C05-28: Integrated Health and Usage Monitoring System
Objective:
- To study the Health and Usage Monitoring System (HUMS) test board (which was evaluated using simulations and testing in C04-19) for a real temperature profiles collected by monitoring in actual use environment or programmable chamber that can successively produce different temperature cycles.
- To validate the HUMS for predicting remaining life using monitored temperature profiles (use environment) and actual thermal cycling (in chamber).
- To explore means for vibration and shock assessment using HUMS
- To extend the HUMS 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 using HUMS
Background:
The following requirement appeared in a recent United States Department of Defense (DoD) statement of work:
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 C04-19 project, a methodology for assessing solder joint remaining life, based on monitoring and modeling of environmental and usage data was developed. Test board (to be used for C05-28 project) was characterized to assess solder joint failures under thermal cycling conditions by modeling and testing. Algorithms used for data reduction were assessed to evaluate the impact of variations in measurement interval and reversal elimination on accumulated damage.Approach:
First year (2005) - The test board (already simulated and tested) will be monitored using HUMS in a real or simulated environment (with a programmable chamber, which could successively present different temperature profiles).
- Use the monitored test board and estimate the accumulated damage and remaining life using HUMS software. Convert the remaining life into equivalent number of cycles of a particular temperature profile (using simulation results). Conduct tests using this profile to validate HUMS.
- Explore methods for vibration and shock assessment
Second Year (2006) - Embed the developed software and HUMS into hardware or equipment to test under real field conditions
- Develop software for vibration and shock assessment
- Explore methods for humidity assessment
- Explore methods for contamination assessment
Reports:
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Final Project Report