OEMs in the machinery industry have to develop drivetrain components for a wide range of applications with extremely heterogeneous operation conditions. Moreover, lifetime targets of machinery drivetrains are the highest among all combustion engine applications. The limited market volume for each type of application does not pay for a separate validation program, while it is not evident if the executed tests are also sufficiently demonstrating validation for another ensemble of machinery. Uptime Engineering was asked by an OEM in the machinery sector to identify necessary extension of an established validation program in order to cope with the requirement from several new types of machinery.
The assessment of validation in Uptime LOCATE™ requires a detailed assessment of representative load profiles for all the intended applications. A dedicated test program is not feasible. It is expected that the majority of test results can be transferred to the new application, but it is not transparent to which extent this is justified.
The analysis was done based on an existing assessment project for a validation program in Uptime LOCATE™. Reference duty cycle measurements for new applications were uploaded to that project and initially assessed with respect to technical differences in load, dynamics, cold-start frequency and further damage drivers. A test assessment on this basis uncovered the need for one additional type of durability test, addressing certain high-load conditions. The demonstration of reliability was evaluated with this extended ensemble of test, showing that some of the need to be extended to cover severe load cases over long time as given in the new duty cycles. In total an extension of about 20% test volume on the test rig was sufficient to demonstrate the additional reliability targets. A combined consideration of test rig and vehicle durability testing resulted in a constant volume of vehicle testing but with a more heterogeneous selection of machinery applications. The optimum validation program was designed as a combination of existing plus new vehicle durability operation.
Extension of the market volume by about 100% could be achieved by application of an existing engine to new machinery applications in new market. The on-costs could be limited to about 15% of the original validation budget without reduction in target achievement. This synergy effect was significant for the business case and helped to bring this new low-emission engine to the market.
Uptime Engineering supports the implementation of reliability related processes in your organisation through the provision of software and technical consulting.