Abstract
To improve the reliability of mechanical parts that have failed in the field, a reliability methodology for parametric accelerated life testing (ALT) is proposed. It consists of: (1) a parametric ALT plan, (2) a load analysis, (3) a tailored series of parametric ALTs with action plans, and (4) an evaluation of the final designs to ensure the design requirements are satisfied. This parametric ALT should help an engineer reproduce the fractured or failed parts in a product subjectedto repetitive loading and correct the faulty designs. As a test case, the helix upper dispenser of a refrigerator ice-maker fractured in field was studied. Using a load analysis, we discerned that the helix upper dispenser fracture was due to repetitive loads and a faulty design with a 2 mm gap between the blade dispenser and the helix upper dispenser. During the first and second ALTs, the fracture in the helix upper dispenser was reproduced. The failure modes and mechanisms found were similar to those of the failed sample in field. As an action plan, the design of the helix upper dispenser was modified by eliminating the 2 mm gap and adding enforced ribs. In the third ALT there were no problems. After three rounds of parametric ALTs, the reliability of the helix upper dispenser was guaranteed as a 10-year life with an accumulated failure rate of 1%.
Highlights
A refrigerator is designed to store fresh food
After three rounds of parametric accelerated life testing (ALT), the reliability of the helix upper dispenser was guaranteed as a 10-year life with an accumulated failure rate of 1%
The purpose of this paper is to present a reliability methodology of mechanical parts like the fractured helix upper dispenser which is subjected to repetitive loading in field
Summary
A refrigerator is designed to store fresh food. Its evaporator supplies chilled air to both the freezer and refrigerator compartments. Because customers have requested the inclusion of an ice-maker in a refrigerator, manufacturers have developed refrigerators with this feature. For this (intended) function, a mechanical module like the ice-maker is designed to harvest ice. As seen, the mechanical parts in an ice-maker should operate under the conditions subjected to it by consumers. The ice-maker might experience failures which were not anticipated in the design process. In such cases, the company may have to decide to perform a massive recall of the product. Reliability testing should reproduce any defective configurations or uses of the product which failed in field and correct them immediately
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