tool centered safety design supportconference.vde.com/fs/2017/vortragsfolien/documents...tool...
TRANSCRIPT
Tool centered Safety Design Support
Stephan Aschenbrenner
exida.com GmbH
Tel: +49-8362-507274email: [email protected]
3/10/2017 2
About myselfStephan H. Aschenbrenner, CFSE� Dipl. Ing. (Univ) for Electrical Engineering and Automation of the
Technical University of Munich (TUM)� Start as a software and hardware developer of programmable
electronic systems� At TÜV Product Service GmbH responsible for machinery safety
components later at TÜV Product Service Inc. in the USA responsible for setting up a functional safety department for the Americas
� Business Unit Manager at TÜV Product Service� Since 2001 at exida.com GmbH involved in both product analysis
and design process improvements in the process industry, the machinery industry, as well as in the automotive and semiconductor industry
� Responsible for exida‘s FMEDA tool SILcal
� Since 2007 Certified Functional Safety Expert (CFSE)� Since 2013 Operational Manager at exida.com GmbH
� Over twenty years of experience and extensive knowledge in the safety and reliability field
Copyright © exida.com 2000-2017
3/10/2017 3
Quellen von Ausfallraten
FUNKTIONALE SICHERHEIT UND IT-SICHERHEIT 2017
Kaisersaal Erfurt
22.- 23. März 2017
Copyright © exida.com 2000-2016
Warum benötigen wir Ausfallraten?
IEC 61508 (SIL)
FMEDA
classified failure rates
Failure rate λ, failure modes, failure mode distribution
ISO 13849-1 (PL)
calculate
PFD PFHSFF
MTTFd
DC
Random hardwarefailure rate
calculate
3/10/2017 4Copyright © exida.com 2000-2017
3/10/2017 5
What determines Achieved SIL?
Minimum
SILAC
SILPFD
Conceptual DesignEquipment Design
Failure Modes
Failure rate
Proof Test Frequency
SFF HFT
Achieved SIL
Diagnostics
SILCAP
IEC 61508 capability
Copyright © exida.com 2000-2017
Getting Failure Data
• Industry Databases• Manufacturer Field Return Data Studies• B10 Data• End User Field Failure Data Studies
3/10/2017 6Copyright © exida.com 2000-2017
Industry Databases
3/10/2017 7Copyright © exida.com 2000-2017
Good base for comparison reasons.Often not applicable for all industriesOften not updated anymore.Lots of parameters which are often unknown or not available.Use of parameters is not harmonized.
Manufacturer Field Return Data Studies
3/10/2017 8Copyright © exida.com 2000-2017
Manufacturer Field Return Data Studies– PLUS:
• Real Data
– MINUS:• Cannot know what percentage of actual failures are returned• Different definitions of “FAILURE” (Not a problem scenario)
Many manufacturers classify returned items as a “failure” only if a manufacturing defect is found. Many returned items are marked “no problem found.” In some calculations operational hours are estimated based on shipping records and it is assumed that all failures are returned.The data can be valuable to identify root causes and compare to establish upper/lower bounds on failure rates.
B10 Data
3/10/2017 9Copyright © exida.com 2000-2017
B10 data is derived from a cycle test of a mechanical / electro-mechanical product.Failure rate is calculated based on 10% failures in time period.B10d (dangerous failure rate) is half that number based on the assumption that 50% of the failures are dangerous.B10 data is used for high demand mode applications.Not suitable for all uses of failure rate information.The B10 method assumes that the constant failure rate during the useful life is due to premature wear-out where other failure modes are insignificant.Research shows other failure modes become significant when these products do not move frequently – some failure modes become significant if a product is static for 24 hours.
End User Field Failure Data Studies
3/10/2017 10Copyright © exida.com 2000-2017
PLUS:– Field failure studies with sufficient information represent a rich
opportunity to obtain failure rate and failure mode information about a product in a specific application.
MINUS:
– Variations in the amount of collected data– Different definitions of “FAILURE”– Categorizing and Merging Technologies
After performing dozens of studies exida experience recognized that the data collection process varies by an order of magnitude or more! – When is a failure report written?– What is the definition of failure?– Are "as found" conditions recorded during a proof test?– What were the operating conditions?– Use of new data collection software can improve failure data availability
Source of industry databases – failure rates
SN 29500
IEC 62380 Ed.1 /TR (formerly known as UTE C 80-810)
FIDES Guide 2009
RAC FMD
exida Electrical & Mechanical Component Reliability Handbook
MIL HDBK 217F
3/10/2017 11Copyright © exida.com 2000-2017
Sources of industry databases –failure modes / distributions
RAC FMD
IEC 62061 (1st edition)
EN ISO 13849-2 (failure modes only)
IEC 61496-1 (failure modes only)
EN 298 (failure modes only)
IEC 62380 Ed.1 /TR (formerly known as UTE C 80-810)
exida Electrical & Mechanical Component Reliability Handbook
3/10/2017 12Copyright © exida.com 2000-2017
Sources of failure modes / distributions
IEC 62061 (1st edition)
3/10/2017 13Copyright © exida.com 2000-2017
Sources of failure modes / distributions
RAC FMD-91
3/10/2017 14Copyright © exida.com 2000-2017
Sources of failure modes / distributions
ISO 13849-2
3/10/2017 15Copyright © exida.com 2000-2017
Calculation examples
SN 29500-4
3/10/2017 16Copyright © exida.com 2000-2017
Calculation examples
SN 29500-4
3/10/2017 17Copyright © exida.com 2000-2017
Calculation examples
IEC 62380
3/10/2017 18Copyright © exida.com 2000-2017
Calculation examples
IEC 62380
3/10/2017 19Copyright © exida.com 2000-2017
Calculation examples
IEC 62380
3/10/2017 20Copyright © exida.com 2000-2017
Calculation examples
FIDES Guide 2009
3/10/2017 21Copyright © exida.com 2000-2017
Calculation examples
FIDES Guide 2009
3/10/2017 22Copyright © exida.com 2000-2017
Calculation examples
FIDES Guide 2009
3/10/2017 23Copyright © exida.com 2000-2017
Calculation examples
FIDES Guide 2009
3/10/2017 24Copyright © exida.com 2000-2017
Calculation examples
FIDES Guide 2009
3/10/2017 25Copyright © exida.com 2000-2017
Calculation examples
FIDES Guide 2009
3/10/2017 26Copyright © exida.com 2000-2017
Calculation examples
FIDES Guide 2009
3/10/2017 27Copyright © exida.com 2000-2017
Calculation examples
FIDES Guide 2009
3/10/2017 28Copyright © exida.com 2000-2017
Questions and Answers
3/10/2017 29Copyright © exida.com 2000-2017
Many Thanks for your [email protected]
+49/8362-5072743/10/2017 30