Author : David Lee

David Lee

November 15, 2013

Presenter� Name: David Lee

� King Design Industrial Co., Ltd.

� E-mail address: davidlee@kdi.tw

Accelerate stress testing and certification

on products quality - in vibration and

shock field.

“Advanced and Precise Newly HALT / HASS system Comparing Features of the Newly

Developed

Electrodynamics Hammer and the General Pneumatic Hammer Used in

Environmental Stress Screening Systems,”

Author : David Lee

David Lee

November 15, 2013

Incumbent:

•King Design Industrial Co., Ltd., Since 1983--Chairman & Chief technology officer

•Taiwan Industrial Development Bureau & ECT Vibration, Shock, and Reliability Lecturer.

•Ministry of Education, University 、Technical and Vocational Colleges - Subject Lecturer.

•Reliability Engineering Association - Council

•Taiwan Accreditation Foundation (TAF)Technical Committee

•Ministry of Economic Affairs - Energy Review Committee

•Society for Quality Reliability Engineering group - Council

•Taiwan Invention Association - Vice Chairman

•Highest of Executive Branch - Committee of Public Safety - Wind Power Facilities to

•Promote Review Committee

•ITRI-Industrial Technology Research Institute - Future Technology Innovation of the

Year / Final Evaluation Committee.

•SEMI-TC members of the international semiconductor industry and Materials.

•SEMI-PV reliability task of packing and shipping work.

Author : David Lee

David Lee

November 15, 2013

Learn and Experience: • American University of Management Technology UMT Project Management Master./ Mechanical Engineering NPUST

• CPC vibration measurement manager class lecturer

• CMS-NML measurement center the vibration lab about a consultancy

• CMS knowledge and measurement of economic advisers

• U.S. JPL jet Propulsion Laboratory stress analysis consultancy

• Successfully assist domestic and international industrial, aerospace components to improve its Reliability.

• 2000 / 2001 National Invention Award Winner

• 2005/4 the International Exhibition of Inventions in Geneva, Switzerland - Gold Medal.

• 2005/4 Personal Invention Achievement Award , Malaysia University

• 2005/6 American INPEX Pittsburgh International Invention bonus card and the first prize of the General Assembly.

• 2006/4 the International Exhibition of Inventions in Geneva, Switzerland - gold medal.

• 2006/4 Outstanding Invention Achievement Award of the Federation of Swiss invention.

• 2006/10 Taiwan International Invention Award Innovation Shield

• 2007/10 Korea International Invention Award Gold Medalist

Specialty:• Dynamic Stress Analysis, Innovation R & D and marketing strategies

• Project Engineering Analysis and Management

• Vibration and impact of structural stress analysis and improvement• Reliability Analysis and Projections

• High acceleration (120,000 g) Impact Test planning and stress Analysis

• Active vibration isolation , Anti-vibration engineering application

• Laser Doppler modal analysis, FEA & EMA analysis

• Familiar AST / HALT / HASS / HASA / ESS……..

• IEC the international photovoltaic cells standard laboratory instrument manufacture.

Author : David Lee

David Lee

November 15, 2013

Contents:Contents:

� Introduction of the Pneumatic Hammer System

� Response of a Pneumatic Hammer

� Introduction of the Electric Dynamic Hammer

System (ED Hammer)

� Comparing the ED Hammer with the Pneumatic

Hammer

� Response of an ED Hammer

� Conclusion

Author : David Lee

David Lee

November 15, 2013

INTRODUCTIONINTRODUCTION

Author : David Lee

David Lee

November 15, 2013

Express The Deepest Respect to All theExpert and Great Companies, Who

Devoted so much In ESS/HALT/ALT..

…Reliability Fields to help people have

more Quality Life and Safety in past 50 y’s.

Author : David Lee

David Lee

November 15, 2013

The Use of Accelerated Life Test for The Use of Accelerated Life Test for

Reliability AssuranceReliability Assurance

� Product’s life assessment through a series of

Environmental Loading Test are always necessary

for the Reliability Assurance though they are always

Time Consuming.

� Some accelerated test methods are then developed,

such as:� HALT (Highly Accelerated Life Test),

� HASS (Highly Accelerated Stress Screening),

� HASA (Highly Accelerated Stress Audit),

� ESS (Environmental Stress Screening).

Author : David Lee

David Lee

November 15, 2013

The Role of ESSThe Role of ESS

� ESS is use the environmental stresses for the

quality check of products based on the physics

of materials and all of components.

♦ It is mainly to expose those potential defects of

the product so that those inferior items / designs

weakness can be screened out .

