Tool centered Safety Design Supportconference.vde.com/fs/2017/Vortragsfolien/Documents...Tool...

30
Tool centered Safety Design Support Stephan Aschenbrenner exida.com GmbH Tel: +49-8362-507274 email: [email protected]

Transcript of Tool centered Safety Design Supportconference.vde.com/fs/2017/Vortragsfolien/Documents...Tool...

Page 1: Tool centered Safety Design Supportconference.vde.com/fs/2017/Vortragsfolien/Documents...Tool centered Safety Design Support Stephan Aschenbrenner exida.com GmbH Tel: +49-8362-507274

Tool centered Safety Design Support

Stephan Aschenbrenner

exida.com GmbH

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

Page 2: Tool centered Safety Design Supportconference.vde.com/fs/2017/Vortragsfolien/Documents...Tool centered Safety Design Support Stephan Aschenbrenner exida.com GmbH Tel: +49-8362-507274

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

Page 3: Tool centered Safety Design Supportconference.vde.com/fs/2017/Vortragsfolien/Documents...Tool centered Safety Design Support Stephan Aschenbrenner exida.com GmbH Tel: +49-8362-507274

3/10/2017 3

Quellen von Ausfallraten

FUNKTIONALE SICHERHEIT UND IT-SICHERHEIT 2017

Kaisersaal Erfurt

22.- 23. März 2017

Copyright © exida.com 2000-2016

Page 4: Tool centered Safety Design Supportconference.vde.com/fs/2017/Vortragsfolien/Documents...Tool centered Safety Design Support Stephan Aschenbrenner exida.com GmbH Tel: +49-8362-507274

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

Page 5: Tool centered Safety Design Supportconference.vde.com/fs/2017/Vortragsfolien/Documents...Tool centered Safety Design Support Stephan Aschenbrenner exida.com GmbH Tel: +49-8362-507274

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

Page 6: Tool centered Safety Design Supportconference.vde.com/fs/2017/Vortragsfolien/Documents...Tool centered Safety Design Support Stephan Aschenbrenner exida.com GmbH Tel: +49-8362-507274

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

Page 7: Tool centered Safety Design Supportconference.vde.com/fs/2017/Vortragsfolien/Documents...Tool centered Safety Design Support Stephan Aschenbrenner exida.com GmbH Tel: +49-8362-507274

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.

Page 8: Tool centered Safety Design Supportconference.vde.com/fs/2017/Vortragsfolien/Documents...Tool centered Safety Design Support Stephan Aschenbrenner exida.com GmbH Tel: +49-8362-507274

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.

Page 9: Tool centered Safety Design Supportconference.vde.com/fs/2017/Vortragsfolien/Documents...Tool centered Safety Design Support Stephan Aschenbrenner exida.com GmbH Tel: +49-8362-507274

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.

Page 10: Tool centered Safety Design Supportconference.vde.com/fs/2017/Vortragsfolien/Documents...Tool centered Safety Design Support Stephan Aschenbrenner exida.com GmbH Tel: +49-8362-507274

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

Page 11: Tool centered Safety Design Supportconference.vde.com/fs/2017/Vortragsfolien/Documents...Tool centered Safety Design Support Stephan Aschenbrenner exida.com GmbH Tel: +49-8362-507274

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

Page 12: Tool centered Safety Design Supportconference.vde.com/fs/2017/Vortragsfolien/Documents...Tool centered Safety Design Support Stephan Aschenbrenner exida.com GmbH Tel: +49-8362-507274

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

Page 13: Tool centered Safety Design Supportconference.vde.com/fs/2017/Vortragsfolien/Documents...Tool centered Safety Design Support Stephan Aschenbrenner exida.com GmbH Tel: +49-8362-507274

Sources of failure modes / distributions

IEC 62061 (1st edition)

3/10/2017 13Copyright © exida.com 2000-2017

Page 14: Tool centered Safety Design Supportconference.vde.com/fs/2017/Vortragsfolien/Documents...Tool centered Safety Design Support Stephan Aschenbrenner exida.com GmbH Tel: +49-8362-507274

Sources of failure modes / distributions

RAC FMD-91

3/10/2017 14Copyright © exida.com 2000-2017

Page 15: Tool centered Safety Design Supportconference.vde.com/fs/2017/Vortragsfolien/Documents...Tool centered Safety Design Support Stephan Aschenbrenner exida.com GmbH Tel: +49-8362-507274

Sources of failure modes / distributions

ISO 13849-2

3/10/2017 15Copyright © exida.com 2000-2017

Page 16: Tool centered Safety Design Supportconference.vde.com/fs/2017/Vortragsfolien/Documents...Tool centered Safety Design Support Stephan Aschenbrenner exida.com GmbH Tel: +49-8362-507274

