fmea of co air conditioning systems and reliability... · 2010-06-01 · fmea of co 2 air...
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FMEA of CO2 Air ConditioningSystems
On SAE 2000 Automotive Alternative Refrigerant Systems SymposiumJuly 11-13, 2000, Resort Suites Hotel, Scottsdale, AZ
by Dr.-Ing. Ulrich HusselsRISA Sicherheitsanalysen GmbH, Germanye-mail: [email protected]
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SAE 2000 Automotive Alternative Refrigerant Systems Symposium, July 11, 2000 2
The RISA Companyn Founded in 1990, situated in Berlin,
Germanyn 10 specialized engineers from research
institutes of the Technical University ofBerlin
n Working areas are safety analysis andsoftware development (databases)
n Customers from nuclear-, automotive-and LPG-industry
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SAE 2000 Automotive Alternative Refrigerant Systems Symposium, July 11, 2000 3
Where this kind of Analysis is needed (examples):n Higher amount of energy in a small
amount of space (high energy density)n Nuclear Power Plants: reactor core
cooling, pressuren Automotive: velocity, pressuren LPG: great amount of inflammable and
explosive fluid/gas mixture
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SAE 2000 Automotive Alternative Refrigerant Systems Symposium, July 11, 2000 4
Initiators and Core Teammembers
n Robert Mager, BMW AG (Chairman)n Jürgen Wertenbach, DaimlerChrysler AGn Baroto Adiprasito, Volkswagen AGn Ralf Köneke, Denso Automotive Deutschlandn Frank Obrist, Obrist Engineering
OBRIST__ENGINEERING__
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Aims of the analysis for aprototypical CO2 AC-Systemn Diagnosis of potential effects of failure eventsn Determination of countermeasuresn Proof of mastering all relevant effectsn Confirmation of the usability of CO2-
technology regarding to safety and productliability
n System-FMEA as a basis for a design-FMEA
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SAE 2000 Automotive Alternative Refrigerant Systems Symposium, July 11, 2000 6
Form of the Analysis
n System-FMEA based on SAE J-1739n Additional classification for
consequences to human healthn Instructions to reduce the risk priority
number if it is greater than 108 to get abalanced risk level over all failureevents
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Risk Priority Number
RPN = Severity x Occurrence x Detection
Severity 1 - 10 (8 = Very High, 9 Hazardouswith warning)
Occurrence 1 - 10 (4 - 6 = Moderate)
Detection 1 - 10 (3 = High)
⇒ RPN 1 - 1000 (9 x 4 x 3 = 108, accordingto an engineering judgement )
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Table-Layout
Item Function
Potential
Failure
Mode
Potential
Effect(s) of
Failure
Sev
Cla
ss
Potential Cause(s)/
Mechanism(s) of
Failure
Occ
ur Current Design
Controls Det
ec
RP
N Recommended
Action(s)
Responsibility
(for the Rec-
ommended
Action)
Actions
Taken Sev
Occ
Det
RP
N
Com-
pressor
Transports
the medium;
Compresses
the medium
Loosening
of fasten-
ings
Refrigerant
pipe de-
taches, ex-
ternal leaks
9 B Material faults,
loosening of fas-
tenings
1 Quality control 2 18 Oscillation
tests
9 1 1 9
Gas
cooler
Conducts
heat to the
external
environment
Blockage
in refriger-
ant flow
Low cooling
capacity,
increase in
pressure
6 A Bends, blockages 2 Deformation
guard, layout;
design of com-
ponent
10 120 Parallel proce-
dures, pres-
sure sensor
switched in
front of the gas
cooler, plausi-
bility control
via regulation
control
6 2 6 72
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Scope of the Analysis
n 23 components within the system withn 107 failure events
in respect ton 3 operating modes,n 3 (+2) vehicle running modes andn 3 environment conditions
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PI-Diagram
hose linepiping
gas
cool
er
accumulator
expansion valve with safety system
evap
orat
or
internal heatexchanger
T
temperature sensor 1
filling socket
p
pressure sensor
savety valve HP
compressor with safety system and
auxiliary unit
savety valve LP
filling socket
HP high pressureLP low pressure
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SAE 2000 Automotive Alternative Refrigerant Systems Symposium, July 11, 2000 11
Results
n An automotive CO2 AC-system is safe:n General rules for the arrangement of the
components have to be taken intoaccount
n Safety components and/or systemshave to be present
n Critical components are detected
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Outlook
n Development of common safety-standards for an automotive CO2 AC-system
n Systematic sampling of all failure eventsfrom existing prototype-systems
n Evaluation of specific failure rates duringthe operation of prototype system hours
n Performing a fault- and event treeanalysis
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SAE 2000 Automotive Alternative Refrigerant Systems Symposium, July 11, 2000 13
Further Activities
n Further activities should be done to gaininternational acceptance