documentations, PhDs…)

Example of Grease behavior under various stresses (oil bleeding)

Aggressive on Test Time but Conservative on Physics & Mechanisms of failure modes


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ACCELERATING FACTORS




Valeo / PSA Field

PV / DV data gatheringSupplier InvolvementWarranty Return analysisFTA definitionAnalysis Protocol


1


3

Test (Field/Labs)

ACCELERATING FACTOR

4

2

From a mission and conditions a short list of damaging factors is establishedIn order to build accelerated test, models are needed.


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Gate Chart file

Car Manuf. Specifications Comparisons

Validation tests

Stress Factors

Life cycles

EnvironmentalStudy

From Failure mode to Accelerated models

Warranty returnAnalysis

Laboratory tests (accelerated tests)

Experts + Bibliography contributions

Main failure mechanisms

Mission Profile Analysis and update Short list of

Stress Factors

Failure Tree Analysis

A short list of Stress factors is defined They are combined to create a failure mechanism


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16From Failure Mechanism to Accelerated models

Short list of Stress Factors Accelerated

Tests

Field parts analysis

Parametric testing

* : examples

Ranking of Stress Factors

Stress Factor 1 Stress factor 2 Stress Factor 3

(SF 1 + SF 2) + SF3

FAILURE MECHANISMexpressed by STRESS FACTOR Sequencing

The process stops when stress factors are sequenced and failure obtainedCould last a little…

Since the failure mechanism is not reproduced, loops on testing are usual business.


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Car Manuf. 1 : 27,3°C 76% RhInternet : Avg : 12,1°C 61,3% RhInternet : Maximum : 30,3°C 71,9% RhKöppen : Subtropical (Cfa) : 29°C 86% RhValeo : Tropical Rain Forest : 35°C 90% RhCar Manuf. 2 : 23°C 65% Rh

Stress Factor Sequencing leads to Accelerated Test SequenceExample 1 : Humidity Stress

Example of Climatic Data Sources PSA Data Data internet

(http://globalweather.tamu.edu/) Valeo Data (Classification de Köppen) Data Specification Car Manuf. 2 ……ASTE

1. PSA Model

2. Valeo : Peck or Lawson model

3. Car Manuf.2 : Lawson model

Parameters (Ea, ..) from bibliographyand TESTING


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16Stress Factor Sequencing leads to Accelerated Test Sequence

Runs on models provide equivalencies of field exposures upon corrosion :

Variations on field exposures are validated by Accelerated Tests

Some equivalencies are very far from others : from months to 113 years!

Models are tested using witness parts during longer periods.

Then witness parts are compared with field parts.

Ex : corrosion on unprotected brackets


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16Stress Factor Sequencing leads to Accelerated Test SequenceExample 2 : Component change due to High Temperature

Exposure Calculation of applied Ea From Arrhenius Model and testing upon

International Standard test procedures

Components are tested at 3 operating temperatures 23°C : Base line60°C : Common Hot 85°C : Rare situation

Climatic Chamber associated with actuations on TCM product

Example of thermal conditioning on components


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16Stress Factor Sequencing leads to Accelerated Test Sequence

Input for Ea calculations : Component characteristic changes accordingly to time and temperatures …. The “speed of the reaction” is link to temperature and time.

Example 2 : Component change due to High Temperature Exposure Components are tested at 3 operating temperatures : 23°C, 60°C and 85°C

Calculation of applied Ea From Arrhenius Model and testing upon International

Standard test procedures

Ea calculated and adjusted to the REAL component behavior


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Test Sequencing

Multi-stress sequencing are usual in TCM car manufacturer specifications.A typical test sequence is combining stresses because 1. It is seen as relevant of the life cycle :

1. Products are vibrated AND exposed to thermal cycling AND …. 2. Life cycle is complex => Multi-stress

2. It allows to actuate complex failure mechanisms (SF1 + SF2) combined with SF3

3. Number of Devices Under Test is reduced

Hurdles :If Failures detected in test durability 2 : what is the real field equivalency ? For a complete Test shall we repeat a single Durability Test or the whole test sequence ?

Initial Quality Test

Durability Stress

Factor 1+2 Quality Test 2

Durability Stress

Factor 3Quality Test 3

Durability Stress

Factor 4

Final Quality

Test


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Test Sequencing


Durability Stress


Durability Stress

Factor 3Quality Test 3

Durability Stress

Factor 4

Final Quality

Test

Stresses considered as pre-Ageing

Cycling until failure for Weibull calculation

Complete Test cycling : Out of FTA, Mission and life cycles, a pre-Ageing is consideredStress Factor 1 is seen in transportationStress Factor 2 is seen in transportation and Stockpiling..Stress Factor 3 is seen in Stockpiling and early life phase

ANALOGIC Scrutinizing

LOGIC Monitoring

Example of test monitoring during durability test

Fabrice Blasenhauer, Valeo / Jorge-Filipe Carvalho, PSA Slide Number: 32 Session 7 Green Room App

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Durability Stress


Durability Stress

Factor 3 Quality Test 3

Durability Stress

Factor 4

Final Quality

Test

Test sequences are tested on various technologies Ex : sliding contact coatings, extra surface treatments, different coding strategies

Coating Version 1

Coating Version 2

Test Sequencing Validation

Project 2 Project 3 Project 1

Test Failures, Warranty returns and High Mileage parts comparison

The Validation is obtained out of part examinations after testing


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Summary

This specification Tailoring is a success because:

OEM and Car Manufacturer Partnership External Experts involvement and Suppliers Regular Failure modes challenged. “Let’s find out !” Stress factors ranking (combined stress identified) New Failure Mechanism Comprehensive Test Sequences Understanding of lacks (example of Contamination tests) Instant application on next generation Products Public funding (Gov. Help to industries) provides opportunities in test tailoring

Thank you for your attention.Do you have any questions?


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Jorge-Filipe CARVALHOMechatronic Expert of CommutationDRD/DSEE/MCSI/EMCDElectronics Modules of Controls and [email protected] Tel : +33.9.66.66.35.90

+33.1.57.59.71.83

Centre Technique de Vélizy (case courrier VV064)Route de Gisy78943 VELIZY-VILLACOUBLAY Cedex


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Fabrice BLASENHAUERCIC Validation Métier – Reliability Manager Valeo SC2N

45 Rue Charles de Coulomb14125 Mondeville - FRANCE

[email protected] : +33 6 03 78 59 94

Master Degree in Acoustics - UTC (Compiegne)15 years of experience in Environmental TestingAcoustic ExpertReliability and NVH Network Manager

Documents

2016 ARS Europe · PDF file2016 ARS Europe Green Room, Session 7 ... Valeo / PSA Field FTA update PV / DV data gathering Supplier Involvement Warranty Return analysis Analysis Protocol