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Physics Procedia 25 (2012) 1816 – 1822
2012 International Conference on Solid State Devices and Materials Science
Reliability Analysis of Aircraft Equipment Based on FMECA
Method
Li Jun, Xu Huibin
Department of Aviation Control and Engineering
Aviation University of Air Force
Changchun, Jilin Province, China
Abstract
It is well known that reliability of aircraft equipment is very important to aircraft during the flight because
performance of aircraft product can affect flight safe directly. In order to make the equipment work normally,
FMECA is applied in an aircraft equipment to analyze its reliability and improve operational reliability of the
product. Through its reliability mathematical model, average of operational time is predicted based on calculating
failure probability of all electrical components. According to the process of reliability theory FMECA, all kinds of
the failure mode, reasons, effects and criticality of the products can be determined completely. By comparing these
criticality data as shown, the paper analyses adopted method by that the contents, accents and operating process of
maintenance may be instituted finally. FMECA-based method for reliability analysis of the equipment and the
equipment maintenance performs well. The results indicate that application of FMECA method can analyze
reliability in detail and improve operational reliability of the equipment. Therefore this will supply theoretical bases
and concrete measures of maintenance of the products to improve operational reliability of products. FMECA can be
feasible and effective for improving operational reliability of all aircraft equipments.
© 2012
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Open access under CC BY-NC-ND license.
Keywords:Reliability Analysis, Aircraft Equipment, FMECA
1. Introduction
With the development of electronic technology, the performance of the aircraft equipments tends to
be growing better. In order to ensure their working order, enhance their performance, the operational
reliability of the aircraft equipments should be guaranteed. Low failure probability and long time running
are required of plane-carried products [1]. Thus, it is necessary to analyze the reliability of products and
do a good maintenance to the aircraft equipments under the guidance of proper theories. Failure Mode
Effect and Criticality Analysis (hereafter called FMECA) is one of the methods for reliability analysis
and valuation [2]. FMECA is designed to analyze all sorts of the potential failure in each component, and
by analyzing and computing criticality, FMECA may tell the incoming failure and its effect, that is,
1875-3892 © 2012 Published by Elsevier B.V. Selection and/or peer-review under responsibility of Garry Lee
Open access under CC BY-NC-ND license. doi:10.1016/j.phpro.2012.03.316
Li Jun and Xu Huibin / Physics Procedia 25 (2012) 1816 – 1822 1817
FMECA can tell the staff the exact service job [3]. According to what has been produced by FMECA, a
well-scheduled job list may be done to enhance the reliability of the plane-carried equipments.
Aiming at the plane-carried equipment of a certain type of aircraft and applying FMECA, we
conducted its reliability modeling and prediction of average of operational time [4], pointed out the issues
which should be paid attention to in maintenance while using the equipment, thus ensure and improve the
operational reliability of the plane-carried equipment. In the following part, this equipment is used as an
example to introduce the process and effect of using FMECA method.
2. The modeling of the aircraft equipment reliability
The reliability modeling of the aircraft equipments is conducted by dividing the whole working
process into different functional system and sub-system, each of which fulfills its respective function and
finally the systematic functional diagram is designed. Based on this systematic functional diagram, the
reliability model with one-to-one clear administrative levels is built, that is the reliability diagram of the
aircraft equipment [5].
2.1 The Main Structure and Functions of the Equipment
According to the design and application characteristics of the equipment, the systematic functional
diagram is formed. Based on this, this equipment can be divided into eight functional modules:
microcomputer system, pulse width regulating D/A converter, volt-control vibes system, digital
trigonometric function generator system, D/A transition network system, numerical control gaining
system, power magnification system, and display system [6]. The main function can be further divided
into the sub-systems which fulfill the most basic functions. For example, D/A transition network system,
used to realize the production and output of the analog quantity, consists of R/2R transition network and
operational amplifier unit. Each sub-system can also be divided into parts and components and other
apparatus. This kind of division is in accordance with units of the equipment while designing and
manufacturing.
2.2 The Reliability Diagram of the Equipment
Based on the systematic functional diagram, those parts and components which have the same
function are used to form a sub-system, and many sub-systems form the reliability system of the
equipment. The reliability modeling is conducted according to the function each part fulfills and then the
whole system is divided into many sub-systems, and the sub-system is further divided into individual part
and component. The reliability diagram is drawn according to this. The reliability diagram should be in
accordance with the schematic diagram of the whole equipment and with all the functional part. Then, the
encoding process is conducted according to the hierarchy relation of system and sub-system. The eight
functional modules are seen as eight systems and are encoded as microcomputer system (01), pulse width
regulating D/A transmitter (02), Volt-control vibes system (03), digital trigonometric function generator
system (04), D/A transition network system (05), numerical control gaining system (06), power
magnification system (07), and display system (08). The sub-systems, parts and units in each system are
also encoded. For example, RAM (010310), etc. The reliability diagram is shown in Figure 1.
