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Machine - Automation & Electricity / World News 2023 3

CONT

EDITOR

3

Contents

World Media Group: Leader Publications for

at the New Economy, ındustry, technology

6

14

4 Machine - Automation & Electricity / World News 2023

CONTENTS

Euro zone accounting for

significant proportion of

machine

tool orders at present

22

FMEA

Managment İn

PLM Systems

Leybold wins

Product of the Year

category “Cases

and Enclosures” for

Hygienic Enclosure.

ENTS

Contens

Integrating

PLM and

ALM Using

Teamcenter-

Polarion:

Levels and

Benefits

Basic Principles Of

Product Desing In

Reliability Method

Increasing Productivity with Drive

Intelligence

28

36

44


Inovative

Euro zone accounting

for significant

proportion of machine

tool orders at present

This represents a 13 percent drop in orders in real

terms. “There was a further surprising increase in order

intake at the end of the second quarter, similar to March,”

reports Dr. Wilfried Schäfer, Executive Director of the

VDW (German Machine Tool Builders’ Association),

Frankfurt am Main.

the VDW forecast of 10 percent growth in production

in the current year remains valid,” concludes Schäfer.

Foreign markets continue to represent the principal

driving force, and Asia is the only region with a positive

balance sheet.

The main impetus came from the euro countries in

the second quarter. The increase in orders which

materialized at the end of the second quarter applied

to both machining and forming equipment. “We know

from experience, of course, that the result of a single

month does not signal a turnaround,” Schäfer continues.

Rather, the fluctuations were attributable to project

business, particularly to forming technology. In addition,

orders from growth sectors such as e-mobility, wind

power, aerospace and defense are boosting order intake

levels. The conventional machine business, on the other

hand, was somewhat weaker, as small and medium-sized

customers are unsettled and are postponing investments.

Credit-financed machine purchases are also becoming

more challenging due to the rise in interest rates.

Sales remained steady at a high level. In nominal terms,

it grew by 21 percent in the first half of the year, and by

13 percent in real terms. Capacity utilization rose again

slightly in July this year, from 88.3 to 90.5 percent. The

order backlog is dropping relatively slowly. “Accordingly,

Orders received by the German machine tool industry in the second quarter

of 2023 were 3 per cent down in nominal terms on the same period last year.

Orders from Germany declined by 11 percent whereas those from abroad rose

by 1 per cent. The level of orders fell by 7 percent overall in the first half of the

year. Domestic orders were 15 percent down on last year, whereas orders from

abroad were down by 4 percent.


welding process

ELC 6 from EMAG

LaserTec: Perfecting the

welding process for

rotor shafts

Sales of electric cars are on the rise - and at an

enormous pace worldwide. The International Energy

Agency (IEA), for example, estimates that 14 million e-

vehicles will be sold this year, representing a 35 percent

increase in sales compared with the previous year. This

means that they already account for almost one-fifth of

the total car market. As a result, production planners

are focusing on the manufacture of key components of

the e-motor, such as the rotor shaft. They are looking

for innovative solutions “from a single source,” with

which the component can be machined particularly

efficiently and reliably in ever larger quantities. EMAG

LaserTec is currently setting an example in the market

with its ELC 6 laser welding machine. In the machine,

joining, preheating and welding processes are

compactly combined on an assembled rotor shaft with

its rotary table system ensuring optimum cycle times.

Visitors to the EMO trade show in Hanover, Germany,

from September 18-23, can find out exactly what this

manufacturing system looks like and what possibilities

it offers at the EMAG Group’s booth in Hall 17, C 34.


welding process

Advances in e-mobility, including hollow designs of

components, allow great freedom in design, lighten the

weight and lower material costs for assembled rotor

shafts. At the same time, this “heart” of the electric

motor has to withstand particularly high loads, as motor

speeds of up to 20,000 rpm are now possible. Compared

to a camshaft in a combustion engine, for example, this

value is many times higher! Thus, the production of

assembled rotor shafts is always about manufacturing

tolerance - even minimal imbalances must be avoided

at all costs, because they would endanger the service life

of the engine. In addition, the process must result in a

highly stable component.

In this context, what is the most efficient way to

reliably produce increasing quantities in the face of an

expanding market?

One answer to this question leads directly to the

innovative technology of EMAG LaserTec, because the

company, based in Heubach near Aalen, has an impressive

track record with laser welding, which is indispensable

in “building” the two-piece rotor shaft. All the leading

automotive manufacturers have the associated systems

with the abbreviation “ELC” (EMAG Laser Cell) in use

in various application areas. The key to success is a

high level of competence as a system supplier: EMAG

LaserTec knows the entire production sequence of the

respective components and develops the complete

process chain on this basis. On the customer side, the

planning of new or the expansion of existing production

facilities is therefore massively simplified. In addition, the

whole process is based on EMAG’s modular mechanical

engineering, which includes a large number of proven

components. Therefore, these plants and their processes

are exceptionally stable and efficient in every detail.

All processes in rapid change

It is precisely this quality that the southern German

laser specialists have been bringing to the production

of assembled rotor shafts for some time now. The ELC 6

machine is at the center of this - a highly efficient solution

for joining the two halves of the component, with part

handling, preheating and joining as well as welding

taking place in quick succession and perfectly timed by

the rotary table. The precisely metered, concentrated

energy of the laser beam permits high welding speeds

with minimal distortion on the welded component.

A look at the details reveals the performance of the

machine, which was specially developed for powertrain

components with circumferential welds:

• Before the individual parts are loaded into

the ELC 6, the workpieces are laser cleaned. For this

purpose, EMAG LaserTec offers the LC 4 laser cleaning


machine, which can be optimally link-up with the ELC 6,

thus ensuring seamless line integration.

welding process

Overall, this solution has an enormous production

speed - partly because the machine with its rotary

table is loaded and unloaded during welding (and

thus cycle time-concurrent). In addition, the individual

subprocesses are perfectly synchronized. The “fixed

optics/moving workpiece” principle ensures a high level

of operational reliability. In addition, EMAG LaserTec

designs this solution very flexibly for customers in

terms of technology, output and automation, whereby

workpieces up to a maximum height of 300 millimeters

can be machined in the ELC 6.

The whole solution from a single source

• In the next step in ELC 6 (preheating and

joining), the induction technology first ensures an ideal

processing temperature on the component before the

two components are joined.

• Before welding, the weld seam position is

checked and the component position is readjusted.

The contour is scanned with precision and the data is

communicated to the welding optics and the NC axes.

• During the subsequent welding process, the

vertically arranged workpiece rotates, while the laser

optics only move radially towards the workpiece. The

welding process with its focused energy thus takes place

virtually from the side at the circumferential weld. A

pyrometer controls the process temperature.

In principle, EMAG scores with a comprehensive

technology portfolio in this field of application, because

the machine builders have already developed various

solutions, for example, for the subsequent joining of

the rotor shaft and rotor-sheet package as well as the

high-precision overturning of this package. The same

applies to the turning, gear cutting and grinding of the

two individual rotor shaft parts before welding. When

it comes to the automation technology that ensures

transport between the machines, EMAG adapts to

the customer’s ideas. For example, line gantries,

stacking cells, accumulating conveyors or EMAG’s own

TrackMotion system are used - in any case, the overall

system benefits from the uniformity of the machines

used with their optimized interfaces. The end result is

complete solutions for the customer. EMAG is the only

contact required during planning, implementation and

servicing. Technological competence and experience

guarantee a perfect process chain with extreme speed

and high safety.

• After welding, the component is transported

out of the machine by a swiveling motion of the rotary

table and unloaded by a robot.


Component

Leybold wins Product of

the Year category “Cases

and Enclosures” for

Hygienic Enclosure.

Vacuum equipment specialist Leybold UK, based in Chessington, Surrey, has

been recognised by the Instrumentation Excellence Awards. The Leybold

Hygienic Enclosure for vacuum pumps has won Product of the Year Cases

and Enclosures. The Awards celebrate the very best professionals, products,

projects and companies from across the test, measurement, sensing and control

sectors. Leybold UK was honoured and pleased to receive the Instrumentation

Excellence Awards during the award ceremony on 19th October in London.


