Light-emitting diodes (LEDs) offer energy-efficient lighting and are widely adopted. However, LED drivers that regulate power can fail when subjected to voltage disturbances on the electrical grid. This research investigates how components within LED drivers durability when undergoing voltage impulses and swells using simulation-based methods. An LED driver circuit was modeled in LTspice circuit simulation software. Impulses from 35-65V and equivalent voltage swells were applied to the simulated driver. The electrical stresses on components were statistically analyzed using the design of experiments and general full factorial. This methodology identified the most vulnerable components and their common durability/failure mechanisms during impulse and swell events. The findings provide insights into design changes that harden drivers against grid disturbances. This study determines that higher capacitor voltage ratings improved voltage impulse and swell withstand. Additionally, adding a surge suppression diode across the LED minimized diode reverse breakdown during swells. This simulation-based approach enables the informed design of robust LED drivers that can withstand electrical grid perturbations through strategic hardening of the most vulnerable components. The methodology and findings provide a framework for the reliability optimization of LED drivers and other power electronic systems exposed to power quality disturbances.Keywords: LED driver, voltage disturbance, component failure, circuit simulation, design of experiments (DOE), general full factorial.

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The reliability of a mechanical system containing electronic packages is highly affectedby the environment the system is stationed in. The difference and fluctuationsbetween the ambient temperature and the operating temperature of the electronicpackage cause accumulation of inelastic strains in the package components thusdecreasing the service life. The most common failure modes of an electronic packagehas been identified from inspection of malfunctioning machines as cracks in the solderjoint and delamination between the glue and the die. Knowledge regarding therelationships between parameters affecting these failure modes, which are importantand which are not, is of high interest when developing new and existing products. SAAB AB would like to develop a methodology using design exploration to allow forevaluation of electronic packages using nonlinear finite element methods. A surrogate model was created and parameterized with HyperMorph to be used forthree linear static variations of design of experiments, where both the performance ofthe methods themselves and the relative importance of the parameters were ofinterest. A connectivity condition was also implemented to allow for relativemovement between components while keeping the mesh intact. The designexploration was executed using a Taguchi design, a Modified extensive latticesequence design and a fractional factorial design where the three methods werecompared as well as the parameter significance analysed. An optimization was thenperformed to find the optimal parameter settings within the allowed bounds to beused where a nominal model and an optimized model are evaluated with animplemented creep law. The fatigue life of the two models were then estimated. / Tillförlitligheten hos ett mekaniskt system med elektroniska kretsar påverkas starkt av miljön systemet används i. Skillnader och fluktuationer mellan omgivningens temperatur och arbetstemperaturen för de elektroniska kretsarna orsakar ackumulering av inelastiska töjningar, därmed förkortas det mekaniska systemets livstid. Dem vanligaste fel-moderna för en elektronisk krets har identifierats genom inspektion av felande maskiner som sprickbildning i lödfogarna och delaminering mellan processorn och dess lim. Kunskap hur förhållandet mellan parametrar som påverkar dessa fel-moder, vilka som är viktiga och vilka som inte är viktiga är av högt intresse vid utveckling av nya och redan existerande produkter. SAAB AB vill utveckla en metodik som utnyttjar statistisk försöksplanering för analyserande av elektroniska kretsar med hjälp av olinjära finita element metoder för att kunna spegla dess beteende på ett realistiskt sätt. En surrogatmodell skapades och parametriserades med hjälp av HyperMorph för att användas inom tre statiskt linjära varianter av statistisk försöksplanering, där både metodens prestanda och den relativa påverkan från parametrarna var av intresse. Ett kontaktvillkor implementerades för att tillåta relativ rörelse mellan komponenter samtidigt som nätet av finita element hölls intakt. Försöksplaneringsimuleringar utfördes med en Taguchi design, en Modified extensive lattice sequence design och en fractional factorial design, där de tre metoderna jämfördes mot varandra samt analyserades vad gäller respektive parametersignifikansen. Med optimering fanns sedan en optimal modell för att kunna jämföras med en nominell modell där en kryplag implementerades i lödfogen. Livslängden beräknades sedan för båda modeller.

