Systematic Methods to Increase the Lifetime of Mechanical Products Such as Refrigerators by Employing Parametric Accelerated Life Testing

Abstract

This investigation practically explains the implementation of parametric accelerated life testing (ALT) as an algorithm to recognize design imperfection and rectify it in creating a reliable quantitative (RQ) statement by sample size equation. It covers: (1) a module BX life that X% of a collection of system items is unsuccessful with an ALT plan, (2) design for fatigue, (3) ALTs with alterations, and (4) discernment as to if the final design(s) obtains the targeted BX lifetime. A (generalized) life–stress formulation by the linear transport process is recommended for the mathematical work of the parametric model. As a case study, an ice-maker including gear system in a refrigerator was utilized. The gear teeth made of cast iron (carbon, 3 wt% and silicon, 2 wt%) was fracturing in a refrigerator ice-maker. To reproduce the field failure and rectify the problematic designs in the marketplace, a parametric ALT was carried out. At the first ALT, the gear teeth made of cast iron partly cracked and fractured under severe cold conditions (below −20 °C) in the freezer. It was modified by changing the material from cast iron to a sinter-hardened powder metallurgy nickel steel because high fatigue strength in the low temperature was required. At the second ALT, we discovered the fractured helix made of polycarbonates (PC). As a modification, strengthened rib on the front and side of the helix the thickness of gear teeth was attached. At the third ALT, there was no concern, and the life of the auger motor including gear system was manifested to have a B1 life 10 years.