Hygienic Enclosures for Vacuum Pumps

Food Safety is essential for the food market and typically

food producers & processors disinfect their installations

and machines daily just to guarantee a high Food Safety

level. Vacuum pumps are mainly built-in or installed next

to the machinery and that’s with only poor or even no

protection at all. Most vacuum pumps cannot cope with

daily washdowns, especially with aggressive cleaning

media, these result in corroded vacuum pumps, reduced

life cycles or even increased risks of pollution. To avoid

this, Leybold has developed a range of Stainless-Steel

Hygienic Enclosures. The enclosures are simple and

don’t interfere with the pump’s operations.

“Receiving the Product of the Year Award in this category

in particular is a special recognition of the quality of our

products in the area of food processing,”says Juliane

Garz, Business Line Manager Leybold. “It’s impossible to

Component

overstate the importance of safety and quality in food

manufacturing and with the Hygienic Enclosure food

applications can now be operated more hygienically,

ergonomically and flexibly.”

Vacuum systems are used in a wide range of applications

and processes

Leybold designs and manufactures vacuum pumps,

systems and components that create the necessary

production conditions for the industrial manufacture

of semiconductors, data carriers, displays, coated

architectural glass and solar cells. Vacuum systems are

critical to food processing and packaging, especially

when it comes to food safety, improved shelf life and

ease of processing. Vacuum is also indispensable for

the operation of mass spectrometers and electron

microscopes as well as in almost all areas of modern

research and development, including space simulation

and exploration.


Industrial advertising

is our job!

Tecnology

Energy-saving powerful

and quiet

Edwards Vacuum, one of the world’s leading designers and manufacturers of vacuum pumps,

has launched a new oil-sealed rotary vane vacuum pump. The company offers a reliable product

in the form of the powerful, robust E2S series for low and medium vacuum in industry and

research. The E2S has a simple design and is suitable for various standard applications. “It

pumps quickly, handles any vapours that arise and, with its quiet operation, helps to reduce

the noise level in working environments,” says Product Manager Jessie Huang, summarising the

advantages of the vacuum pump.

pump is also reflected in its user-friendly design. Thus,

the E2S has also been developed along the most modern

needs of its users in terms of simple, intuitive handling.

The operating elements are correspondingly functional

and ergonomic, offering a high level of safety against

operating errors. The quiet running of the E2S series is

also due to its technology. The low-noise plain bearings

are made of sintered steel, have a simple design and do

not dry out even with low oil lubrication. Edwards has

integrated an oil pump for continuous lubrication over

the entire pressure range.

Shorter cycle times, higher throughput

Thanks to the modern technical design, users increase

the economic efficiency of their processes with the

rotary vane pump. This is based not least on the high

pumping speed of the E2S. This shortens cycle times and

increases production capacity in standard processes.

“An important advantage: the higher throughput is

achieved without additional energy requirements, so the

ecological footprint is not increased,” assures Edwards

Product Manager Jessie Huang. According to Product

Manager Jessie Huang, the pumping speed of the E2S

is 90 m3/h and enables an ultimate vacuum of 3 x 10-3

mbar. At ultimate pressure, the performance of the E2S

thus meets the requirements of industrial applications.

For special performances, Edwards offers optional

standard combinations of two-stage E2S pumps including

a mechanical booster.

Intuitive handling

The modern technology of the compact rotary vane

Duo Seal, Gas ballast increases water vapour tolerance

To prevent oil loss, the rotary vane pump contains two

shaft seals. Edwards has also optimised the cylinder bore

for the highest possible stable discharge pressure and

increased leak tightness. In addition, a built-in oil filter

prevents oil leaks and protects the inside of the pump

from particles and contaminants. If the application

requires it, the adjustable gas ballast function can be

used to increase the water vapour tolerance of the E2S.

In the standard setting, small amounts of water vapour

are pumped out via this, while at the same time a good

ultimate pressure is maintained.

Wide range of applications

Edwards offers the E2S series in three pump sizes – the E2S

45, E2S 65 and E2S 85. The rotary vane pump is primarily

suited for vacuum drying and degassing, heat treatment

and vacuum furnaces; as well as for leak testing of

components and systems in automotive manufacturing,

coating applications, research and development and

analytical applications.

For further information about Edwards products please

visit www.edwardsvacuum.com.


Tecnology


Tecnology

Parker announces

start of operating

new test rig, a major

milestone for fuel cell

technology

Parker Hannifin’s Filtration business has reached a major milestone on the journey towards

mass production of hollow fibre membrane technology for fuel cell humidification applications,

a vital step towards reducing carbon emissions.

By enabling optimal moisture levels, hollow fibre

membrane technology allows fuel cells to last longer and

to perform more efficiently and reliably. It supports the

transition from fossil fuels, accelerating the shift to fuel

cell electrical vehicles in the next five years.

Parker announced the successful completion of the

specialized test rig which is to validate products by Parker

OEM (Original Equipment Manufacturer) customers. This

new technology enable Parker to test the membrane

technology in ways that are much more advanced and

aids to develop robust system solutions for fuel cell.

It was produced in partnership with the Fraunhofer

Institute for Microengineering and Microsystems (IMM),

a Germany-based non-profit for scientific research.

Burkhard Hartmann, R&D Officer at Parker’s Engine

Mobile Filtration Europe (EMFE) Division, said: “The

results speak for themselves: This has been an outstanding

collaboration with the Fraunhofer Institute. It moves us

all towards better, more efficient, more reliable fuel cell

electrical vehicles, a vital step towards a cleaner, better

tomorrow.”

Dr. Gunther Kolb, Representative from the Fraunhofer

Institute for Microengineering and Microsystems,

said: “Fuel cell technology is key to reduce emissions

worldwide. The partners are confident that the hollow

fibre membrane technology will be further improved, the

service life of the fuel cell humidifiers will be extended,

and their efficiency will be increased for the customers.”









Article

FMEA MANAGEMENT İN

PLM SYSTEMS

Hasan Anıl ASLAN1,3, Alican Yılmaz4, Prof.Dr.Semih ÖTLEŞ1,2

1Product Lifecycle Management M.Sc. Programme, Institute of Science, Ege

University

2Excellence Center for PLM, Ege University

3TEI, TUSAŞ Engine Industries, Inc.

4Director, Beemobs (Bee Mobility Solutions) Otomotiv Sanayi ve Ticaret A.Ş.

Keywords: FMEA, PLM, RPN, Risk Analysis, Quality Management

1. Introduction

In today’s competitive marketplace,

organizations strive to deliver high-quality

products that meet customer expectations and

exhibit exceptional reliability. To achieve this,

companies leverage advanced technologies

and methodologies throughout the product

development lifecycle. One such methodology

is Failure Mode and Effects Analysis (FMEA)

which plays a crucial role in identifying

and mitigating potential failure modes.

Integrating FMEA management into Product

Lifecycle Management (PLM) systems allows

organizations to enhance product reliability,

improve quality, and ultimately, achieve

customer satisfaction. This article explores

the significance of FMEA management in PLM

systems and its impact on product reliability

and quality improvement.

2. Failure Mode and Effects Analysis

Failure mode and effects analysis is a systematic

approach to identifying and mitigating

potential failures in products and processes.

It is a valuable tool for improving product

quality and reliability and reducing the risk of

product recalls and warranty claims.

FMEA can be applied at any product lifecycle

stage, from design and development through

manufacturing, testing, and use. It can be

used to analyze individual components,

subsystems, or entire systems.

There are basically two types of FMEA: Design

FMEA (DFMEA) and Process FMEA (PFMEA).

The FMEA process (by AIAG and VDA standards)

is typically defined in seven steps. Each step

is sequential, so the previous step creates an

output that serves as the next step’s input.

1- Planning & Preparation: The team

defines the purpose and definition of the

scope, sets boundaries of the analysis (what

needs to be included or excluded), and

establishes the foundation for the entire

FMEA process.

