Vorbeugende QM-Techniken operationalisieren die Funktionen des Qualitätsmanagements (QM) mit dem Ziel einer abgesicherten Produktentstehung. Sie leisten einen wesentlichen Beitrag zur Erhöhung der Produktqualität. Jedoch zeigen Untersuchungen, dass deren Einsatz häufig sehr große Probleme bereitet. Die vorliegende Arbeit untersucht vordergründig die FMEA, QFD und DRBFM. Neben der Beschreibung ihrer Anwendungsbereiche, werden die Vorteile und Schwächen gegenübergestellt. Es gilt, die Schwächen mit Hilfe einer neu entwickelten Methode zu umgehen bzw. zu eliminieren. Die Entwicklung zentraler Schwerpunkte zur Erreichung von Null-Fehlerqualität liefert die Basis für die Erstellung einer Checkliste in Form eines Fragenkataloges. Ziel soll es sein, durch die Systematik des Fragenkataloges und Wahl des Antwortformates Fehlerursachen zu vermeiden.

In the automotive industry, the Safety Function-FMEA according to ISO 26262 and its application to functional safety relevant systems is a well-established process in the form of Automotive Safety Integrity Levels (ASILs). These represent the failure mitigation that must be applied to ensure an acceptable residual risk of malfunctioning behaviour. The DIN EN ISO 13849 (ISO 13849) already describes a process to reduce risks for machines which starts with a Hazard And Risk Analysis (HARA) as described in DIN EN ISO 12100 and concludes with the Safety Requirements Specification (SRS). The SRS is a functional and technical safety concept defining requirements and guidelines to make sure the design conforms to defined safety goals. ISO 13849 lists important faults and failures for various technologies. The defined Safety Functions (SFs) can be classified in corresponding categories that lead to the particular hardware/system structure. This applies to mechatronic systems consisting of at least one sensor, one control unit and one actuator to monitor the system and effect a response in case of failure. Compared to the methods described in ISO 13849, the Safety Function-FMEA allows systematic identification of additional failures resulting from combinations of effects, rather than only listing the main failure causes. Based on the complexity of the machines it is highly recommended to perform a Safety Function-FMEA as a complementary method to assess and improve the overall safety of machinery.

Plasma pretreatments are environmentally benign and energy efficient processes for modifying the surface chemistry of materials. In an effort to improve the strength of the titanium alloy/FM-5 polyimide adhesive joint for aerospace applications, oxygen plasma pretreatments and novel thin plasma polymerized (PP) films were investigated as adhesion promoters. Plasma treatments were carried out using custom-built, low pressure, radio frequency, inductively coupled plasma reactors. Ti-6Al-4V coupons were plasma treated and used to prepare miniature single lap shear (SLS) joints. The effects of plasma pretreatments on surface chemistry were studied using x-ray photoelectron spectroscopy (XPS), Auger electron spectroscopy (AES), Fourier transform infrared analysis (FTIR), and contact angle measurements. Relationships between composition, mechanical properties, and adhesion of PP films on Ti-6Al-4V and silicon wafers were investigated. The nanomechanical properties (modulus, hardness and adhesion) were studied using atomic force microscopy (AFM) nanoindentation and nanoscratch testing. A design of experiments (DOE) three factorial model was used to optimize the parameters for oxygen plasma treatments. Oxygen plasma pretreatments enhanced joint strength by cleaning the titanium surface and creating an extended oxide layer. Nanoindentation of oxygen plasma treated substrates showed no change in the surface mechanical properties due to the oxygen plasma treatment. This suggested that the improved SLS strength of the oxygen plasma pretreated substrates was due to the cleaning of the substrate and the removal of carbonaceous contaminants, rather than any changes in the morphology of the oxide layer. PP acetylene films were predominantly carbon, with oxygen as the other main constituent (incorporated mostly as C-O and C=O). For all SLS specimens tested, the adhesion between PP acetylene and FM-5 adhesive was adequate. However, the strength of SLS joints was limited by the adhesion of the PP acetylene to the Ti-6Al-4V substrate. The effects of a large number of plasma parameters, such as substrate pretreatment, carrier gas, input power, flow rate and film thickness were investigated. All samples failed at the PP film/Ti-6Al-4V interface or within the PP acetylene film, and thicker PP films yielded lower SLS strengths. PP films deposited at lower power exhibited higher hardness and reduced modulus than films deposited at higher power. Overall, thinner films exhibited higher hardness and reduced Young's modulus than thicker films. PP films of higher hardness yielded higher critical loads at debond (thickness normalized) during the nanoscratch test. Thin films were developed via the vapor plasma polymerization of titanium(IV) isobutoxide (TiiB). XPS results suggested that titanium was incorporated into the film as TiO2 clusters dispersed in an organic matrix. No evidence for Ti-C was obtained from the XPS spectra. PP films of TiiB were much more compliant than PP acetylene films. This behavior was attributed to decreased fragmentation and lower crosslinking that occurred during PP TiiB film deposition. These PP films did not exhibit sol-gel-like qualities, and because of the way titanium was incorporated into the films, a more appropriate name for these films might be "titanium dioxide-doped plasma polymerized films." / Ph. D.

