C04-19: Integrated Health and Usage Monitoring System
Objective:
- To integrate a cycle counting algorithm and the capability to evaluate the remaining life of a monitored electronic board in an embedded software
- To study the software of the health and usage monitoring system (HUMS) and the board for different temperature cycles and acceleration factors
- To study the algorithms (needs, results, improvements - what can be neglected?
- To study the impact on the electronic board for a real temperature profile (collected by monitoring)
- To document the level of integration and robustness that is required for a HUMS
- To extend the embedded software for vibration and shock assessment
- To embed the developed software into hardware or equipment to test under real field conditions
- To explore methods for humidity and contamination assessment of HUMS
Background:
Health monitoring is a method of evaluating the extent of a product's reliability in terms of product degradation in its life cycle environment. Health monitoring methods use some combination of physical degradation (e.g., cracks, corrosion, delamination), electrical degradation (e.g., increase in resistance, increase in threshold voltage), and performance degradation (e.g., shift of the product's operating parameters from expected values) to assess health. Methods employed for health monitoring are non-destructive test (e.g., ultrasonic inspection, liquid penetrant inspection, and visual inspection) and operating parameter monitoring (e.g., vibration monitoring, oil consumption monitoring and thermography (infrared) monitoring).
In the past, project C99-43 had analyzed the underlying philosophies of available health and usage monitoring technologies for use in monitoring the life consumption of electronic systems. In C00-50 a methodology to use CALCE physics-of-failure (PoF) method for life consumption monitoring (LCM) was developed. In the next two years CALCE demonstrated the methodology based on data collected from sensors in an automobile underhood environment. Project C01-19 demonstrated that life consumption monitoring is possible in an automobile application. Further, in C02-10 two comparisons were conducted to assess the remaining life prediction through LCM with actual life obtained from in-situ resistance monitoring.
In C03-26 project, CALCE has developed and integrated software modules (data collection, simplification and damage accumulation and remaining life estimation) for life consumption monitoring using temperature and vibration data with validation of results from C02-10 project. Also, a modular strategy to support a general approach towards environment and usage data collection and system level issues with health and life consumption monitoring were developed.
In the proposed C04-19 project, the cycle counting and remaining life estimation software is embedded in HUMS. The HUMS along with the embedded software is validated using simulations and actual thermal cycling.Approach:
First year - Develop software modules for cycle counting and remaining life estimation for solder joint failure due to thermal cycling
- Integrate the cycle counting and the remaining life estimation software modules of a monitored electronic board in a single software
- Determine the integrity of HUMS for the experimental and simulated studies for constant thermal cycling case on a board. The board will be complex enough to bear interesting components, yet simple enough to be cheap and easily measured
Second year - A report on the algorithm study
- A report on the impact on the electronic board under real temperature profile (collected by monitoring)
- A report on the vibration and shock assessment findings
Third Year - A report on the performance of the hardware or equipment containing the embedded software
- A report on software development for vibration and shock
- A report on the humidity and contamination assessment findings
Reports:
Final Project Report