2- Structure Analysis: the system structure

is further clarified for technical analysis. The


boundaries set up in Planning & Preparation

are analyzed to identify which systems, subsystems,

and/or components will be part of

the FMEA.

3- Function Analysis: the product and

process functions are explored as well as the

criteria on how to evaluate the performance

of functions.

4- Failure Analysis: The team establishes

a Failure Chain through the cause-and-effect

relationships of these 3 categories:

Failure mode: An item/element that fails to

meet its intended function.

Failure effect: The consequences.

Failure cause: Why the failure mode would

happen.

Article

Actions are divided into 2 categories:

prevention and detection. Assignments of

responsibilities and deadlines are given.

After actions have been performed, the team

reviews the results to rescore the risks.

7- Result Documentation: he FMEA is

summarized, documented, and communicated

to the team and stakeholders. The FMEA report

includes summary of scope, identification

of high-risk failures, the corrective actions

taken and their effectiveness, and insights/

plans for current and future processes. The

results documentation is to summarize

and communicates the results of the FMEA

activity.

The system elements done in the Structure

Analysis are individually analyzed of its

functions and corresponding requirements.

5- Risk Analysis: Root cause analysis is

estimated and prioritized by evaluating these

3 categories:

Severity: How badly does this affect the

customer?

Occurrence: How often will it happen?

Detection: How easy is it to detect?

Each risk category has a scoring matrix from 1

to 10 with 1 being low-risk to 10 being highrisk.

Each score is multiplied together (Severity

x Occurrence x Detection) to produce a Risk

Priority Number (RPN).

6- Optimization: The team develops a

plan of action to mitigate risks and assess

the effectiveness of the optimization actions.

FMEA can be a valuable tool for improving

product quality and reliability. However, it is

important to note that FMEA is not a guarantee

against failure. It is a risk management tool

that can help to identify and mitigate potential

failures.

2.1. Product Lifecycle Management (PLM)

Product Lifecycle Management (PLM) is a

strategic approach to managing the entire

lifecycle of a product, from its conception

and design to its manufacturing, distribution,

and eventual retirement. PLM software tools

are essential in enabling and supporting the

effective implementation of PLM processes

within an organization. These tools provide

a centralized platform for data management,

collaboration, and decision-making throughout

the product lifecycle.

PLM software tools offer a range of

functionalities that support different stages of

the product lifecycle:

1- Design and Development: PLM tools

assist in capturing, organizing, and managing

product design data. They facilitate the creation

and management of digital product models,

specifications, and engineering documents.


Article

These tools often include computer-aided

design (CAD) capabilities, allowing designers

to create and visualize product designs in a

virtual environment.

2- Bill of Materials (BOM) Management:

PLM software helps in managing BOMs,

which list all the components, materials, and

assemblies required to build a product. It

enables efficient BOM creation, versioning, and

synchronization across different departments,

ensuring accurate and up-to-date information

is available to all stakeholders.

regulations, standards, and certifications,

ensuring that products meet legal and safety

requirements.

8- Service and Maintenance: PLM

software supports the service and maintenance

phase of the product lifecycle by managing

product updates, warranties, and customer

support information. It helps organizations

track product performance, manage service

requests, and provide timely maintenance

and support to customers.

3- Change Management: PLM tools

provide workflows and processes for

managing change requests, engineering

changes, and revisions throughout the

product lifecycle. They facilitate collaboration

and communication among cross-functional

teams, ensuring that changes are properly

evaluated, implemented, and tracked.

4- Collaboration and Communication:

PLM software tools offer features that enable

effective collaboration and communication

among team members, departments,

and external stakeholders. They provide a

centralized platform for sharing information,

documents, and design revisions,

fostering efficient teamwork and reducing

communication gaps.

5- Quality Management: PLM tools

include quality management capabilities,

allowing organizations to define and enforce

quality standards and processes. These tools

enable the tracking and management of

quality-related data, such as inspections,

non-conformances, and corrective actions,

ensuring that products meet the required

quality levels.

6- Supply Chain Management: PLM

software tools integrate with supply chain

systems to manage supplier information,

sourcing, procurement, and inventory. They

enable organizations to track and manage the

movement of materials, components, and

finished products across the supply chain,

improving visibility and optimizing logistics.

7- Regulatory Compliance: PLM tools

assist in managing regulatory compliance

requirements by capturing and organizing

relevant documentation and data. They

facilitate compliance with industry-specific

The use of PLM software tools offers numerous

benefits, including enhanced collaboration,

improved data accuracy, increased

productivity, reduced time to market, better

quality control, and improved customer

satisfaction. These tools provide organizations

with a comprehensive framework to

effectively manage the complexities of the

product lifecycle, from ideation to retirement,

and drive innovation and competitiveness in

the marketplace.

3. Integrating FMEA Management into

PLM Systems

Product Lifecycle Management systems

serve as a comprehensive platform for

managing product development processes,

from conception to disposal. Integrating

FMEA management into PLM systems offers

numerous advantages. Here are the key

elements to consider when implementing

FMEA within PLM systems:

3.1. Cross-functional Collaboration


Article

Successful FMEA implementation requires

collaboration among various departments,

including engineering, manufacturing, quality

assurance, and supply chain. PLM systems

provide a centralized platform that facilitates

collaboration and knowledge sharing among

different stakeholders throughout the product

development lifecycle. By involving experts

from multiple disciplines, organizations

can ensure a comprehensive and accurate

assessment of potential failure modes.

3.2. Automated FMEA Workflows

PLM systems offer the capability to automate

the FMEA process through pre-defined

templates and workflows. These standardized

workflows guide users through the FMEA

steps, ensuring consistency and efficiency

in the analysis. Automated workflows also

facilitate data collection, analysis, and

documentation, reducing manual effort and

the likelihood of errors. By streamlining the

FMEA process, organizations can save time

and resources, allowing for a more thorough

and effective risk assessment.

3.3. Integration with Design and Simulation

Tools

PLM systems should seamlessly integrate

with design and simulation tools to enable

the efficient transfer of information between

FMEA and product development activities.

Integration with design tools allows engineers

to identify potential failure modes early in the

design phase. By simulating various scenarios

and evaluating the effects of potential failures,

engineers can make informed design decisions

and implement necessary modifications

to mitigate risks. This integration ensures

a proactive approach to risk management,

minimizing the likelihood of failures during

the product’s operational life.

3.4. Risk Priority Number (RPN)

Calculation

PLM systems can automatically calculate

the Risk Priority Number (RPN) based on

severity, occurrence, and detectability

ratings assigned to failure modes. RPN is

a quantitative measure used to prioritize

corrective actions by focusing on high-risk

failure modes. By assigning numerical values

to severity, occurrence, and detectability,

organizations can prioritize their resources

effectively and address critical failure modes

with the utmost urgency. Automating the RPN

calculation within PLM systems streamlines

the prioritization process, ensuring that the

most significant risks receive immediate

attention.

4. Benefits of FMEA Management in PLM

Systems

Integrating FMEA management into

PLM systems offers several benefits for

organizations:

1. Early Risk Identification: Conducting

FMEA within PLM systems helps identify

potential failure modes at the earliest stages

of product development. By proactively

addressing these risks, organizations can

implement appropriate corrective actions

to minimize the likelihood of failures during


Article

the product’s operational life. Early risk

identification leads to improved product

reliability, reducing the chances of customer

dissatisfaction, warranty claims, and costly

product recalls.

2. Enhanced Collaboration: PLM systems

provide a collaborative environment,

enabling cross-functional teams to work

together seamlessly on FMEA activities. By

involving experts from various departments,

organizations can leverage diverse

perspectives and knowledge, ensuring a

comprehensive and accurate risk assessment.

Enhanced collaboration fosters effective

communication, facilitates knowledge sharing,

and promotes a shared understanding of risks

and mitigation strategies.

3. Improved Product Reliability: The

systematic analysis of failure modes and the

implementation of appropriate corrective

actions result in enhanced product reliability.