This thesis deals with the design and solving construction of devices for centering cargo tires. Another part of this work is a concept of the clamping head for fixation of tires by industrial robot and its following placement on a palette. Construction solution will be drawn up with access and without access of human operator. All structural variations will be reviewed by risk analysis and analysis of possible incidence and influence of defects.

Der Verbundwerkstoff Stahlbeton zeichnet sich durch das effektive Zusammenwirken seiner beiden Einzelkomponenten Stahl und Beton aus. Dieses wiederum kann nur durch ausreichend gute Verbundbedingungen zwischen beiden Baustoffen gewährleistet werden. Die Verbundeigenschaften werden von zahlreichen Faktoren beeinflusst, zu denen u.a. die Oberflächenprofilierung des Stahls, die Betonfestigkeit und die Umschnürungswirkung durch den umgebenden Beton oder eine Querbewehrung zählen. Auch eine quer zum Stab angreifende Belastung kann einen erheblichen Einfluss auf den Verbundmechanismus und die Verbundversagensart haben. Bei Stahlbetonbauteilen unter einer zweiaxialen Zugbelastung, wie sie z.B. in Behälterwänden oder zweiachsig gespannten Platten auftritt, unterliegt die Bewehrung sowohl einer Längszug- als auch einer Querzugbeanspruchung. Im Rahmen der vorliegenden Arbeit wurde der Einfluss einer Querzugbelastung auf das Verbundverhalten zwischen Rippenstählen und Normalbeton mit Hilfe von würfelförmigen Ausziehkörpern mit einer kurzen Verbundlänge untersucht. Dabei lag das Querzugniveau stets unterhalb der Risslast des Betons, so dass keine Risse entlang des einbetonierten Stabes auftraten. Neben der Höhe der Querzugbelastung wurden im Versuchsprogramm die Betonfestigkeit, der Stabdurchmesser und die Betondeckung variiert. Anhand der Versuchsergebnisse konnte gezeigt werden, dass sich auch unter einer Querzugbelastung der Verlauf der Verbundspannungs-Schlupf-Beziehung nicht ändert. Die Art des Verbundversagens wird jedoch maßgeblich durch den Querzug beeinflusst, welcher ein Spaltbruchversagen in jedem Fall begünstigt. Mit steigendem Querzug tritt auch bei großen Betondeckungen statt eines Ausziehversagens ein Spaltbruchversagen ein. Mittels des vorgeschlagenen Berechnungsmodells können in Abhängigkeit des Querzugniveaus und der Größe der Betondeckung Grenzlinien für den Wechsel im Verbundversagensmodus bestimmt werden. Hierbei wurde ebenfalls der Einfluss der Probekörpergeometrie auf die Versuchsergebnisse in die Berechnung einbezogen, so dass die angegebenen Grenzlinien auch für reale Einbettungslängen der Bewehrung gelten. Weiterhin wurde anhand der Versuchsdaten sowie eines Datensatzes aus der Literatur ein Verbundmodell für kurze Verbundlängen entwickelt, das den Einfluss der bezogenen Rippenfläche der Bewehrung und der Betonfestigkeit sowohl auf die Verbundspannungen als auch auf die zugehörigen Schlupfwerte berücksichtigt. Über einen zusätzlichen Datensatz zum Einfluss der Verbundlänge im Ausziehversuch konnte ebenfalls die Abhängigkeit zwischen den mittleren Verbundspannungen, den zugehörigen Schlupfwerten und der Verbundlänge spezifiziert werden. Somit ist eine Übertragbarkeit der Ergebnisse von Ausziehversuchen mit kurzen Verbundlängen auf eine reale Einbettungslänge im Bauteil möglich. Für die Bemessung von Stahlbetonkonstruktionen in den Grenzzuständen der Tragfähigkeit und der Gebrauchstauglichkeit erfolgt die Ableitung geeigneter Verformungskriterien für die Relativverschiebung zwischen Betonstahl und Beton und deren Verifizierung an Versuchsdaten aus der Literatur. Die aufgestellten