1818 Li Jun and Xu Huibin / Physics Procedia 25 (2012) 1816 – 1822
y ( )
01 02 07 08
0701 0702
070101 070102 070201 070202 070203
Fig. 1 Reliability diagram of the aircraft equipment
2.3 The Reliability Mathematical Model of the Equipment
The reliability mathematical model of the tester while working is shown in formula (1) and (2).
Os ¦O i . (1)
MTBFs 1 . (2)
Os
Ȝs——failure probability of the equipment.
Ȝi——failure probability of Unit i.
MTBFs——average of interval between failures of the equipment.
3. The prediction of the reliability
The prediction of the reliability of this equipment starts with the parts and components and ends with
the whole equipment [7]. The data are from the GJB/Z299-91. We also refer to the external field data of
some other similar products [8]. For example, the resistance R in the numerical control gaining system,
n=30, the working failure probability model of the resistance is: Ȝp=Ȝb×E×Q×R. Since S=0.3,
according to Chart 2.4.1—5, Ȝb=0.056×10-6/h. according to Chart 2.4.1—1, 2.4.1—2, and 2.4.1—3,
E=1, Q=0.3, R=1.0. thus, Ȝp=0.056×10-6×1×0.3×1.0=0.0168×10-6/h, the failure rate of all the
resistance Ȝ=Ȝi (i=1,2,•••,30) Ȝ=0.504×10-6/h. By using this method, we can get the failure rate (Ȝs) of
the equipment:
Ȝs=Ȝi=(1.45+2*0.01188+8*0.01133+•••)=985.7×10-6/h
MTBFs=1/Ȝs=1/(985.7×10-6)=1014.5(h)
4. The FMECA analysis of the equipment
4.1 The Working of FMEA
FMEA is a bottom-up failure analysis method.According to the FMECA working program of the
reliability theory, conduct the FMEA analysis of the aircraft equipment [9].
1) List the Equipment Failure Model Checklist: According to the national military standard GJB299,
the reliability estimation handbook of electronic equipments and working experience of maintenance, list
the typical failures of this equipment.
2) Reasons Analysis: Analyze the reasons causing the failures. Careful analysis should be conducted
to judge every possible failure or problem, such as the reason of joins and quality.
Li Jun and Xu Huibin / Physics Procedia 25 (2012) 1816 – 1822 1819
3) Possible Effect: Analyze the possible effect of each problem to the part or component itself, to the
upper level and to the whole equipment.
4) Measures: Propose some possible preventive measures according to each kind of problem model,
reasons and effect.
5) Degree of the Seriousness of the Failures: The degree of seriousness can be classified into the
following four types: Type I (disastrous), Type II (fatal), Type III (critical) and Type V (slight).
Take D/A transition network system for example, FMEA analyzing table of some parts and
components is shown in Table I.
TABLE I D/A Transition Network System Fmea
Failure effect
Code Function Function Failure Failure Compensation Severity
sign mode cause Oneself Upper Last Measure
05020 Operationa Magnification Loose contact Disqualifica- Amplifier Transition system Equipment no- Choosing product
1 l amplifier or break tion no-working no-working working improvement of the ċ
or solder-off welding quality
Capacitor Magnification Equipment no- Improve welding ċ
Open-circuit Solder-off no-function change working quality
05020 Capacitor Feed-back
2 (100PF) Short-circuit Disqualific- Capacitor Magnification =1 Equipment no- ċ
ation short- working Choosing product
Parameter- connection
drift Long-use Value of Transition system Equipment Č
capacitor work work Improve daily
change maintenance
4.2 The CA Analysis of the Equipment
Under a specific degree of seriousness, the criticality value of a certain failure model in those failure
models is Cmj. As for a given degree of seriousness and a given phase of mission, the Cmj of the number j
of the product can be calculated by using the following formula: Cmj=Ȝp*Įj*ȕj*t. In this formula, Įj shows
the percentage of failure displayed as model j. If all the failure models of a product are listed, the totality
of Įj would be 1. ȕj, a number got by the analyzing faculty from their working experience, is the
conditional probability of the lose of the systematic mission when the product breaks down as model j.
The working time t can be calculated from the definition of the system. Generally, it is shown by the
hours used to finish each mission or by the times of the working circle. The Cr (the destructive degree of
a product) refers to the estimated failing numbers of a certain type of product caused by this failure model
of the product. As for a given degree of seriousness and a given phase of mission, Cr is the totality of Cmj
under this degree of seriousness. Cr can be calculated according to the following formula:
n n
Cr ¦ C mj
j 1
¦O
j 1
p Dj Ej t
Take the example of power amplification, and the analytic table of CA is shown as Table II.