By addressing potential failure modes early

in the development cycle, organizations can

ensure that products meet the required quality

standards. Improved product reliability leads

to higher customer satisfaction, increased

brand loyalty, and a competitive advantage in

the marketplace.

4. Cost Reduction: Effective FMEA

management within PLM systems minimizes

the occurrence of failures and the need

for costly corrective actions or recalls. By

identifying potential failure modes during the

product development stage, organizations

can implement preventive measures and

design modifications to mitigate risks. This

proactive approach reduces costs associated

with warranty claims, customer complaints,

product recalls, and reputational damage.

corrective actions, and enhance overall

product performance. Investing in FMEA

management within PLM systems enables

organizations to proactively address risks,

reduce costs, and gain a competitive edge

in today’s dynamic market landscape. By

continuously improving product reliability

and quality, organizations can build a strong

brand reputation and achieve long-term

success.

References

- AIAG. (2019). Potential Failure

Mode and Effects Analysis (FMEA) (4th ed.).

Southfield, MI: Automotive Industry Action

Group.

- Jia, R., Xie, X., & Chen, X. (2017).

Integrated FMEA and PLM approach for risk

management in product design. Journal of

Engineering Design, 28(10-12), 672-696

- Kostoulas, N., & Chryssolouris, A.

(2020). FMEA integration in PLM systems

for quality management. CIRP Journal of

Manufacturing Science and Technology, 13(1),

9-20.

- Siemens Digital Industries Software.

(n.d.). PLM and FMEA. Retrieved June 14,

2023, from https://www.plm.automation.

siemens.com/global/en/our-story/what-isplm/what-is-fmea/

5. Conclusion

Integrating FMEA management into PLM

systems is a strategic approach to enhance

product reliability, improve quality, and

ensure customer satisfaction. By leveraging

cross-functional collaboration, automated

workflows, and integration with design and

simulation tools, organizations can identify

potential failure modes early, prioritize


- VDA-QMC. (2019). FMEA Handbook:

Methodical Implementation and Continuous

Improvement (1st ed.). Frankfurt: Verband

der Automobilindustrie.

- Vose Software. (n.d.). Introduction

to FMEA. Retrieved June 14, 2023, from

https://www.vosesoftware.com/riskwiki/

FailureModeandEffectAnalysisFMEA.php

Article


Article

Integrating PLM and

ALM Using Teamcenter-

Polarion: Levels and

Benefits

Batuhan ÇOPUR1,3, Alican Yılmaz4, Prof.Dr.Semih ÖTLEŞ1,2

1Product Lifecycle Management M.Sc. Programme, Institute of Science, Ege

University 2Excellence Center for PLM, Ege University

3TEI, TUSAŞ Engine Industries, Inc. 4Director, Beemobs (Bee Mobility Solutions)

Otomotiv Sanayi ve Ticaret A.Ş.

Abstract: The integration of Product Lifecycle Management (PLM) and Application Lifecycle

Management (ALM) systems has emerged as a strategic initiative for organizations seeking

to bridge the gap between product development and software development lifecycles. This

article explores the various integration levels of PLM-ALM integration and the benefits

they offer. Starting with basic data exchange, the integration progresses to process

synchronization, workflow automation, and ultimately traceability and analytics. At each

level, organizations experience improved collaboration, reduced duplication of efforts,

streamlined workflows, increased efficiency, enhanced visibility, and better decision-making.

By integrating PLM and ALM systems, organizations can achieve a holistic view of their

product development process, eliminate silos, and drive efficiency and innovation throughout

the entire lifecycle.

Key Words: PLM, ALM, Teamcenter, Polarion, Integration

1. Introduction

In today’s competitive business landscape, organizations

face challenges in managing the complexities of both

physical product lifecycles and software development

lifecycles separately. The integration of Product

Lifecycle Management (PLM) and Application Lifecycle

Management (ALM) systems offers a solution to this

problem.

PLM focuses on the lifecycle of physical products, while

ALM addresses software development. Integrating

PLM and ALM using the Teamcenter and Polarion

tools provides a unified solution, enabling improved

collaboration, streamlined workflows, and better

decision-making. This integration progresses beyond

data exchange, encompassing process synchronization,

workflow automation, and traceability and analytics,


resulting in benefits such as efficiency gains, reduced

duplication of efforts, enhanced visibility, and improved

product quality.

2. Product Lifecycle Management

Product Lifecycle Management (PLM) is the business

activity of managing, in the most effective way, a

company’s products all the way across their lifecycles;

from the very first idea for a product all the way through

until it is retired and disposed of. PLM is the management

system for a company’s products.

At the highest level, the objective of PLM is to increase

product revenues, reduce product-related costs,

maximize the value of the product portfolio, and

maximize the value of current and future products for

both customers and shareholders. The typical 5 phases

of PLM are explained below;

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3. Application Lifecycle Management

ALM can be thought of as PLM for software.

Similarly, to Product Lifecycle Management,

ALM encompasses the entire lifecycle,

from requirements management, through

development, testing, maintenance, all the way

to the release and maintenance of software

products. Project management, integrated

data management and collaboration are parts

of any ALM solution.

ALM systems are used to create, deploy, and

operate software over its lifecycle. There are

many different ALM systems on the market.

Different systems have different functionality.

This may address areas such as requirements

management, development, architecture,

testing, quality assurance, maintenance,

coding, variant management, change

management, project management and

release management. The typical 8 phases of

ALM are explained below;

4. ALM and PLM Similarities and

Differences

In order to get a better understanding on

why the product lifecycle management and

software application lifecycle management


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• Figure 1: Lifecycle model of PLM and ALM


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• Figure 2: ALM – PLM integration in a typical product development process

processes cannot be managed in a single

tool, we must explain the differences and

similarities.

5.ALM – PLM Integration in Product

Development

When initiating the mechatronic product development

process, the first phase of the lifecycle involves defining

the product requirements. During this phase, the toplevel

system requirements are established and analyzed.

Subsequently, these high-level requirements are further

refined into domain-specific, low-level requirements.

Once this phase is completed, the development of

hardware, software, and mechanical designs commences

simultaneously.

Upon the completion of the design phase, the hardware,

software, and mechanical designs undergo simulation and

verification processes. Following successful simulation

verifications, the hardware, software, and mechanical

units are manufactured and individually tested.

2. Change and propagate

3. Act and communicate

4. Align and unify

5. Collaborate and report

Level 1: Link and trace

“Link” is the capability of creating a physical or logical

relationship between ALM and PLM data assets. “Trace”

is the ability to automatically navigate this relationship.

It is important to mention that using the same part

number in disparate ALM and PLM solutions and then

searching for it in both environments does not constitute

automated navigation of the logical link.

Once the unit tests are finalized and validated, the

integration of the hardware, software, and mechanical

units takes place, initiating system-level testing.

During the system-level testing, any identified defects

are documented, and necessary design revisions or

improvements are implemented.

6. Five levels of ALM-PLM Integration

There are five main levels of ALM-PLM integration;

1. Link and trace

• Link a product test case to a software test case.

• Find all software test cases connected to a

product test case.


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• Link a product defect to a software defect

• Find the product component(s) impacted by a

software defect.

Level 2: Change and Propagate

At this level companies manage the impact of changes.

Changes happen and companies need to ensure that they

are properly managed. Typical questions answered at this

level are related to the ability to assess the downstream

impact of any change in design on the development and

production chain, and vice versa, as well as to determine

the related hardware or software components involved

in a product issue or failure.

• Change a product test case and propagate the

change to the software test cases.

• Change a product requirement and propagate

the change to the impacted software user stories.

• Fix a software bug and update the product Bill

of Materials (BOM).

Level 4: Align and Unify

Level 4 addresses the need of aligning product versions,

configurations and variants to software versions,

configurations and variants. In complex product

development, a product is segmented into different

versions. Each version can be produced as different

variants or configurations allowed by all the possible

combinations of options. Software concepts like releases,

branches, baselines and parameters must be aligned to

product-specific variants, configurations and versions.

