FUNDAMENTOS DE CONFIABILIDAD, DISPONIBILIDAD Y MANTENIBILIDAD

ASIGNATURA: TECNICAS AVANZADAS DE MANTENIMIENTO

JOSE GUILLERMO NIEVES ZARATE

PEDRO SAÚL GOMEZ MERCADO

PROFESOR: PhD. CARLOS BORRAS

MAESTRIA EN GERENCIA DE MANTENIMIENTO

ESCUELA DE INGENIERÍA MECÁNICA

FACULTAD DE INGENIERÍAS FISICOMECÁNICAS

UNIVERSIDAD INDUSTRIAL DE SANTANDER

2019
 1) For 10000 devices 10 failures are observed each year. Determine the failure rate and MTF.

Solución:
# 𝐷𝑒 𝐹𝑎𝑙𝑙𝑎𝑠
o 𝜆 = [# 𝐸𝑙𝑒𝑚𝑒𝑛𝑡𝑜𝑠 𝐹𝑢𝑛𝑐𝑖𝑜𝑛𝑎𝑛𝑑𝑜∗𝐼𝑛𝑡𝑒𝑟𝑣𝑎𝑙𝑜 𝑑𝑒 𝑇𝑖𝑒𝑚𝑝𝑜 ]

o # 𝐷𝑒 𝐸𝑙𝑒𝑚𝑒𝑛𝑡𝑜𝑠 𝐹𝑢𝑛𝑐𝑖𝑜𝑛𝑎𝑛𝑑𝑜 = 1´000

o # Fallas en el año = 10

10
 𝝀 = [10´000 = 𝟎, 𝟎𝟎𝟏]
1
 𝑴𝑻𝑻𝑭 = [ ] = 𝟏´𝟎𝟎𝟎 𝒂ñ𝒐𝒔
𝜆

1
2) The mortality rate of a 30-year-old man is 𝜆 = 10−3 [ ]. Determine the estimated lifetime as
𝑦𝑒𝑎𝑟
MTTF if the man would stay in same health condition.

Solución:
1
o 𝜆 = 0,001 [𝑌𝑒𝑎𝑟]

1
 𝑴𝑻𝑻𝑭 = [𝜆] = 𝟏´𝟎𝟎𝟎 𝒂ñ𝒐𝒔

3) The failure rate of a manufacturing unit be 𝜆1 = 1 failure per year. Determine the overall failure
rate and MTTF if 2, 3, 5, 10 units with the same failure rate are connected in series. How are these
numbers for parallel connection?

Solución:
1
o 𝝀1 = 0,001 [𝑌𝑒𝑎𝑟]

o Para Conexión en Serie 𝝀𝑡𝑜𝑡 = ∑𝒎

𝒊=𝟏 𝝀𝑖

o Para Conexión en Serie 𝑴𝑻𝑻𝑭𝑡𝑜𝑡 = ∑𝒎

𝒊=𝟏 𝑴𝑻𝑻𝑭𝑖

1 1
o Para Conexión en Paralelo: 𝑴𝑻𝑻𝑭𝑡𝑜𝑡 = 𝜆 ∑𝒎
𝒊=𝟏 𝑖

 En Serie:
 Si m=2
 𝝀𝑡𝑜𝑡 = 𝝀1 + 𝝀2 = 1 + 1  𝝀𝑡𝑜𝑡 = 𝟐

1 1
 𝑴𝑻𝑻𝑭𝑡𝑜𝑡 = 𝝀  𝑴𝑻𝑻𝑭𝑡𝑜𝑡 = 2 = 0,5
𝑡𝑜𝑡
  Si m=3
 𝝀𝑡𝑜𝑡 = 𝝀1 + 𝝀2 + 𝝀3 = 1 + 1 + 1  𝝀𝑡𝑜𝑡 = 3
1 1
 𝑴𝑻𝑻𝑭𝑡𝑜𝑡 = 𝝀  𝑴𝑻𝑻𝑭𝑡𝑜𝑡 = 3 = 0,33
𝑡𝑜𝑡
 Si m=5
 𝝀𝑡𝑜𝑡 = 5
1
 𝑴𝑻𝑻𝑭𝑡𝑜𝑡 = = 0,2
5
 Si m=10
 𝝀𝑡𝑜𝑡 = 10
1
 𝑴𝑻𝑻𝑭𝑡𝑜𝑡 = 10 = 0,1