♦ Some of the design improvements can be

conducted after examining the failure mechanism.

Author : David Lee

David Lee

November 15, 2013

Road Transportation / Shipping

should Include Vibration and Shock

Accelerometer(g)

time ( t )

Vibration

APIC

Vibration Vibrationshockshock

Author : David Lee

David Lee

November 15, 2013

Vibration / Shock environment measurement method

and specifications development process

磁帶機錄製

量測資料擷取

溫度時域圖

溫度

音壓位準

音壓時域圖

加速度

／振動 衝擊時域圖

1/3 Octave Band (Hz)

APSD Level (dB)

APSD Level (dB)

環試規格制訂量測資料分析

試驗規格

頻率(Hz)

加速度

衝擊環境

加速

度時間(ms)

dB

音壓位準

頻率(Hz)

試驗規格

振動環境

頻率(Hz)

PSD

加加加加速速速速儀儀儀儀

加速儀加速儀加速儀加速儀

信號放大器信號放大器信號放大器信號放大器

Develop specificationsDevelop

specifications Data Analysis Retrieve Data

Signal RecordingSignal amplifiers

Author : David Lee

David Lee

November 15, 2013

Environment, product and optimum packaging

Enviro

nm

enta

l

require

ments strength capacity

on Transport

strength capacity

on Transport

strength capacity

on Transport

strength capacity

on Transport

Pro

duct c

apabilitie

s

optimum packaging

Inadequately

shielded

Over Protective

Reduce p

ackagin

g

costs

,but c

ost

more

Increase in

packaging costThe best

combination

Protection Needs = Intensity of Environmental Stress - Resistance to Environmental Stress

Author : David Lee

David Lee

November 15, 2013

INTRODUCTION OF THE PNEUMATIC INTRODUCTION OF THE PNEUMATIC

HAMMER SYSTEMHAMMER SYSTEM

Author : David Lee

David Lee

November 15, 2013

Typical HALT MachineTypical HALT Machine

(a) HALT machine

(b) Chamber

(c) Driving hammer

Author : David Lee

David Lee

November 15, 2013

Pneumatic Hammer SystemPneumatic Hammer System

(a) Pneumatic hammer system

(b) Driving hammer

(c) Pneumatic hammer

�Sectional view for a

typical model of the

pneumatic hammer

Author : David Lee

David Lee

November 15, 2013

Repetitive Shock (RS) System with the Repetitive Shock (RS) System with the

Pneumatic HammerPneumatic Hammer♦ 6DOF Shock (Vibrator)

Author : David Lee

David Lee

November 15, 2013

Motion of the Piston in Pneumatic Hammer(1)Motion of the Piston in Pneumatic Hammer(1)

� When the piston at the position where the air input and exhaust ports both are

open, the supply air goes into chamber of the hammer then passes through the

central channel to the end of the thrust chamber.

Exhaust

Air

Input

Air

� When the pressure at the end chamber is the same as the incoming supply air, the

resulting force then push the piston to move forward.

Force

Exhaust Air Input Air

Author : David Lee

David Lee

November 15, 2013

Forc

e

� When the piston approaches the front end of the hammer, the air in front of

the piston is compressed and some of them also goes through the upper air

passage to the original air input chamber at the rear of the hammer.

� These resulting forces altogether push the piston to move backward to its

starting position. Thus, the next cycle repeated itself again.

Exhaust

Air

Exhaust

Air

Input

Air

Input

Air

Motion of the Piston in Pneumatic Hammer(2)Motion of the Piston in Pneumatic Hammer(2)

Author : David Lee

David Lee

November 15, 2013

Some Features of the Pneumatic Hammer SystemSome Features of the Pneumatic Hammer System

� It combines both Vibration and Shock Waves in a

continuous impact strokes.

� However, before generating the shock pulse, purely

vibration wave was observed.

� Not only does it hard to control the magnitude of each

shock pulses but also hard to control the shock

frequencies. Since the movement of the impacting

piston is completely depends upon the supply air

pressure and it’s hard to manipulate.

Author : David Lee

David Lee

November 15, 2013

RESPONSE OF A PNEUMATIC HAMMERRESPONSE OF A PNEUMATIC HAMMER

Author : David Lee

David Lee

November 15, 2013

Response of a Pneumatic Hammer (1)Response of a Pneumatic Hammer (1)

Time signals under 0.08MPa

Time Signals for 0.1 and 0.08MPa

�As shown at right, only vibration

accelerations were measured

before reaching the Critical

Pressure (i.e. that can generate

the shock pulses).