Verformungskriterien in Abhängigkeit der Stahlspannung erlauben eine direkte Ermittlung bemessungsrelevanter Verbundspannungen anhand experimenteller Ausziehversuche. Die Berücksichtigung einer Querzugbelastung ist dabei in allen vorgestellten Berechnungsansätzen ebenfalls möglich. / Reinforced concrete as composite material is characterised by an effective interaction of its individual components reinforcing steel and concrete. This only can be assured by adequate bond conditions between these two materials. The bond quality is influenced by a wide range of parameters, amongst others including the rib geometry of the bar, the concrete strength and the confining action by the surrounding concrete or transverse reinforcement. Moreover loads, which act transverse to the reinforcing bar, can influence the bond mechanism and the bond failure mode significantly. Reinforced concrete structures, such as containment walls or two-way slabs, are often exposed to multiaxial loading conditions. In case of biaxial tensile stresses, reinforcement and surrounding concrete are loaded in tension in longitudinal as well as in transverse direction. An extensive experimental program was carried out in order to investigate the bond behaviour between reinforcing steel and normal strength concrete due to transverse tension. Cubic-shaped pullout specimens with a short bond length were used. The transverse tension level remained always below the cracking stress of concrete, meaning that no crack occurred along the pullout bar. The test program contained the variation of the transverse tension level, the concrete strength, the bar diameter and the concrete cover. From the test results no systematic influence of the transverse tension level on the shape of the bond stress-slip-relationship can be detected. The bond failure mode is significantly influenced by transverse tension, which promotes splitting failure. The higher the transverse tension level, even for high concrete covers, splitting failure occurs instead of pulling out the bar. From the test results, a failure criterion depending on the concrete cover and the transverse tension level could be determined, which indicates the failure mode and corresponding bond stress. For this purpose, the influence of the specimen geometry on the test results was considered, which results in a failure criterion that is also valid for real embedment lengths of the reinforcement. Furthermore, a bond model for short bond lengths has been developed, based on the test results and a dataset from literature. The model considers the influence of the related rib area of the reinforcing bar and the concrete strength on the bond stresses as well as on the corresponding slip values. By an additional dataset concerning the influence of bond length in pullout tests, the bond stresses and corresponding slip values could be specified as a function of the bond length. Therefore, the test results of pullout test with short bond lengths are transferable to real embedment lengths in structural elements. For the structural design of reinforced concrete elements in the ultimate and serviceability limit states, appli\\-cable deformation criterions concerning the relative displacement between reinforcing steel and concrete has been derived and verified by test data from literature. By means of the developed deformations criterions dependent on the steel stress, design bond stresses can be determined directly from experimental pullout tests. The consideration of transverse tensile loads is also possible for all presented design formulas.