Such alignment of concepts allows the unification of

hardware and software parts into unique configurations.

• Find the software source code running on a

specific product version or variant.

• Find the software variants that can be installed

on a product.

• Navigate the full BOM (with product and software

artifacts) in the context of a product configuration,

without leaving the PLM environment.

Level 3: Act and Communicate

After data is available in both environments, connected

and traceable, and change can be governed, companies

must be able to orchestrate the different activities in

product and software development. In other words, at

this level companies achieve the integration of processes.

Examples of this integration include task assignment,

progress control and project management scenarios.

• Change the status of a software change request

into “analyze” when a product change request gets into

the “evaluate” state.

• Automatically create a product defect when a

software bug is discovered.

• Assign a test run task to a software tester when

a new product test round begins.

Level 5: Collaborate and Report

At this level, software and product engineers are able

to collaborate (joining their skills in creating a solution);

the toolset embeds the process knowledge; and process

improvements happen by means of reconfiguring the tool

instead of changing the habits of people. The alignment

of concepts and the unification of the UX at this level

are complete. Users access every software and product

artifact through the same user interface.

Process improvements are driven by analytical

dashboards that, besides providing status reports on

projects, allow the identification of process bottlenecks,

shortfalls, etc.

• Define and monitor unified product and

software key performance indicators (KPIs).

• Co-engineer a product.


• Implement and measure product and software

process improvements.

• Software and hardware engineers are part of

the same Scrum team.

7. Conclusion

In conclusion, integrating PLM and ALM

using the Teamcenter-Polarion tools offers significant

benefits. While many companies are currently using

or implementing PLM systems, the majority of the

industry lags behind in adopting ALM systems. To

remain competitive, organizations must recognize the

importance of managing software within a separate

lifecycle environment. By embracing the integration

of PLM and ALM, organizations can enhance their

competitiveness and effectively manage both physical

product development and software engineering

processes.

References

Bayram, G. 2022. “PLM – ALM Integration for Original

Aviation Propulsion Systems”. Applied Propulsion System

Design Engineering in Aviation and Space Technologies,

Article

Gebze Technical University M.Sc. Programme.

Deuter, A., Rizzo, S. 2016. “A critical view on PLM/ALM

convergence in practice and research.” 3rd International

Conference on System-integrated Intelligence: New

Challenges for Product and. Elsevier. 405 – 412.

Stark, J. 2011. “Product Lifecycle Management: 21st

Century Paradigm for Product Realization (Decision

Engineering)” Springer.

“Improving product and software development by

integrating ALM and PLM” A white paper issued by:

Siemens PLM Software. https://www.plm.automation.

siemens.com/media/global/de/Siemens-PLM-Polarion-

Improving-product-and-software-development-byintegrating-ALM-and-PLM-wp-55667-A9_tcm53-53421.

pdf

“Why ALM and PLM need each other” A white paper

issued by: Siemens PLM Software.

https://polarion.plm.automation.siemens.com/

resources/download/why-alm-and-plm-need-eachother-whitepaper


Article

BASIC PRINCIPLES OF PRODUCT

DESIGN IN RELIABILITY

METHOD

Hakan Atamil (b,c), Prof.Dr.Semih Ötleş (a,b)

a) Ege University, PLM Excellence Center

b) Ege University, PLM MSc Programme

c) Plant Manager-PI Oluklu Mukavva Kutu Sanayi

Basic Principles

Reliability, among many other product

qualities, is often attributed particular value

in customer surveys [1] p. 2. The guarantee

of adequate product reliability is therefore

a key factor for business success. To achieve

this in these times of reduced development

cycles yet increasingly exacting product

requirements, new approaches are necessary.

In addition to traditionally important

experimental tests to demonstrate reliability,

targeted design for reliability, combined with

an arithmetical prediction of reliability and

optimization, are increasingly at the center

of development activities. This is reflected

in the frontloading strategy, which requires

work on reliability to be shifted to an earlier

phase of product development, in order to

reduce overall expenditure.

Furthermore, high customer expectations

and global trends such as miniaturization,

growing complexity and reduced weight, for

example, are leading to greater performance

densities and so to declining reliability

reserves. This situation can often only be

offset by employing more appropriate and

accurate methods.

This volume is addressed to associates

whose work involves design for reliability,

verification and validation. It presents

important methods that satisfy the

requirements described above. The content

should be read in conjunction with the BES

Practice Description “Design for Reliability”

[2], in which the basic principles of design for

reliability are explained in more detail.

Definition of Terms

Reliability is one of the most important product

characteristics and is therefore an aspect and integral

component of quality. For its part, reliability exerts an

influence on further quality features, such as safety. The

visual demarcations of the terms quality, reliability and

safety are illustrated in Fig. 1.

Fig. 1: Quality, reliability and safety


According to [3], reliability is an umbrella term that

describes availability and its influencing factors

performance reliability, maintainability and maintenance

support.

In order to take account of the broad use of these

terms, the hierarchical demarcations illustrated in Fig.

2 and based on the system shown in [4] are employed

in [2] and in the present volume. Dependability can

therefore be regarded as an umbrella term for reliability,

availability, safety and security, all of which make up

the attributes of dependability. This volume focuses on

design for reliability for design elements and systems.

Here, a “design element” denotes the smallest selfcontained

component that can fulfill one or more

functions (Glossary BES-PE 3-2009/11). It may consist of

one or several components.

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stress time can be expressed as safety versus failure. The

above terms are graphically illustrated in Fig. 3.

Fig. 3: Relationship between useful time, stress time and lifetime

For the sake of simplicity, hereinafter the words “time”

or “duration” are used to represent all possible, damage

mechanism-specific lifetime characteristics such as time

(hours, months, years), travel, distance covered, mileage,

cutting length of a tool, number of load cycles, actuations,

switching operations, work cycles, revolutions, etc.

Design for reliability is a discipline in engineering science,

which applies scientific findings to ensure that the design

of the product possesses the product characteristic

“reliability”. This also includes incorporating the ability

to maintain, test and support the product over the entire

life cycle.

Fig. 2: Dependability and reliability

According to [2], reliability is the ability of the product to

perform a required function in the predefined operating

range over a defined useful time.

This useful time is divided into operating time and

idle time. The operating time is the time during which

the unit is functioning in accordance with its intended

purpose. During idle time, on the other hand, the unit is

not in operation.

The stress time is the time during which a damage

mechanism (processes that lead to a gradual change

in a unit’s properties due to load) is acting on the unit.

It generally consists of parts of the operating time and

idle time, operating time does not necessarily concur

with the stress time: for example, certain electronic

components in a parked vehicle are still under stress or

exposed to corrosion.

Lifetime is the time during which a unit can be exposed

without interruption to a damage mechanism until

failure. In general, developers endeavor to achieve

a sufficiently long lifetime in terms of the stress time;

the correlation to useful time or operating time, on the

other hand, is not crucial. The ratio between lifetime and

Where reliability is concerned, different objects can be

examined:

• Mechanical and electrical/electronic hardware,

• Software,

• People,

• Systems composed of the above units, and

• Services.

This volume deals primarily with the reliability of design

elements consisting of mechanical and electrical/

electronic hardware in terms of durability, and the

system reliability derived from these design elements,

see Fig. 2.

Causes of Component Failure

Local and Global Approaches

Fig. 4: Global (left) and local (right) reliability assessment concepts


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Ostensibly, component failure occurs when a load exceeds

the amount of load that can be withstood (load capacity)

by the component. However, this statement is not really

helpful, because it expresses the reasons for failure in a

very superficial way and does not contribute to a deeper

understanding of the causes of failure. Furthermore, we

can soon observe that certain components may fail while

others do not, under the same load. The cause of failure

cannot therefore be found in load alone. Concepts that

explain the failure of a component by comparing load

and load capacity are referred to as global or load-based

concepts.

A more in-depth method of observation starts with the

premise that the external load at each location on the

component generates a (locally variable) stress. Failure

then occurs when the local stress exceeds the amount

of stress that can be withstood at the location of failure

(strength). Both stress and strength are dependent upon

the nature of the load, as different types of load can

give rise to different damage mechanisms, which are

characterized by different parameters.

