• Transactions of the Korean Society of Automotive Engineers
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• v.11 no.3
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• pp.209-213
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• 2003

It is advantage of accelerated vibration testing to compress service exposures to operating vibration into a reduced laboratory test by increasing the amplitude or frequency of the applied input excitations. This paper proposes an accelerated test method to estimate the high-cycle fatigue life under random excitation. The method consists of conducting a test with amplified input excitation and extrapolating linearly the lift in the accelerated condition into the real lift in field condition. The extrapolation is carried out applying the high-cycle irregular excitation fatigue theory including the rainflow counting, Miner’s damage accumulation rule, and Goodman’s mean stress correction. As a verification, those estimated lift is compared with that acquired by experiment f3r the simple case of spot welding specimen with good agreement. This testing procedure will provide an useful scheme that can reduce testing period associated with developing time schedule of new product.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.21 no.6
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• pp.67-73
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• 2022

Industrial inverters are used in a variety of fields for electric power supply. They may be exposed to vibration and heat once they are installed. This study focused on a framework of accelerated life testing of an industrial inverter considering fatigue damage as the primary source of deterioration. Instead of analyzing detailed failure mechanisms and the product's vulnerability to them, the potential of fatigue failure is considered using the fatigue damage spectrum calculated from the environmental vibration signals. The acceleration and temperature data were gathered using field measurement and spectral analysis was conducted to calculate the vibration signal's power spectral density (PSD). The fatigue damage spectrum is then calculated from the input PSD data and is used to design an accelerated fatigue life testing. The PSD for the shaker table test is derived that has the equivalent fatigue damage to the original input signal. The tests were performed considering the combined effect of random vibration and elevated temperature, and the product passed all the planned tests. It was successfully demonstrated that the inverter used in this study could survive environmental vibration up to its guarantee period. The fatigue damage spectrum can effectively be used to design accelerated fatigue life testing.

• Transactions of the Korean Society for Noise and Vibration Engineering
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• v.22 no.10
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• pp.968-973
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• 2012

Slam testing is a mandatory testing process to evaluate the fatigue resistance of a door plate module before delivering it to car makers. This process is very hard job to complete it since the testing facilities are considerably expensive and the required testing time is relatively very long, i.e. more than eight days for a single specimen. In this paper, an accelerated testing method of a door plate module is proposed using vibration test equipment instead of the current one by exposing to the critical excitation of a door glass. Under the proposed excitation method, the similar testing result can be evaluated within less than two hours. The suitability of the proposed testing method was demonstrated by comparing failure modes of both the current testing method and the proposed one.

• Transactions of the Korean Society for Noise and Vibration Engineering
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• v.18 no.3
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• pp.323-334
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• 2008

According to the delivery condition, the breakage of a product occurs when it is delivered to the customers. Therefore product's makers evaluate the durability under the delivery process by accelerated life testing. In order to conduct this accelerated life testing accurately, it is very important to identify the acceleration-factor exactly between on-road and accelerated life test condition. In this paper, the acceleration-factor is identified by applying linear damage summation law, rain-flow cycle counting and Dirlik theory under the conditions of the random vibration. And approximated FEM model of the connecting-pipe to the compressor is developed for fatigue analysis. This model is finally verified by comparing the experiment results to the numerical analysis results.

• Proceedings of the Korean Reliability Society Conference
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• 2004.07a
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• pp.129-137
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• 2004

This paper presents an accelerated life test for burnout of tungsten filament of incandescent lamp. From failure analyses of field samples, it is shown that their root causes are local heating or hot sports in the filament caused by tungsten evaporation and wire sag. Finite element analysis is performed to evaluate the effect of vibration and impact for burnout, but any points of stress concentration or structural weakness are not found in the sample. To estimate the burnout life of lamp, an accelerated life test is planned by using quality function deployment and fractional factorial design, where voltage, vibration, and temperature are selected as accelerating variables. We assumed that Weibull lifetime distribution and a generalized linear model of life-stress relationship hold through goodness of fit test and test for common shape parameter of the distribution. Using accelerated life testing software, we estimated the common shape parameter of Weibull distribution, life-stress relationship, and accelerating factor.

