Mechanistic-based Design-Integrated Reliability Validation Framework for Mechanical Systems

Abstract: New product design challenges, related to customer needs, product usage and environments, face companies when they expand their product offerings to new markets; Some of the main challenges are: the lack of quantifiable information, product experience and field data. Designing reliable products under such challenges requires flexible reliability assessment processes that can capture the variables and parameters affecting the product overall reliability and allow different design scenarios to be assessed. These challenges also suggest a mechanistic (Physics of Failure-PoF) reliability approach would be a suitable framework to be used for reliability assessment. Mechanistic Reliability recognizes the primary factors affecting design reliability. This research views the designed entity as a “system of components required to deliver specific operations”; it addresses the above mentioned challenges by; Firstly: developing a design synthesis that allows a descriptive operations/ system components relationships to be realized; Secondly: developing component’s mathematical damage models that evaluate components Time to Failure (TTF) distributions given: 1) the descriptive design model, 2) customer usage knowledge and 3) design material properties; Lastly: developing a procedure that integrates components’ damage models to assess the mechanical system’s reliability over time. Analytical and numerical simulation models were developed to capture the relationships between operations and components, the mathematical damage models and the assessment of system’s reliability. The process was able to affect the design form during the conceptual design phase by providing stress goals to meet component’s reliability target. The process was able to numerically assess the reliability of a system based on component’s mechanistic TTF distributions, besides affecting the design of the component during the design embodiment phase. The process was used to assess the reliability of an internal combustion engine manifold during design phase; results were compared to reliability field data and found to produce conservative reliability results. The research focused on mechanical systems, affected by independent mechanical failure mechanisms that are influenced by the design process. Assembly and manufacturing stresses and defects’ influences are not a focus of this research.

Mission and Scenario Planning for Unmanned Aerial Vehicles (Path Planning and Collision Avoidance Systems)

As unmanned autonomous vehicles (UAVs) are being widely utilized in military and civil applications, concerns are growing about mission safety and how to integrate dierent phases of mission design. One important barrier to a coste ective and timely safety certication process for UAVs is the lack of a systematic approach for bridging the gap between understanding high-level commander/pilot intent and implementation of intent through low-level UAV behaviors. In this thesis we demonstrate an entire systems design process for a representative UAV mission, beginning from an operational concept and requirements and ending with a simulation framework for segments of the mission design, such as path planning and decision making in collision avoidance. In this thesis, we divided this complex system into sub-systems; path planning, collision detection and collision avoidance. We then developed software modules for each sub-system