Concepts that are based on the local comparison of

stress and strength are referred to as local concepts.

EXAMPLE:

Let’s take a look at a stepped bar with a fillet radius of R0,

which is subjected to quasi-static load from an external

force L0, Fig. 4.

In order to ascertain the safety of a component with

respect to brittle facture by the help of a global concept,

component experiments must be performed under

different forces L, and the force L0* determined at which

failure first occurs. This force represents the global load

capacity. The quotient L0*/L0 constitutes a measure of

the safety of the component in terms of failure.

The results cannot simply be transferred to other

components, however: the complete component

experiments must be repeated for a different bar with a

fillet radius of R1, in order to ascertain its load capacity

L1*. Moreover, statements about safety cannot be made

before a component is available.

For reliability assessments using a local concept, first

of all we have to find a local variable that characterizes

stress as a result of the external force. In this example,

this would be mechanical stress. Assuming a linear

elastic characteristic, this stress can simply be calculated

at the notch root (the point of the highest stress) as s0

= c(R0)L0 from the force L0, whereby the transfer factor

c(R0) depends on the fillet radius but not on the load.

The variable s0 represents the stress.

Likewise, a local quantity can be derived that

characterizes load capacity: s0* = c(R0)L0*, this being

strength. The quotient s0*/s0 constitutes a local measure

of component safety versus failure. This procedure has

clear advantages: for assessing a design alternative, e.g.

a bar with a fillet radius R1, it would not be necessary to

conduct further experiments, but simply to recalculate

c(R1), as s1*/s1 = s0*/(c(R1)L0).

At this point we have simplified the process by assuming

that s1*= s0*, i.e. all bars have the same local strength,

which therefore represents a real material parameter.

This does not necessarily have to apply to all damage

mechanisms, however; the fundamental laws defining

the dependence of strength on various influences have

to be known. This is a key element of a local assessment

concept.

The above example clearly illustrates the advantages

and disadvantages of the two assessment concepts. So,

for load-based (global) concepts:

• The advantage is high accuracy, as all

experimentally determined variables were ascertained

on the component itself.

• On the other hand, transferability to other

components cannot simply be assumed, and relatively

little can be learned about the causes of failure. What

is more, conducting the component experiment with

complex load is often difficult or impossible, or too

expensive.

As for local concepts, on the other hand:

• Their advantage is their suitability for use in

earlier stages of the product creation process, or where

component experiments are difficult, too expensive or

unfeasible. In addition, they can be used to build up a

deeper understanding of the causes of failure.

• As a disadvantage of local concepts, insufficient

accuracy can sometimes be mentioned. Furthermore, a

lot of expertise has to go into the assessment concept.

As is often the case, the solution here is to use a

combination of both approaches: the strength that is to

be employed with a local concept must be determined

in an experiment, if possible on the component. This

approach covers all influences that may not explicitly be

included in an assessment concept due to insufficient

knowledge.

Damage Characteristic, S/N Diagram

The deliberations above always focused on the level of

load/load capacity or the local variables stress/strength.


This only result in a meaningful procedure if a load is

applied that either immediately leads to failure or can

be withstood for an infinitely long time. Such cases are

seldom of any practical meaning, particularly in the

context of examining reliability.

Failure often does not occur immediately, even under

constant or periodic load, but only after a certain duration,

Fig. 5. Examples are metal creep at temperatures above

40 % of the melting temperature, or crack propagation

in brittle materials. This model assumes that the load

provokes a certain damage that increases over time

(and possibly depending on location), which may lead

to failure. This must be characterized by a damage

parameter that conforms to the physical laws of the local

processes taking place.

Thus, the load is a two-dimensional quantity; it

features both a (possibly variable) level, and a duration.

Consequently, when stating the level of load the

duration of load must also be mentioned, and if the level

is variable the complete load-time curve (often referred

to as a load-time series) must be indicated.

Fig. 6: Lifetime points in an S/N diagram.

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It is extremely important to clearly differentiate the S/

N diagram from an illustration of damage over time by

means of a damage parameter. The latter is crucial for

visualizing and understanding the physical processes at

work. In practical reliability assessments, however, it is

the Wöhler representation of lifetime points that plays a

key role. This is also because knowledge of the nature of

a damage parameter and the concrete course of damage

over time is not necessarily available for every damage

mechanism.

The S/N diagram does not illustrate a time series, but

rather a boundary between the zones “unit under

observation intact” (bottom left) and “unit under

observation failed” (top right). Both the “in load

direction”, for a constant lifetime feature, and the “in

lifetime direction”, at a constant load or stress, can be

examined.

Distributed Characteristics, Failure Probability

Fig. 5: Delayed fracture as a result of progressive damage. Left: Metal

creep under constant load (damage parameter elongation e). Right: Crack

propagation (damage parameter crack length a). t* indicates the lifetime.

Different lifetimes can be achieved with different load

levels. To put it simply, the information about the

dependence of lifetime on the load level, particularly

where load is uniform, can only be illustrated in a t-L

diagram by means of corresponding lifetime points (t*,

L0), whereby the nature of the load must be described

by other means (e.g. constant, uniform, cyclic with

zero underload, etc.). The lifetime points can also be

connected via a curve (assuming continuous behavior),

to illustrate the dependence of lifetime on the load level,

Fig. 6. This dependence is often described by means of

a power function, which appears in logarithmic form as

a straight line. Under uniform cyclic loading, this type of

representation is traditionally referred to as a Wöhler

curve (or S/N diagram).

As already mentioned above, a concrete component fails

if its load exceeds its load capacity, or its local stress at

the location of failure exceeds its strength.

If we now conduct a series of experiments with several

components under the same load, different lifetimes will

result, despite the same test conditions and (nominally)

identical components. Lifetime is therefore a statistically

distributed, not a deterministic, quantity. What this

means is that due to randomly fluctuating material and

manufacturing conditions, the lifetime of a component

cannot be exactly predicted. The same frequently applies

to its load, as a result of fluctuating conditions of use.

As the local variables stress and strength are derived

from global load and load capacity, these are also

distributed variables. They are characterized by their

statistical distribution. Details on distributions and their

characteristic values can be found in section 6.1.3 of the

Annex. The fact that lifetime is a distributed variable is

sometimes implied symbolically by entering a distribution


Article

density function above the lifetime points, Fig. 7.

In the field of quality assurance, in particular, it is

common to express the failure characteristic by means

of the failure rate A:

(2.2)

Fig. 7: Distributed lifetime. The points indicate the variable lifetime ti* of

the i-th, nominally identical part at a constant load quantity L0 (top). Failure

probability F dependent on the lifetime characteristic t (bottom).

The distributed characteristics approach opens up an

entirely new perspective regarding the question as to

why components fail: as neither the exact stress nor

the exact strength of a concrete component is known in

advance (but can only possibly be recorded or measured

afterwards), the question as to whether a concrete

component will fail will not be answered deterministically.

In response to this question, we can only state a failure

probability. In other words, we can only determine what

proportion, from the population of all components, can

fail, but not whether a particular component will fail.

As a rule, tq* (also occasionally known in the literature as

Bq) signifies the lifetime until which the proportion q of a

population of products has failed. Common values for q

are e.g. 10 %, 2 % or 1 %. Expressed mathematically, tq* is

the q-quantile of distribution. t10*, for example, denotes

the lifetime up to which 10% of products of a population

have failed. The median of the distribution is the 50%

quantile t50*. Where generally skewed distributions

are concerned, the median differs from the mean, also

known as MTTF (mean time to failure); in most cases,

however, a relationship can be illustrated between two

variables. tq* can be determined easily with the aid of

the failure probability curve F(t) (possibly as a straight

line in a suitable probability paper). To this aim, the point

where the q%- horizontal intersects with the failure

probability curve is determined and the associated

lifetime characteristic read on the t-axis, Fig. 7.

