Research field Reliability Engineering

The department of Reliability Engineering at the Institute of Machine Components is actually represented by approximately 20 academic staff members.

The research field deals holistically with the reliability of components and systems, as well as with methods for reliability analysis and assurance. In this context, the development of a reliability database is also included. Methods for test planning and the statistical evaluation of failure data and lifetime tests are investigated. Further topics are the realistic modeling of complex technical systems and the simulation of reliability and availability in early development phases. Calculations of system lifetime and the determination of load spectra are carried out. One area of work is the execution of FMEAs and the creation of development-accompanying documentation.

The focal points of the research field Reliability Engineering are the following: 

  • Reliability of components and systems
  • Methods for reliability analysis and reliability assurance
  • Reliability test planning and testing systematics
  • Statistical evaluation of failure data and life tests
  • Reliability and availability simulation
  • Calculation of the system lifetime
  • Functional safety
  • FMEA
  • PHM

Prognostics and Health Management (PHM)

Evaluation and regulation of the usable remaining service life of systems (in operation).

Main focus of the projects:

  • Function-based predictive diagnostics of batteries for autonomous vehicles
  • Virtual sensor development
  • Cost-benefit analysis and design of PHM systems
  • Analysis and development of smart maintenance concepts

Functional safety

Methods and analyses for the development and assurance of safe systems (system states)

Focal points of the projects:

  • Risk assessment of safety-critical systems
  • Methods and technologies for fail-safe elements and for adaptive structures
  • Proof of operational reliability for machine tool controls

Testing and reliability assurance

Statistical test planning for modeling reliability on component and system level considering test effort and a confidence intervall.

Project focuses:

  • Efficient life cycle test planning
  • Statistical test planning (DoE)
  • Statistical test planning for lifetime data (Lifetime-DoE)
  • Inclusion of prior knowledge in test planning
  • Reliability predictions based on field data
  • Reliability prediction based on findings from exchange-reconditioned PKW (passenger cars)
  • Optimized accelerated test planning
  • Development of degradation models using the example of gear pits
  • Determination of customer-relevant load spectra
  • Design of experiments and reliability analyses of electronic components and systems

Repairable systems simulation

Close to reality analysis of reliability and availability to optimize maintenance planning, taking into account components, costs and confidence levels.

Main focus of the project:

  • Modeling and analysis of reliability and availability with a confidence interval
  • Investigation of the properties of production systems in Industry 4.0
  • Prediction of availability taking into account random machine failures and stochastic processes

Partners

  • Daimler AG
  • Festo AG & Co. KG
  • INDEX-Werke GmbH und Co. KG
  • Knorr-Bremse Systeme f. Nutzfahrzeuge GmbH
  • MTU-Friedrichshafen GmbH
  • Robert Bosch GmbH
  • Trumpf GmbH und Co. KG
  • Verband Deutscher Werkzeugmaschinenfabriken
  • Walther Flender GmbH
  • ZF Friedrichshafen AG

Contact Head of Reliability Engineering

This image shows Martin Dazer

Martin Dazer

Dr.-Ing.

Head of Reliability and Drive Technology Department, temporary Head of Railway Vehicle Department

 

Institute of Machine Components (IMA)

Pfaffenwaldring 9, 70569 Stuttgart

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