Calculation examples

SN 29500-4

3/10/2017 16Copyright © exida.com 2000-2017

Page 17: Tool centered Safety Design Supportconference.vde.com/fs/2017/Vortragsfolien/Documents...Tool centered Safety Design Support Stephan Aschenbrenner exida.com GmbH Tel: +49-8362-507274

Calculation examples

SN 29500-4

3/10/2017 17Copyright © exida.com 2000-2017

Page 18: Tool centered Safety Design Supportconference.vde.com/fs/2017/Vortragsfolien/Documents...Tool centered Safety Design Support Stephan Aschenbrenner exida.com GmbH Tel: +49-8362-507274

Calculation examples

IEC 62380

3/10/2017 18Copyright © exida.com 2000-2017

Page 19: Tool centered Safety Design Supportconference.vde.com/fs/2017/Vortragsfolien/Documents...Tool centered Safety Design Support Stephan Aschenbrenner exida.com GmbH Tel: +49-8362-507274

Calculation examples

IEC 62380

3/10/2017 19Copyright © exida.com 2000-2017

Page 20: Tool centered Safety Design Supportconference.vde.com/fs/2017/Vortragsfolien/Documents...Tool centered Safety Design Support Stephan Aschenbrenner exida.com GmbH Tel: +49-8362-507274

Calculation examples

IEC 62380

3/10/2017 20Copyright © exida.com 2000-2017

Page 21: Tool centered Safety Design Supportconference.vde.com/fs/2017/Vortragsfolien/Documents...Tool centered Safety Design Support Stephan Aschenbrenner exida.com GmbH Tel: +49-8362-507274

Calculation examples

FIDES Guide 2009

3/10/2017 21Copyright © exida.com 2000-2017

Page 22: Tool centered Safety Design Supportconference.vde.com/fs/2017/Vortragsfolien/Documents...Tool centered Safety Design Support Stephan Aschenbrenner exida.com GmbH Tel: +49-8362-507274

Calculation examples

FIDES Guide 2009

3/10/2017 22Copyright © exida.com 2000-2017

Page 23: Tool centered Safety Design Supportconference.vde.com/fs/2017/Vortragsfolien/Documents...Tool centered Safety Design Support Stephan Aschenbrenner exida.com GmbH Tel: +49-8362-507274

Calculation examples

FIDES Guide 2009

3/10/2017 23Copyright © exida.com 2000-2017

Page 24: Tool centered Safety Design Supportconference.vde.com/fs/2017/Vortragsfolien/Documents...Tool centered Safety Design Support Stephan Aschenbrenner exida.com GmbH Tel: +49-8362-507274

Calculation examples

FIDES Guide 2009

3/10/2017 24Copyright © exida.com 2000-2017

Page 25: Tool centered Safety Design Supportconference.vde.com/fs/2017/Vortragsfolien/Documents...Tool centered Safety Design Support Stephan Aschenbrenner exida.com GmbH Tel: +49-8362-507274

Calculation examples

FIDES Guide 2009

3/10/2017 25Copyright © exida.com 2000-2017

Page 26: Tool centered Safety Design Supportconference.vde.com/fs/2017/Vortragsfolien/Documents...Tool centered Safety Design Support Stephan Aschenbrenner exida.com GmbH Tel: +49-8362-507274

Calculation examples

FIDES Guide 2009

3/10/2017 26Copyright © exida.com 2000-2017

Page 27: Tool centered Safety Design Supportconference.vde.com/fs/2017/Vortragsfolien/Documents...Tool centered Safety Design Support Stephan Aschenbrenner exida.com GmbH Tel: +49-8362-507274

Calculation examples

FIDES Guide 2009

3/10/2017 27Copyright © exida.com 2000-2017

Page 28: Tool centered Safety Design Supportconference.vde.com/fs/2017/Vortragsfolien/Documents...Tool centered Safety Design Support Stephan Aschenbrenner exida.com GmbH Tel: +49-8362-507274

Calculation examples

FIDES Guide 2009

3/10/2017 28Copyright © exida.com 2000-2017

Page 29: Tool centered Safety Design Supportconference.vde.com/fs/2017/Vortragsfolien/Documents...Tool centered Safety Design Support Stephan Aschenbrenner exida.com GmbH Tel: +49-8362-507274

Questions and Answers

3/10/2017 29Copyright © exida.com 2000-2017

Page 30: Tool centered Safety Design Supportconference.vde.com/fs/2017/Vortragsfolien/Documents...Tool centered Safety Design Support Stephan Aschenbrenner exida.com GmbH Tel: +49-8362-507274

Many Thanks for your [email protected]

+49/8362-5072743/10/2017 30