1 1
 Si es en Paralelo : 𝑴𝑻𝑻𝑭𝑡𝑜𝑡 = ∑𝒎
𝒊=𝟏 𝜆 𝑖

 Si m=2
1 1 1 1 1 1 1 1 1
 𝑴𝑻𝑻𝑭𝑡𝑜𝑡 = [𝝀 ∗ 1 ] + [𝝀 ∗ 2 ] = [1 ∗ 1 ] + [1 ∗ 2 ] = 1 + 2
1 1
3
 𝑴𝑻𝑻𝑭𝑡𝑜𝑡 = = 1,5
2

 Si m=3
11
 𝑴𝑻𝑻𝑭𝑡𝑜𝑡 = = 1,83
6
 Si m=5
137
 𝑴𝑻𝑻𝑭𝑡𝑜𝑡 = 60
= 2,28
 Si m=10
7381
 𝑴𝑻𝑻𝑭𝑡𝑜𝑡 = 250
= 2,92

1
4) Passenger cars have about 300 years/old operation time. Given a failure rate of 𝜆 = 10−3 [ℎ],
how many can fail for a population of 106 cars in the 1st and the 5th year?

Solución:
ℎ𝑜𝑟𝑎𝑠
 Tiempo de Operacion = 300 𝑎ñ𝑜
 𝜆 = 0,003 ℎ−1
 Poblacion de Carros = 1´000´000 = 106 = N
 𝒕1𝑒𝑟 𝑎ñ𝑜 = 300 horas
 𝒕5𝑡𝑜 𝑎ñ𝑜 = 1´200 horas

 ∆𝒏𝑓 ≅ 𝑁 ∗ 𝜆 ∗ 𝑒 −𝜆∗𝑡 ∗ ∆𝑡
 ∆𝒏𝑓1 = 106 ∗ 0,003 ∗ 𝑒 −0,003∗300 ∗ 300
 ∆𝒏𝑓1 = 106 ∗ 0,003 ∗ 0,406 ∗ 300
 ∆𝒏𝑓1 = 365´400 ≙ 36,5%
  ∆𝒏𝑓5 = 106 ∗ 0,003 ∗ 𝑒 −0,003∗1´200 ∗ 1´200
 ∆𝒏𝑓5 = 106 ∗ 0,003 ∗ 0,0273 ∗ 1´200
 ∆𝒏𝑓5 = 98´280 ≙ 9,82%

5) The hydraulic brake system of passenger’s cars consists of redundant paths in a parallel configuration.
1
The failure rate of one path is 𝜆 = 𝑤𝑠 [ℎ]. Determine MTTF of whole brake system.

6) Determine the availability of a machine tool for the MTTF = 1 year and MTTR = 1 day.

Solución:

𝑀𝑇𝑇𝐹 365 365

 𝐴 = 𝑀𝑇𝑇𝐹+𝑀𝑇𝑇𝑅 = 365+1 = 360
 𝐴 = 99.73%
7) Determine the failure rate 𝜆 and MTTF for an electric motor with gear for a series connection of a
switch, cable, motor, gear according to the failure rates of table 3.2 and 3.3.

Solución:

o Para Conexión en Serie 𝝀𝑡𝑜𝑡 = ∑𝒎

𝒊=𝟏 𝝀𝑖
−6
o 𝝀𝑚𝑜𝑡𝑜𝑟 𝑒𝑙𝑒𝑐𝑡𝑟𝑖𝑐𝑜 = 9 ∗ 10
o 𝝀𝑔𝑒𝑎𝑟 = 4,69 ∗ 10−6
o 𝝀𝑠𝑤𝑖𝑡𝑐ℎ = 20 ∗ 10−6
o 𝝀𝑐𝑎𝑏𝑙𝑒 = 1 ∗ 10−6