�Even after reaching the Critical

Pressure, the acceleration

signals measured still contain

both the shock and vibration

waves.

Author : David Lee

David Lee

November 15, 2013

Different impact waves under 0.3MPa

�When taking the 1st

and 8th pulses as an

example on a

continuous impact test

for comparison

purpose, it was found

that the former with a

peak acceleration of

1,213g, while the latter

has a peak

acceleration of 926g

with a difference of

23.7% between them.

Response of a Pneumatic Hammer (2)Response of a Pneumatic Hammer (2)

Author : David Lee

David Lee

November 15, 2013Variations of impact forces and frequencies for different

supply air pressure

�The impact Force / Acceleration

/ Speed increase with the

increase of supply air pressure

from 0.1 to 0.3MPa.(..Vice Versa..

decrease air pressure….)

�Both the impact forces and

frequencies increase with the

raise of the supply air pressure.

�More of phenomenon are focus

on vibration and with a little

portion of Shock.

Acceleration comparison under different

pressure

Response of a Pneumatic Hammer (3)Response of a Pneumatic Hammer (3)

Author : David Lee

David Lee

November 15, 2013

Variations of impact Grms with

supply Air Pressure increases

�The resulting

impact Grms

increases following

the pressure

increases in the

supply air on the

pneumatic hammer.

Response of a Pneumatic Hammer (4)Response of a Pneumatic Hammer (4)

Author : David Lee

David Lee

November 15, 2013

INTRODUCTION OF THE INTRODUCTION OF THE

ELECTRIC DYNAMIC HAMMER ELECTRIC DYNAMIC HAMMER

SYSTEM (ED HAMMER) SYSTEM (ED HAMMER)

Author : David Lee

David Lee

November 15, 2013

Shock Stress Screening System Shock Stress Screening System --27 27

Axes (SSSSAxes (SSSS--27)27)

Author : David Lee

David Lee

November 15, 2013

66--DoF Shock CubeDoF Shock Cube

Author : David Lee

David Lee

November 15, 2013

MultiMulti--axes Shock Table Driven with ED Hammeraxes Shock Table Driven with ED Hammer

May Cause Centrifugal Force

Author : David Lee

David Lee

November 15, 2013

Author : David Lee

David Lee

November 15, 2013

Author : David Lee

David Lee

November 15, 2013

The Electric Dynamic Hammer SystemThe Electric Dynamic Hammer System

Author : David Lee

David Lee

November 15, 2013

Newly Developed ESS System Driven Newly Developed ESS System Driven

by the ED Hammerby the ED Hammer

�A Newly ESS system that was driven by Electric Dynamic Hammer (2007) .

�Some features of the system are:1) The duration between each impact can be precisely controlled

so that the phases of each hammer on a multiple hammer system can be manipulated individually.

2) Both the Impact Forces and Frequencies can be controlled precisely.

3) Great Repeatability for the magnitudes of impact forces are superior. Variations of the forces are very small comparing with those in the pneumatic hammer.

Author : David Lee

David Lee

November 15, 2013

RESPONSE OF AN ED HAMMER RESPONSE OF AN ED HAMMER

Author : David Lee

David Lee

November 15, 2013

Different impact frequencies

generated under the same

power input but with different

force release interval.

Response of the ED

Hammer

� The timing and impact

duration of the ED

hammer are controllable.

Response of an ED Hammer (1)Response of an ED Hammer (1)

Author : David Lee

David Lee

November 15, 2013

Different settings of Impact force

levels of the ED hammer

Relationship between input

power and impact acceleration

�The impact forces in ED

hammer are controlled

through adjusting the

energy input to it.

Response of an ED Hammer (2)Response of an ED Hammer (2)

Author : David Lee

David Lee

November 15, 2013

Time domain signals with level 3

power input to the ED Hammer

Compare the Different Impact

�The impact pulses generated

are extremely identical for the

ED hammer under the same

energy input setting.

�The magnification plot of two

over-lapped single impact

pulses (i.e. the 1st & 8th

impact ) on the ED hammer

indicating no noticeable

difference observed.