• Smart Structures and Systems
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• v.29 no.6
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• pp.799-805
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• 2022

Permanent magnet synchronous motors (PMSMs) are widely used in systems requiring high control precision, efficiency, and reliability. Predicting the remaining useful life (RUL) with health monitoring of PMSMs prevents catastrophic failure and ensures reliable operation of system. In this study, a model-based method for predicting the RUL of PMSMs using phase current and vibration signals is proposed. The proposed method includes feature selection and RUL prediction based on a particle filter with a degradation model. The Paris-Erdogan model describing micro fatigue crack propagation is used as the degradation model. An experimental set-up to conduct accelerated life test, capable of monitoring various signals was designed in this study. Phase current and vibration data obtained from an accelerated life test of the PMSMs were used to verify the proposed approach. Features extracted from the data were clustered based on monotonicity and correlation clustering, respectively. The results identify the effectiveness of using the current data in predicting the RUL of PMSMs.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.29 no.7 s.238
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• pp.921-929
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• 2005

This paper presents an accelerated life test for burnout of tungsten filament of incandescent lamp. From failure analyses of field samples, it is shown that their root causes are local heating or hot spots in the filament caused by tungsten evaporation and wire sag. Finite element analysis is performed to evaluate the effect of vibration and impact for burnout, but any points of stress concentration or structural weakness are not found in the sample. To estimate the burnout life of lamp, an accelerated life test is planned by using quality function deployment and fractional factorial design, where voltage, vibration, and temperature are selected as accelerating variables. We assumed that Weibull lifetime distribution and a generalized linear model of life-stress relationship hold through goodness of fit test and test for common shape parameter of the distribution. Using accelerated life testing software, we estimated the common shape parameter of Weibull distribution, life-stress relationship, and accelerating factor.

• Proceedings of the Korean Society for Noise and Vibration Engineering Conference
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• 2010.05a
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• pp.47-47
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• 2010

Over the past 20 years, constant progress in noise and vibration (NVH) engineering has enabled to constantly advance quality and comfort of operation and use of really any products - from automobiles to aircraft, to all kinds of industrial vehicles and machines - to the extend that for many products, supreme NVH performance has becomes part of its brand image in the market. At the same time, the product innovation agenda in the automotive, aircraft and really many other industries, has been extended very much in recent years by meeting ever more strict environmental regulations. Like in the automotive industry, the drive towards meeting emission and CO2 targets leads to very much accelerated adoption of new powertrain concepts (downsizing of ICE, hybrid-electrical...), and to new vehicle architectures and the application of new materials to reduce weight, which bring new challenges for not only maintaining but further improving NVH performance. This drives for innovation in NVH engineering, so as to succeed in meeting a product brand performance for NVH, while as the same time satisfying eco-constraints. Product innovation has also become increasingly dependent on the adoption of electronics and software, which drives for new solutions for NVH engineering that can be applied for NVH performance optimization of mechatronic products. Finally, relentless pressure to shorten time to market while maintaining overall product quality and reliability, mandates that the practice and solutions for NVH engineering can be optimally applied in all phases of product development. The presentation will first review the afore trends for product and process innovation, and discuss the challenges they represent for NVH engineering. Next, the presentation discusses new solutions for NVH engineering of products, so as to meet target brand values, while at the same time meeting ever more strict eco constraints, and this within a context of increasing adoption of electronics and controls to drive product innovation. NVH being very much defined by system level performance, these solutions implement the approach of "Model Based System Engineering" to increase the impact of system level analysis for NVH in all phases of product development: - At the Concept Phase, to be able to do business case analysis of new product concepts; to arrive at an optimized and robust product architecture (e.g. to hybrid powertrain lay-out, to optimize fuel economy); to enable target cascading, to subsystem and component level. - In Development Phase, to increase realism and productivity of simulation, so as to frontload virtual validation of components and subsystems and to further reduce reliance on physical testing. - During the final System Testing Phase, to enable subsystem testing by a combination of physical testing and simulation: using simulation models to simulate the final integration context when testing a subsystem, enabling to frontload subsystem testing before final system integration is possible. - To interconnect Mechanical, Electronical and Controls engineering, in all phases of development, by supporting model driven controls engineering (MIL, SIL, HIL). Finally, the presentation reviews examples of how LMS is implementing such new applications for NVH engineering with lead customers in Europe, Asia and US, with demonstrated benefits both in terms of shortening development cycles, and/or enabling a simulation based approach to reduce reliance on physical testing.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.19 no.10
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• pp.424-429
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• 2018

In this study, an expansion joint that is susceptible to waterhammer was tested for its vibration durability. The operation data for the hydraulic actuator was the expansion length of the expansion joint when the waterhammer occurred. In the case of the vibration durability test, the internal temperature status of the expansion joint was assumed to be a stress factor and a lifespan prediction model was assumed to follow the Arrhenius model. A test was carried out by increasing the internal temperature status at $30^{\circ}C$, $50^{\circ}C$, and $65^{\circ}C$. By a linear transformation of the lifespan data for each temperature, a constant value and activation energy coefficient was induced for the Arrhenius equation and verified by comparing the value of a lifetime prediction model with the experimental value at $85^{\circ}C$. The failure modes of the ongoing or finished test were leakage, bellows separation, and internal deformation. In the future, a composite lifespan prediction model, including two more stress factors, will be developed.