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5. the application of FMECA
5.1 Work Out the Content of Maintenance of the Equipment
According to the working of FMEA, the failure models of product in each system which form the product
are seen as the daily maintenance content of the equipment. The failure models of Type III and Type IV
totaled 45 items, all of which have been written in the maintenance and using manual attached to the
equipment.
5.2 Determine the Key Maintenance Point of the Equipment
Based on the FMEA and CA reliability analysis, the key and important parts of the equipment are
CPU, crystal, LED, program and data memorizer, AD652, 74HC573, 74LS393,
D/A transition system adjust resistance, and 74LS273 etc. In the work of maintenance, they are regarded
as key target.
Effective measures should be taken to ensure the normal working of the equipment by considering
the relative failure models.
TABLE II Power Amplifier System Criticality Analysis (CA)
Code Function Function Failure Failure Severity Ȝp Įj ȕj t Cmj Cr=ȈCmj
sign Mode cause 10-6/h
070101 capacitor resist Open-circuit Solder-off ċ 0.0048 0.13 1.00 2 0.001248 0.008348
C disturbance Short-circuit Disqualificat ċ 0.0048 0.74 1.00 2 0.0071
ion
Parameter- Č 0.0048 0.13 0.10 2 0.000124 0.000124
drift Long-use 8 8
070102 Film and feed - Short-circuit Disqualificat ċ 0.02709 0.83 1.00 2 0.045
paper through ion 0.0542
capacitor Open-circuit ċ 0.02709 0.17 1.00 2 0.0092
(10uF) Solder-off
070202A Resistor feed-back Open-circuit Solder-off ċ 0.3336 0.92 1.00 2 0.6138 0.6138
(22K) Parameter- Long-use Č 0.3336 0.08 0.10 2 0.0053 0.0053
drift
070202B resistor feed-back Open-circuit Solder-off ċ 0.53376 0.92 1.00 2 0.9821 0.9821
(215K) Parameter- Long-use Č 0.53376 0.08 0.01 2 0.00854 0.00854
drift
070202D resistor potential- Open-circuit Solder-off ċ 0.53376 0.92 1.00 2 0.9821 0.9821
(600K) divider Parameter- Long-use Č 0.53376 0.08 0.10 2 0.00854 0.00854
drift
070203A Film and feed - Short-circuit Disqualificat Č 0.03843 0.83 0.10 2 0.06379 0.06379
paper through ion
capacitor Open-circuit ċ 0.03843 0.17 1.00 2 0.013 0.013
(2.2uF) Solder-off
Li Jun and Xu Huibin / Physics Procedia 25 (2012) 1816 – 1822 1821
5.3 Work Out the Reasonable Maintenance Working Method
Calculate the criticality of product according to the failure models of the product in all the systems.
Under the principle of maintaining those parts which have high degree of destruction first, work out
reasonable maintenance working order based on the order of the criticality data. Considering the
destructive degrees of those failures belonging to Type III and Type IV, the maintenance working order
is given.
6. The application effect
After investigating the same type of aircraft equipments used in two airports A and B, we collected
the mean lifespan data of the equipments in the two places and they are given in Table III and Table IV.
In airport A, the maintenance of the equipments is not conducted according to the FMECA analysis, and
in airport B, the maintenance of the equipments is conducted according to the FMECA analysis.
From the two tables above, we can find: the MTBF of airport A is 869 hours which is shorter than
the estimated MTBF (1014.5 hours); while in airport B, the MTBF is 1009 hours, which is very close to
the estimated MEBF. From the comparison, we can also find that, for those equipments which have been
maintained according to the analysis of FMECA, their MTBF is much longer than that of other
equipments, the operational time of the product is longer than before and the operational reliability is
also improved.
TABLE III The Mean Lifespan Data Ofairport A (Unit: Hour)
Number 1 2 3 4 5 6 7
87
810 840 1080 790 968 730
Interval time 0
MTBF 869
TABLE IV The Mean Lifespan Data Ofairport B (Unit: Hour)
Number 1 2 3 4 5 6 7
1010 990 1070 998 1050 1000 950
Interval time
MTBF 1009
7. Conclusion
This paper conducts the reliability modeling of an aircraft equipment and predicts its MTBF. In order
to analyze and improve its reliability, reliability technique FMECA method is used to analyze its failure
models and destructive degree, thus propose content, key point and method which should be paid attention
to while using and maintaining the equipment. The result shows that reliability analysis and the application
of FMECA method prolong the lifespan of this equipment and improves the operational reliability greatly,
thus proves that it is correct to apply this method to reliability analysis and improvement of operational
reliability of a product. In the meantime, it may help to improve the reliability of other aviation products.
Acknowledgment
Li Jun and Xu Huibin thank the crew of the plane-carried equipment of a certain type of aircraft.
1822 Li Jun and Xu Huibin / Physics Procedia 25 (2012) 1816 – 1822
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