Response of an ED Hammer (3)Response of an ED Hammer (3)

Author : David Lee

David Lee

November 15, 2013

ED HAMMER CONTROLLER ED HAMMER CONTROLLER

AND THE USER INTERFACE AND THE USER INTERFACE

Author : David Lee

David Lee

November 15, 2013

KD27 Controller KD27 Controller -- Made by Crystal Made by Crystal IInstrumentsnstruments

Author : David Lee

David Lee

November 15, 2013

User Interface of KD27User Interface of KD27

Author : David Lee

David Lee

November 15, 2013

Graphic DisplayGraphic Display

Author : David Lee

David Lee

November 15, 2013

Channel SetupChannel Setup

Author : David Lee

David Lee

November 15, 2013

Measurement DisplayMeasurement Display

Author : David Lee

David Lee

November 15, 2013

Frequency Spectral DisplayFrequency Spectral Display

Author : David Lee

David Lee

November 15, 2013

Shock Impulse DisplayShock Impulse Display

Author : David Lee

David Lee

November 15, 2013

COMPARING THE ED HAMMER COMPARING THE ED HAMMER

WITH THE PNEUMATIC HAMMERWITH THE PNEUMATIC HAMMER

Author : David Lee

David Lee

November 15, 2013

Comparing the generated acceleration/force both for

the ED hammer and the pneumatic hammer

�Under the current test

constraint with a maximum

supply and air pressure is

0.45MPa, the magnitudes of

the impact accelerations of

pneumatic hammer are

located between level 3 and

level 2&1 in ED hammer

that has a scale of 5 input

levels currently.

Comparing the ED Hammer with Comparing the ED Hammer with

the Pneumatic Hammer(1)the Pneumatic Hammer(1)

Author : David Lee

David Lee

November 15, 2013

2012-RD

Author : David Lee

David Lee

November 15, 2013

input2(t)

3.10000 0.3000 0.6000 0.9000 1.2000 1.5000 1.8000 2.1000 2.4000 2.7000

140.00

-140.00-135.00

-120.00

-105.00

-90.000

-75.000

-60.000

-45.000

-30.000

-15.000

0

15.000

30.000

45.000

60.000

75.000

90.000

105.00

120.00

Time (seconds)

G

input2(t)

3.10000 0.3000 0.6000 0.9000 1.2000 1.5000 1.8000 2.1000 2.4000 2.7000

150.00

-150.00

-140.00

-120.00

-100.00

-80.000

-60.000

-40.000

-20.000

0

20.000

40.000

60.000

80.000

100.00

120.00

140.00

Time (seconds)

G

input2(t)

3.10000 0.3000 0.6000 0.9000 1.2000 1.5000 1.8000 2.1000 2.4000 2.7000

180.00

-175.00

-160.00

-140.00

-120.00

-100.00

-80.000

-60.000

-40.000

-20.000

0

20.000

40.000

60.000

80.000

100.00

120.00

140.00

160.00

Time (seconds)

G

Table need apply High Damping Material and Damping sheet in between

Author : David Lee

David Lee

November 15, 2013

Table should use Light Weight / High Damping Material

and Damping sheet in between to avoid Table Resonance

Author : David Lee

David Lee

November 15, 2013

Time domain acceleration signals

of the pneumatic hammer

Time domain acceleration

signals of the ED hammer

�Under the same input energy

level, the magnitudes of impact

pulses for the ED hammer can

be controlled precisely on a

series of consecutive shocks. (upper figure)

�However, the magnitudes of

impact pulses for the

pneumatic hammer can’t be

kept at the same level even

individual. (lower figure)

Comparing the ED Hammer with the Comparing the ED Hammer with the

Pneumatic Hammer(2)Pneumatic Hammer(2)

Author : David Lee

David Lee

November 15, 2013

Response

Spectrum?

50σ σ σ σ peak

Peak

and

Notch in

PSD

Response of RS systemResponse of RS system

Author : David Lee

David Lee

November 15, 2013

Response of shock stress screening system -27 axes driven by ED Hammer

SRS with ED Hammer

2,000Hz

3,000Hz

Author : David Lee

David Lee

November 15, 2013

CONCLUSIONS

Author : David Lee

David Lee

November 15, 2013

ED Hammer:

�The Impact Duration, Force and Phase Modulation can

be controlled individually.

�The pulse magnitudes are precisely the same under a

series of continuity impacts.

�Maximum impact Frequency—25~30 times/sec it generate

great effect implement on the testing.

Target: 100g~200g / 2~6mS

Author : David Lee

David Lee

November 15, 2013

Pneumatic Hammer:

�Both the impact forces and frequencies increase

simultaneously with the raise of the supply air pressure.

�There are some variations in the magnitudes of impact

pulses under a series of continuant impacts. Energy

contribution Shock~10% and Vibration~ 90%.

�The impact acceleration signals contain both the

impact pulse and the vibration waves.

�The impact frequencies can be higher comparing with

ED hammer’s.

Author : David Lee

David Lee

November 15, 2013

♦Questions ?

Author : David Lee

David Lee

November 15, 2013

Thank your attention !

Have a Nice Day !