During the last decades, the power grid is getting rapidly digitalised in order to contribute to theestablishment of Smart Grids and evaluate efficiently the extracted bidirectional data from the powersystem infrastructure. This thesis focuses on the MV grid, since its design and operation have changedmainly because of distributed generation installations and the increased demand of information fromstakeholders. Thus, asset management constitutes a significant tool that can increase the reliability ofthe MV network’s operation and its level of control. Studies have shown that a maintenance planbased on condition monitoring of power system apparatuses would be more effective compared to theimplemented time-based scheduled maintenance.This project focuses on MV remotely controlled disconnectors since studies have shown that theirnumber of failures is double compared to manually operated ones. Since maneuverability andsecondary function are the causes of a major failure with the highest occurrence rate, motor currentmonitoring is studied in this thesis. Some devices that have the capability to monitor disconnectors’motor current, are presented. Additionally, the obtained max motor current measurements areevaluated through a parametric and a non-parametric statistical test. The main challenge of this thesisis to show whether the behaviour of motor current can be an indicator regarding to the disconnector’scondition status.Hence, the impact of different factors on the behaviour of motor current is investigated. It is concludedthat disconnectors without a failure during the studied period are more likely to have max motorcurrent measurements higher than 8A and especially in the interval [10-12]A. The difference in motorcurrent of disconnectors with a work order and without failure is more significant in 2015/2016. Itseems that under the aforementioned values of max motor current, a disconnector is more probable tohave the capability to operate properly. It is also concluded that in case of malfunction “Mellanläge”,the value of max motor current is lower than 8A with higher probability and it maybe indicates aproblem of the studied disconnector.Through the comparison in pairs, it could be concluded that the effect of the external environmentalconditions is not so high on the behaviour of disconnectors’ max motor current measurements. Incontrast, it seems that the implementation of a work order, the number of operations and if adisconnector is installed more northerly in Zone 3 play a more significant role on the behaviour of thisdisconnector’s max motor current measurements. Consequently, based on the aforementioned results itis shown that some of the investigated factors could constitute an indicator whether a disconnector ismore or less probable to have the capability to operate properly.Finally, it is calculated the reduction in the interruption cost that could be achieved in case ofimplementation of motor current monitoring on Vattenfall’s remotely controlled distributeddisconnectors. / Under de senaste årtiondena har kraftnät blivit snabbt digitaliserad För att bidra till upprättandet hosSmart Grids och effektivt utvärdera de extraherade dubbelriktade data från kraftsystemetsinfrastruktur. Denna exjobbsrapport fokuserar på MV-nätet, eftersom dess design och drift harförändrats främst på grund av distribuerade produktionsanläggningar och ökad efterfrågan påinformation från intressenter. Därför utgör ”asset management’’ ett viktigt verktyg som kan öka elnätstillförlitligheten och styrning. Studier har visat att elnäts underhåll baserad på tillståndsövervakningpå kraftsystemkomponenter skulle kunna vara effektivare jämfört med tidsbaserade schemalagdaunderhåll.Detta exjobb fokuserar på MV-fjärrstyrda frånskiljare eftersom studier har visat att deras felfrekvensär dubbelt högre jämfört med manuella. Eftersom problem i manövrerbarhet och sekundär funktionkan orsaka allvarliga fel med hög frekvens, har studien fokuserats på motorströmövervakningen idetta exjobb. Vissa produkter som har förmåga att övervaka frånskiljares motorström, presenteras.Dessutom utvärderas de maximala motorströmsmätningarna genom både parametriskt och ickeparametrisktstatistiskt test. Huvudutmaningen i denna avhandling är att utreda om motors strömmarkan vara en indikator för frånskiljares tillstånd.Olika faktorer hos motorströmmar har också undersökts. Det dras slutsatsen att frånskiljare utanmisslyckande manövern under den studerade perioden är mer benägna att ha maximalamotorströmmar högre än 8A och speciellt i intervallet [10-12] A. Skillnaden i motors strömmar hosfrånskiljare med arbetsorder och utan fel är mer signifikant under åren 2015/2016. Det verkar som attenligt ovan nämnda värden på max motorström, är en frånskiljare mer sannolikt att fungera korrekt.Det kommer också fram till att i händelse av "Mellanläge" är värdet av max motorströmmar lägre än8A med högre sannolikhet, detta kan kanske indikera ett problem hos frånskiljaren.Genom jämförelsen kan man dra slutsatsen att effekten av de yttre miljöförhållandena inte är så högpå maximala motorströmmar hos frånskiljare. Däremot verkar det som om genomförandet av enarbetsorder, antalet operationer och om en frånskiljare är installerad i zon 3 spelar en viktig roll föruppförandet av denna frånskiljares maximala motors strömmen. På grundval av det ovan nämndaresultatet framgår det att några av de undersökta faktorerna kan utgöra en indikator på att om enfrånskiljare är mer eller mindre sannolikt att ha förmågan att fungera korrekt.Slutligen visar beräkningar att minskningen av avbrottskostnaden kan uppnås vid genomförande avmotorströmövervakning på Vattenfalls fjärrstyrda distribuerade frånskiljare.

