Tool centered Safety Design ... Tool centered Safety Design Support Stephan Aschenbrenner exida.com...

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  • Tool centered Safety Design Support

    Stephan Aschenbrenner

    exida.com GmbH

    Tel: +49-8362-507274 email: [email protected]

  • 3/10/2017 2

    About myself Stephan 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 PFH SFF MTTFd

    DC

    Random hardware failure rate

    calculate

    3/10/2017 4Copyright © exida.com 2000-2017

  • 3/10/2017 5

    What determines Achieved SIL?

    Minimum

    SIL AC

    SIL PFD

    Conceptual DesignEquipment Design

    Failure Modes

    Failure rate

    Proof Test Frequency

    SFF HFT

    Achieved SIL

    Diagnostics

    SIL CAP

    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 industries Often 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 Attention [email protected]

    +49/8362-507274 3/10/2017 30