Reliability is described as the survival probability R(t),

which can be determined from the failure probability:

R (t) = 1 - F (t). (2.1)

Failure Characteristic Over Time, Failure Rate and

“Bathtub Curve”

Fig. 8: Failure rate and “bathtub curve” according to [1]

whereby f(t) signifies the failure probability density

function and R(t) denotes the survival probability at the

time t, Fig. 8. The failure rate at a particular point in time

can be estimated empirically, by dividing the number

of failures per time unit by the sum of not-yet-failed

components. This estimation is known as the failure

quota.

The failure rate can be interpreted as a measure of the

probability that a component will fail, if it has not failed up

to this point in time, [1] p. 23. The failure rate is a relative

quantity: the failures are divided by the number of still

intact units. Furthermore, the rate is a time-referenced

quantity, as the name suggests: the failures are stated

per time unit (period, year, hour, etc.). Consequently, the

statement “X-ppm” is not a failure rate.

The failure rate curve over the duration of service

of components has a characteristic shape. Due to its

similarity to the image of a longitudinal section through

a bathtub, it has the name “bathtub curve”. This curve

generally has three segments, although not every

component portrays this typical behavior:

• Segment I shows a falling failure rate and

is typical of early failures due to manufacturing and

assembly errors. An early failure characteristic means

that the probability of failure in the next time segment is

high at the start of stress, and declines over time. These

failures can typically be averted by quality controls or

experiments on a pilot series.

• Segment II shows a constant failure rate, which

is typical for random failures due to operator error or

contamination, for example. Here, the probability of

failure in the following time segment does not depend

on the product’s previous history. The same proportion

of the products still intact at the beginning of each time

segment always fails within time intervals of the same

length. Electronic components may demonstrate this

characteristic, due to cosmic radiation, for example. In

this case, failures can be avoided by correct usage.

• Segment III features a rising failure rate and is

typical of degradation, wear and fatigue. In this area,

it becomes increasingly probable that an as-yet intact

product will fail within the following time segment.

(Premature) failures in this area can only be avoided by

the correct design.


The failure rate must not be equated with the absolute

number of failures, as shown by the following two

examples.

EXAMPLE:

A manufacturer has produced 100 units and records

the following failure numbers in the following 4 time

periods:

Article

As part of product development, endeavors are made to

increase the reliability of a product systematically, i.e. to

avoid early failures as far as possible (quality assurance),

to widen the range of “random failures” (usage period;

useful time) and to delay the beginning of wear and

aging failures as far as necessary, Fig. 9. The failure

characteristic of products is investigated in lifetime tests

accompanying the development process. These are

evaluated by applying Weibull’s theory.

Do you think the failure rate here is falling, constant or

rising?

The failure quota can be used as the basis for estimating

the failure rate. The table below shows that despite

falling failure numbers, the failure quota remains roughly

constant. This effect is due to the fact that the total

number of still intact units falls over time.

Fig. 9: Improving reliability during the course of product development

(schematic)

EXAMPLE:

A manufacturer produces 100 units per period over

4 time periods and then records the following failure

numbers:

Do you think the failure rate here is falling, constant or

rising?

Again, the failure quota is used as the basis for estimating

the failure rate. The following table shows that despite

rising failure numbers, the failure quota remains roughly

constant. This effect is due to the fact that the total

number of intact units rises over time, because newly

produced units are constantly being added.

The failure rates of numerous electronic standard

components are listed in Failure Rate Catalogs, e.g.

Military handbook 217 on predicting the reliability of

electronic components [5]. Starting with the basic,

temperature-dependent failure rates of components

stated therein, failure rates for concrete usage conditions

can be calculated, if simple models are assumed and

load factors are taken into consideration. The load

factors cover mechanical, climatic and electrical stress,

for example.

However, measured and predicted values of reliability

of electronic components (calculated on the basis of

various manuals) may differ by a factor of up to 100.

The calculation methods mentioned must therefore be

critically examined:

• One of the principal problems is that the data

employed for the assessment is old. The manuals are not

always updated regularly (the most recent issue of [5] is

from 1995, for example), so that the information they

contain do not conform to today’s state of the art.

• Secondly, vital predictors such as temperature

change, temperature gradient, shock, vibration, switchon/off

processes, manufacturing quality and aging

cannot be predicted, or not realistically.

• One key objection arises from the fact that

these calculation models always operate with constant


Article

failure rates and can therefore only apply to random

failures (zone II of the bathtub curve). This is because

in this case, calculating the system failure rate from

the failure rates of the individual elements is especially

simple, see section 3.4.5. In the electronic components

of today, however, degradation plays an important role.

Degradation leads to rising failure rates and cannot be

covered using models such as exponential distribution,

which assume constant failure rates.

For the reasons described above, quantitative analysis of

the reliability of electronic components based on manuals

should be employed with caution and understanding.

FIT (Failures In Time) is a unit of measurement showing

the failure rates of electronic components in the area of

random failures, λ = constant:

(2.3)

EXAMPLE:

If 7 out of 500 components fail within an operating time

of one year, the failure rate is

which is synonymous with X = 1598 FIT.

Conversely, the expected number of failures can be calculated

from a known failure rate (e.g. from a tabular value). If 2000

components complete a 1200-hours test with the failure rate

stated above, approximately 2000.1200h .1598 .10-9h-1≈4

failures can be expected.

References

[1] B. Bertsche, G. Lechner: Zuverlassigkeit im

Fahrzeug- und Maschinenbau, 3rd Edition, Springer,

2004

[2] Bosch Product Engineering System:

Committed BES Practice Zuverlassigkeitsgestaltung von

Designelementen, 2010

[3] Standard IEC 60050-191: International

Electrotechnical Vocabulary, Chapter 191: Dependability

and quality of service, 1990

[4] J. C. Laprie (ed.): Dependability: Basic Concepts

and Terminology. In: Dependable Computing and Fault-

Tolerant Systems, Vol. 5, Springer, 1992

[5] MIL-HDBK-217F (Notice 2): Reliability Prediction

of Electronic Equipment, U.S. Department of Defense,

1995


4 rd - INDUSTRY 4.0 SUMMIT

Date: Decembeer - 2023

Location: Istanbul / Turkey

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İndustry

Increasing Productivity

with Drive Intelligence

• Even more flexibility for automation systems: In

the servo drives of the new b maXX 6000 range,

the driveintegrated control unit b maXX PLC di

(“drive-integrated”) handles scalable control

tasks up to high-performant synchronous multiaxis

applications

• Baumüller will be presenting an entirely new automation system at the SPS

2023

This year, SPS is focusing on the megatrend of

automation: productivity, sustainability, and connectivity.

Baumüller is launching numerous new products that

engage with these trends.

On November 14–16, 2023, in Hall 1 at Stand 560 of

the Nuremberg trade fair grounds, the Nuremberg

automation specialist will exhibit an entirely new runtime

system for PLCs, the servo converter range b maXX 6000

including drive-integrated performant control unit b

maXX PLC di and the new DSC2 generation of motors.

New tools for smart energy monitoring in the drive, along

with new ways to model mechanics for drive simulation,

are likewise increasing performance along all steps of

the machine manufacturing value chain. One of the

fastest drive-integrated PLCs on the market Even more

flexibility for automation systems: In the servo drives of

the new b maXX 6000 range, the drive-integrated control

unit b maXX PLC di (“drive-integrated”) handles scalable

control tasks up to high-performant synchronous multiaxis

applications. This reduces the demand on, minimizes,

and accordingly replaces central process loop control,

since the PLC di can also be used as EtherCAT Master to

control additional servo converters. With minimal field

bus cycle times of up to 250 μs, the integrated control

unit is one of the fastest driveintegrated

PLCs on the market.

Through digital inputs, the b maXX PLC di reacts in real

time to important events such as touch probes. The

advantage: The control unit works with greater efficiency

and safety, in particular in environments requiring fast

response times.