Every product has economic, environmental, and social impacts whether or not those impacts are explicitly considered. These impacts affect society and are an important part of engineering design. "Triple Bottom Line Sustainability" focuses on economic, environmental, and social sustainability and has become an important goal for those designing products. Economic considerations are an established part of the engineering design process. Environmental considerations are increasingly being considered in design including the development of design standards and widely used methodologies. Social impact considerations, however, lack the standardization and wide inclusion of economic and environmental considerations. This results in reduced and unbalanced consideration of social impacts compared to economic and environmental impacts. Improved consideration of social impacts in engineered products would benefit society in many areas of life. While many tools and methodologies for assessing social impact exist and are used in the social science and development fields, these tools are not broadly used in the engineering community. Some reasons these methods are not more standardly practiced include designers not being aware of the methods, methods not being widely applicable or adaptable, methods being too complicated or time intensive to use, or methods not being useful in product development processes. The purpose of this research is to classify and organize design tools for social impact and create methods that fill holes in the social impact design tool space. The classification and organization is done through the classification of 374 papers in the EGD literature along several dimensions including method purpose, industry sector, social impacts considered, sustainable development goals, paper setting, and data inputs required. This will increase awareness of available methods and help designers find relevant research to aid them. Additionally, this research describes two methods developed by the author to fill specific gaps identified in the literature.

No description available.

De nos jours, la politique écologique encourage les constructeurs automobiles à réduire le poids global du véhicule. Des tôles d'acier fines d'épaisseur différente optimisant chaque partie de l'assemblage sont utilisées et les sidérurgistes développent des aciers de plus en plus résistants à savoir l'Acier Haute Résistance Avancé (AHSS) avec un bon compromis entre résistance mécanique et ductilité (emboutissage). Lors des essais mécaniques de soudage hétérogène AHSS, des modes de fractures inhabituels sont observés, notamment le long de l'interface entre la zone affectée par la chaleur (ZAT) et la zone de fusion ou zone fondue (ZF). Ces fractures se produisent généralement avec une résistance inférieure à celle attendue pour ces soudures. Les objectifs de l'étude sont de comprendre les mécanismes de rupture au cours des essais mécaniques et de créer un modèle mécanique de FE conçu pour prédire la résistance mécanique des assemblages soudés. Tout d'abord, une étude de soudage hétérogène constituée de deux nuances d'acier bien connues d'ArcelorMittal vise à comprendre le mécanisme de défaillance et les paramètres affectant les modes de défaillance. Différentes configurations sont étudiées avec l'épaisseur. Le modèle FE est construit avec une réponse mécanique identifiée de chaque zone (matériaux de base, zones affectées par la chaleur et zone de fusion), en utilisant des modèles d'ArcelorMittal et des données expérimentales. Des critères de défaillance basés sur des dommages ductiles tenant compte de l'influence de la triaxialité sont utilisés et certains éléments cohésifs sont utilisés pour simuler une défaillance interfaciale. Deux configurations d'essais mécaniques dans le cas du soudage par résistance par points (essais de traction transversale et de traction) sont considérées. Les prédictions du modèle étaient très précises avec les modes de défaillance et les forces expérimentaux. Ensuite, cette méthode de modélisation FE a été appliquée avec succès à un boîtier de soudage par points très hétérogène comprenant un nouveau concept AHSS basse densité de troisième génération à forte teneur en aluminium et en manganèse. Les modes d'échec et les forces obtenues étaient comparables. De plus, la méthode de modélisation FE a été appliquée sur des configurations plus complexes, en particulier sur un assemblage soudé par points triple épaisseur. La robustesse du modèle pour prédire les modes de défaillance partielle et les forces d'une soudure par points triple épaisseur a été démontrée. En outre, la méthodologie de modélisation FE a été étendue à un autre type de soudage: le soudage à l'arc. Dans ce cas, deux feuilles sont soudées en configuration de chevauchement ab avec un fil d'apport. Le modèle FE permet de prédire la zone de rupture et la résistance de l'assemblage soudé. / Nowadays, ecological policy encourages carmakers to reduce the global vehicle weight. Fine steel sheets assemblies with different thickness optimizing each part of the assembly are used and steelmakers develop steels which are more and more resistant namely Advanced High Strength Steel (AHSS) with a good compromise between mechanical