 𝝀𝑡𝑜𝑡 = 𝝀𝑚𝑜𝑡𝑜𝑟 + 𝝀𝑔𝑒𝑎𝑟 + 𝝀𝑠𝑤𝑖𝑐𝑡ℎ + 𝝀𝑐𝑎𝑏𝑙𝑒 = 34,69 ∗ 10−6

1 1
 𝑴𝑻𝑻𝑭𝑡𝑜𝑡 = 𝝀 = 34,69∗ 10−6  𝑴𝑻𝑻𝑭𝑡𝑜𝑡 = 28´826
𝑡𝑜𝑡

Mechanical elements 𝝀[𝒉−𝟏 ] Electromechanical 𝝀[𝒉−𝟏 ]

elements
Ball bearing 1.64𝑥10−6 Actuator, general 26𝑥10−6
Sleeve bearing 2.38𝑥10−6 Brush, general 9𝑥10−6
Belt 19.72𝑥10−6 Cable, general 1𝑥10−6
Coupling 5.54𝑥10−6 Electric motor, general 9𝑥10−6
Gear 4.69𝑥10−6 Generator, general 73𝑥10−6
Pump 43.65𝑥10−6 Regulator, general 13𝑥10−6
Seal 5.47𝑥10−6
Valve, hydraulic 8.83𝑥10−6
Table 3.2 Typical failure rates of mechanical and electromechanical elements.

Electronic/electrical elements 𝝀[𝒉−𝟏 ] Mobile application 𝝅𝚬

Discrete elements
Transistor 1 − 70𝑥10−9
 Diodes 1 − 6𝑥10−9 18
Thyristors 36 − 360𝑥10−9
Resistances 1 − 100𝑥10−9
Condensators 6 − 150𝑥10−9
Analog integrated circuits
Operation amplifier 0.3 − 0.9 𝑥10−9 4.2
Analog switch 20𝑥10−9
Digital integrated circuits
Logical elements 0.03𝑥10−9
Multiplexer 0.05 − 0.2𝑥10−9 4.2
8-bit CPU (8080, 6800) 2 − 5𝑥10−9
Flight computer (80268) 10−4 . . . 10−3 3.18
Table 3.3 Failure rates of electronic/electrical elements stationary, 40°C, 60% power. 𝜋Ε: multiplication factor for mobile application

8) One type of trucks has under same driving condition an MTTF = 8 months and 2 days repair, another
type MTTF = 5 months and 1 day repair. Compare the availability.

Solución:

o 𝑴𝑻𝑻𝑭1 = 𝟖 𝒎𝒆𝒔𝒆𝒔 = 𝟐𝟒𝟎 𝒅𝒊𝒂𝒔

o 𝑴𝑻𝑻𝑹1 = 𝟐 𝒅𝒊𝒂𝒔
o 𝑴𝑻𝑻𝑭2 = 𝟑 𝒎𝒆𝒔𝒆𝒔 = 𝟏𝟓𝟎 𝒅𝒊𝒂𝒔
o 𝑴𝑻𝑻𝑹2 = 𝟏 𝒅𝒊𝒂

𝑴𝑻𝑻𝑭 240
 𝑨1 = 𝑀𝑇𝑇𝐹1+𝑀𝑇𝑇𝑅1
1
= 242
= 99,17%

𝑴𝑻𝑻𝑭 150
 𝑨2 = 𝑀𝑇𝑇𝐹2+𝑀𝑇𝑇𝑅2
2
= 151
= 99,34%

9) Switching solenoid relays in automobiles show about 5 ppm faulty ones. How many cars are effected if
they contains 50 relays each? What is the failure rate if these faulty relays show up in 1 year or 5 years?

Solución:

# 𝐷𝑒 𝐹𝑎𝑙𝑙𝑎𝑠
o 𝜆=[ ]
# 𝐸𝑙𝑒𝑚𝑒𝑛𝑡𝑜𝑠 𝐹𝑢𝑛𝑐𝑖𝑜𝑛𝑎𝑛𝑑𝑜∗𝐼𝑛𝑡𝑒𝑟𝑣𝑎𝑙𝑜 𝑑𝑒 𝑇𝑖𝑒𝑚𝑝𝑜
o # 𝐷𝑒 𝐸𝑙𝑒𝑚𝑒𝑛𝑡𝑜𝑠 𝐹𝑢𝑛𝑐𝑖𝑜𝑛𝑎𝑛𝑑𝑜 = 50
o # Fallas en el año = 5

5
 𝝀1 𝑎ñ𝑜 = [50∗1] = 𝟎, 𝟏
5
 𝝀5 𝑎ñ𝑜 = [50∗5] = 𝟎, 𝟎𝟐