Product reliability is an important characteristic for all manufacturers, engineers and consumers. Industrial statisticians have been planning experiments for years to improve product quality and reliability. However, rarely do experts in the field of reliability have expertise in design of experiments (DOE) and the implications that experimental protocol have on data analysis. Additionally, statisticians who focus on DOE rarely work with reliability data. As a result, analysis methods for lifetime data for experimental designs that are more complex than a completely randomized design are extremely limited. This dissertation provides two new analysis methods for reliability data from life tests. We focus on data from a sub-sampling experimental design. The new analysis methods are illustrated on a popular reliability data set, which contains sub-sampling. Monte Carlo simulation studies evaluate the capabilities of the new modeling methods. Additionally, Monte Carlo simulation studies highlight the principles of experimental design in a reliability context. The dissertation provides multiple methods for statistical inference for the new analysis methods. Finally, implications for the reliability field are discussed, especially in future applications of the new analysis methods. / Ph. D.

The primary objectives of this work are two-fold. First, additive manufacturing (AM) and rapid prototype (RP) testing are evaluated for use in production of a wind tunnel (WT) models. Second, an approach was developed to incorporate stability and control (SandC) WT data into aircraft conceptual design multidisciplinary design optimization (MDO). Both objectives are evaluated in terms of data quality, time, and cost. FDM(TM) and PolyJet AM processes were used for model production at low cost and time. Several models from a representative tailless configuration, ICE 101, were printed and evaluated for strength, cost and time of production. Furthermore, a NACA 0012 model with 20% chord flap was manufactured. Both models were tested in the Virginia Tech (VT) Open-Jet WT for force and moment acquisition. A 1/15th scale ICE 101 model was prepared for manufacturing, but limits of FDM(TM) technology were identified for production. An approach using WT data was adapted from traditional surrogate-based optimization (SBO), which uses computational fluid dynamics (CFD) for data generation. Split-plot experimental designs were developed for analysis of the WT SBO strategy using historical data and for WT testing of the NACA 0012. Limitations of the VT Open-Jet WT resulted in a process that was not fully effective for a MDO environment. However, resolution of ICE 101 AM challenges and higher quality data from a closed-section WT should result in a fully effective approach to incorporate AM and RP testing in an aircraft conceptual design MDO. / Master of Science

When a reliability experiment is used, practitioners can understand better what lifetimes to expect of a product under different operating conditions and what factors are important to designing reliability into a product. Reliability experiments, however, can be very challenging to analyze because often the reliability or lifetime data tend to follow distinctly non-normal distributions and the experiments typically involve censoring. Time and cost constraints may also lead to reliability experiments with experimental protocols that are not completely randomized. In many industrial experiments, for example, the split-plot structure arises when the randomization of the experimental runs is restricted. Additionally, for many reliability experiments, it is often cost effective to apply a treatment combination to a stand with multiple units on it as opposed to each unit individually, which introduces subsampling. The analysis of lifetime data assuming a completely randomized design has been well studied, but until recently analysis methodologies for more complex experimental designs with multiple error terms have not been a focus of the reliability field. This dissertation provides two analysis methods for analyzing right-censored Weibull distributed lifetime data from a split-plot experiment with subsampling. We evaluate the proposed methods through a simulation study. Companies also routinely perform life tests on their products to ensure that products meet requirements. Each of these life tests typically involves testing several units simultaneously with interest in the times to failure. Again, the fact that lifetime data tend to be nonnormally distributed and censored make the development of a control charting procedure more demanding. In this dissertation, one-sided lower and upper likelihood ratio based cumulative sum (CUSUM) control charting procedures are developed for right-censored Weibull lifetime data to monitor changes in the scale parameter, also known as the characteristic life, for a fixed value of the Weibull shape parameter. Because a decrease in the characteristic life indicates a decrease in the mean lifetime of a product, a one-sided lower CUSUM chart is the main focus. We illustrate the development and implementation of the chart and evaluate the properties through a simulation study. / Ph. D.