strength and ductility (stamping). During the mechanical tests of heterogeneous AHSS welding, unusual fracture modes are observed, in particular along the interface between the Heat Affected Zone (HAZ) and the Fusion Zone or molten zone (FZ). These fractures generally occur with lower strength than expected for these welding. The objectives of the study are to understand fracture mechanisms during mechanical testing and create a mechanical FE model is developed to be able to predict mechanical strength of the welded assemblies. Firstly, a study of heterogeneous welding constituted of two well-known steel grades of ArcelorMittal aims at understanding failure mechanism and parameters affecting the failure modes. Different configurations are studied with thickness. FE model is built with mechanical response identified of each zone (base materials, heat affected zones and fusion zone), using ArcelorMittal models and experimental data. Failure criteria based on ductile damage taking into account the influence of the triaxiality are used and some cohesive elements are used to simulate interfacial failure. Two configurations of mechanical testing in the case of Resistance Spot Welding (cross tension and tensile shear tests) are considered. Model predictions were very accurate with experimental failure modes and strengths. Then, this FE modelling method was successfully applied to a highly heterogeneous spot welding case including a new third generation low density AHSS concept with high aluminum and manganese content. Failure modes and strengths obtained were comparable. Moreover, FE modelling method was applied on more complex configurations, in particular on a triple thick spot welded assembly. The robustness of the model to predict partial failure modes and strengths of a triple thick spot weld has been demonstrated. In addition, FE modelling methodology was extended to another welding type: arc welding. In this case, two sheets are welded in ab overlap configuration with a filler wire. FE model allows predicting the failure zone and strength of welded assembly.

Although it offers a wide variety of interesting properties such as fire resistance or durability, stainless steel has been used in limited amount in structures. It is a known fact that the design rules don't properly account for the additional benefits of stainless steel properties and are largely based on the specifications for carbon steel. Indeed, a number of similarities exist between stainless steel and ordinary carbon steel but there is sufficient differences to afford a specific treatment in design standards. And since stainless steel is an expensive material, it is important to accurately predict the resistance of structural members. The present research work is dedicated to the study of cold-formed stainless steel profiles. It actually follows the life of a stainless steel construction element and falls on three fundamental topics: the material behavior, the through-thickness residual stress distribution and mechanical enhancement due to the cold-forming process and, last, the strength of concentrically compressed thin-walled columns. Firstly, several constitutive models are characterized such as Teodosiu-Hu's micro-structural based hardening model, capable of predicting the behavior of the studied stainless steel grade submitted to biaxial loading causing plastic strain. This model accounts for the nonlinear hardening behavior, the anisotropy, the Bauschinger effect and more complex behavior such as the observed work-hardening stagnation under reversed deformation at large strains. For this purpose, a collection of tests is carried out including multiaxial tests such as tensile-shear tests and successive simple shear tests and plane-strain tests. Secondly, the effects of the forming process on the mechanical properties are studied. To begin with, on the basis of the constitutive models developed previously, an analytical method that calculates the biaxial residual stress distribution in the walls and in the corners of cold-formed profiles is established. Based on the conclusions drawn from this theoretical analysis, a new formula for the evaluation of the actual mechanical properties is established. This formula is not restricted to a single alloy or type of cross-section. Current design standards are then used to calculate the strength of lipped-channel section columns failing by combined distortional and overall flexural-torsional buckling and the results are compared to tests. Indeed, full-scale tests on cold-formed stainless steel lipped channel section columns were achieved in the Structures Laboratory of the University of Liège. And, once verified against the test results, finite element models were used to generate additional results when necessary. The author then presents a new Direct Strength Method taking into account this phenomenon. Finally, a wide amount of reference results are gathered from the literature, without limiting oneself to any kind of cross-section or stainless steel grade. This database is used to propose an improved formulation for the design of stainless steel thin-walled section columns failing by distortion, local or combination of local and overall buckling in the low slenderness range.