In addition, the drive-integrated PLC also allows the

implementation of smart applications in addition to

movement control. The extremely fast interface between

PLC di and servocontroller (local axis) provides access

to drive parameters such as voltage, current, power,

torque, revolutions per minute, and position. Using their

own control algorithms and IoT functionalities, engine

manufacturers can thus offer their clients added value

Completely new IoT solutions become possible using

the analog high-speed inputs (no additional hardware

required, minimum scanning time 1 μs). For example, a


mechanical vibration sensor can be attached directly, so

as to perform a vibration analysis directly in the drive

system PLC. This excellent connectivity enables the

design of highly flexible and modular structures through

interfaces such as OPC, UA, MQTT, EtherCAT, and

Ethernet. The b maXX PLC di is thus ideally set up for

future requirements regarding automation or the

Internet of Things.

Faster engineering, greater performance When it comes

to control technology, Baumüller relies on open systems

and simplified engineering: With the new runtime

environment IEC 61131, developed entirely in-house,

Baumüller offers a platform that supports current

standards such as high-level programming languages

and IoT connectivity. This ensures that Baumüller will

continue to be able to react flexibly to client requirements

in the future.

İndustry

is available. For the hardware, the signal bus, service

option, digital and analog I/Os, and brake connection

can be selected, among other things. With regard to

safety, different variations are available, from the simple

hardware-controlled STO (Safe Torque-Off) through to

higher safety functions actuated via FSoE (FailSafe over

EtherCAT), all of which comply with the highest safety

level.

Baumüller is also setting new standards for device

dimensions: In addition to the space-saving side-by-side

system (b maXX 6300), the mono units (b maXX 6500)

are also significantly more compact. The installation

volume is thus greatly reduced, enabling even smaller

control cabinets. But the servo can do a lot more: the

drive can be used as a sensor/sensor hub and provides

scalable IoT connectivity, for example as a cloud link

through edge computing.

The runtime system is based on Linux and allows the coding

of PLC programs using objectoriented programming.

This makes it possible to build modular, reusable and

clearly structured programs. Such programs not only

reduce developer workloads in project implementation,

but also increase flexibility. Existing templates, machine

modules, and libraries following the PLCopen standard

can still be used.

High-level programming languages such as C++ are

likewise integrated into the platform. The advantage:

System expansion after the fact and cross-platform use

are simpler than ever before. This improves development

efficiency, reduces time-to-market, and increases the

flexibility of the overall system.

The new runtime system is available for the driveintegrated

b maXX PLC di from launch. It will also be made

available later for Baumüller’s other control platforms.

Boost your performance, reduce your footprint

The new b maXX 6000 servo controller generation stands

for more performance and maximum scalability. The

increase in performance is achieved for example through

newly developed safety functionalities which were

devised specifically for applications requiring especially

dynamic and precise handling. In the new servocontrollers,

the safety module is integrated directly into

the device. This allows safety-relevant encoder signals to

be analyzed at an even higher resolution. That way, speed

and position precision can once again be significantly

improved, helping reduce machine cycle times.

Numerous hardware and software options ensure

maximum scalability, so that drives can be even better

adapted to the requirements of the specific application.

A large number of encoder, hardware, and safety options

• Even more flexibility for automation systems: In

the servo drives of the new b maXX 6000 range,

the driveintegrated control unit b maXX PLC di

(“drive-integrated”) handles scalable control

tasks up to high-performant synchronous multiaxis

applications

Even more performance, even smaller space

The new DSC2 servo motors are the next generation for

applications requiring high torque densities. Their low

weight and small dimensions make them the series of

choice. One of the reductions was in installed length,

making the DSC2 significantly more compact while

maintaining the same performance.

Machine - Automation Electricity / World News 2023 45

İndustry

Like the DSC1 product family before them, the DSC2

motors are scalable and easy to adapt to specific

requirements. The numerous encoder and cooling

options, optional break, various compatible gear variants

and many additional options ensure that the DSC2, as

well, can be matched perfectly with its individual area

of application.

Increasing productivity and enabling new business

models through smart drive solutions

Condition monitoring solutions allow operators to keep

track of the condition of many machines on a regular

basis. For example, wear on motors can be identified

early, preventing potential machine downtimes. However,

if this function is performed via sensor, it can quickly get

very complicated and costly, depending on the type of

machine and the number of motors used, such as in a

textile machine.

The new Smart Vibration Monitoring software solution

allows machine manufacturers to offer their clients

condition monitoring without external sensors. The

software is directly integrated in the servo-controller

using softdrivePLC, making it easy to retrofit and update.

Machine manufacturers thus have new options, such

as offering runtime models for additional machine

functions.

The new function uses previously recorded and analyzed

process parameters as reference values for monitoring

the mechanics, such as the electric motor, fan, or

hydraulic pump. The software detects vibrations, such

as those created by imbalance or improper alignment,

early on and sends an error signal. This allows planned

maintenance to be carried out on the motor, preventing

further damage to or failure of the machine.

Determining and reducing the product carbon footprintIn

times of rising energy costs, solutions are in demand

that can help determine energy consumption and then

reduce it in a targeted way. With its new Smart Energy

Monitoring software function, Baumüller now presents a

solution for the intelligent energy monitoring of machines

and systems. The software transparently measures

energy use/consumption of individual production steps

and then optimizes energy use based on a reference

measurement. This last also serves as an initial value

for detecting energy changes in the production process.

Warning and error thresholds can then be set on the

basis of these values.

The software is loaded directly onto the servo-controller.

This makes it easy to retrofit and update, allowing the

machine manufacturer to market it as an additional

function. Energy consumption is recorded directly via

the intelligent drive. This saves additional costs for

unnecessary external sensors and reduces the amount

of wiring required.

The new function supports determining energy use/

consumption both overall and for each individual axis

of the drive system per cycle. The energy measurement

is performed autonomously and in real time in the

Baumüller b maXX servo converters. Measurement and

results can be easily displayed through machine

visualization or on the dashboard displays of open IoT

interfaces for alternative devices, such as OPC and UA.

Optimized engineering and increased productivity

thanks to a digital twin

Baumüller offers a wide variety of controller and

mechanics models for virtual commissioning. The

advantage: Using the engineering tool ProSimulation,

the machine manufacturer can determine the ideal drive

system and ideal operating site. In particular for more

complex nonlinear processes, the tool simulates different

movement profiles in order to find the ideal drive system.

This saves the machine builder valuable time in designing

the machine, and reduces energy costs and thus the CO2

emissions of the machine from the very beginning. In

addition, the simulation makes it possible to determine

ahead of time whether the required performance values

will be reached.

• With the newly developed software solution

Smart Vibration Monitoring, condition monitoring

can be implemented with no sensors at all. The

software is integrated directly into the servo

controller, allowing easy retrofitting

The latest model simulates the knee lever in the clamping

unit of an injection molding machine. On request,

Baumüller’s simulation experts can adapt the modeled

mechanics to individual machine types.


İndustry

• ProSimulation offers the possibility of testing the drive behavior

realistically during the design phase, and in addition to optimal design

of the drive components, also enables faster commissioning. The latest

model simulates the knee lever in the clamping unit of an injection molding

machine.

Life-cycle management worldwide

In addition to the development and manufacture of

drive and automation components, the Baumüller group

of companies provides numerous services for plant and

machinery manufacturing and for machine operators.

From project planning, design and engineering

through assembly and commissioning to maintenance,

retrofitting and relocation, Baumüller offers support over

the entire life cycle of machines and systems. With over

40 branches worldwide, Baumüller is a reliable service

partner with decades of experience. Baumüller attaches

particular importance to the sustainable and resourcesaving

production of intelligent drive and automation

solutions.

• Based in Nuremberg, Baumüller is a leading manufacturer of electric automation and

drivesystems. At production sites in Germany, the Czech Republic, Slovenia and China as

well asin over 40 branches worldwide, around 2,000 employees develop and produce

intelligent system solutions for machine manufacturing and e-mobility. İn addition, the

range of services offered by the Baumüller Group includes engineering, assembly and

industrial relocation as well as services, thus covering all aspects of life cycle management.

Machine - Automation Electricity / World News 2023 45

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