FAILURE ANALYSIS

• Why ?

As the standards of our industry rise due to increasing globalization and competition, there is an ever growing need for consistency and reliability. Breakdown of any unit, system or equipment is an avoidable and costly occurrence and must be prevented or minimized. Analysis of such failures becomes a resourceful and affordable tool in addressing such unwanted occurrences.

To establish whether the cause of component failure lay on:

a) Service conditions
b) Design considerations
c) Material and its specification
d) Improper processing and assembly procedures or
e)  Combinations of these.

Only the real “Root cause” can ensure the effectiveness of corrective and preventive actions and avoid recurrence of failure.

• Stages Of Failure Analysis

1. Understanding and assimilation of background data and selection of samples.
2. Examination and documentation of the failed part by the following

1. Visual examination of parts, location (if necessary) and relevant photographs as well.

2.  Non destructive testing by means of Radiography, Dye      penetrant, Magnetic particle testing etc.

3. Mechanical Testing for various physical properties.

3. Vital specimens are selected, classified, and subjected to:

1. Macroscopic examination and analysis. This involves examining the fracture surfaces, secondary cracks, deposits and other such elements
2. Microscopic examination and analysis of fracture surface (by Scanning Electron Microscopy, if required).

4. Chemical analysis of material for conformation to specifications.

5. Chemical analysis of corrosion products, deposits, contaminants etc.

6. The actual state of the failed part and the failure mode are established.

7.  Fracture mechanics study if found necessary.

8. A simulation of the identical working environment to determine if any external      factors have contributed to the failure

9. Conclusions are determined after compiling all evidences and analysis and       then the report is generated.
10. Follow-up recommendations are also provided.

PASSIVE LIGHT SENSOR

Rain sensor systems:

Opto electronic sensors are used in a reflective mode in rain sensor systems to detect the presence of water on the windshield so that the windshield wipers can be controlled automatically.

An LED emits light in such a way that when the windshield is dry almost the entire amount of light is reflected onto a light sensor. When the windshield is wet, the reflective behavior changes: the more water there is on the surface, the less light is reflected. In the new rain sensor, infrared light is used instead of conventional visible light. This means that the sensor can be mounted in the black area at the edge of the windshield and cannot be seen from outside.

Working Operation:

An infrared beam is reflected off the outer windshield surface back to the infrared sensor array. When moisture strikes the windshield, the system detects a reflection to its infrared beam. Advanced analogue and digital signal processing determines the intensity of rain. The sensor communicates to the wiper control module, which switches on the wiper motor and controls the wipers automatically, according to the moisture intensity detected.

Depending on the quantity of rain detected, the sensor controls the speed of the wiper system. In conjunction with electronically controlled wiper drive units, the wiping speed can be continuously adjusted in intermittent operation. In the event of splash water – as when overtaking a truck – the system switches immediately to the highest speed.

The new rain sensor offers further options. For example, it can be used to close windows and sunroofs automatically if the vehicle is parked and it starts to rain. It can even be fitted with an additional light sensor to control the headlights – at night or at the entrance to a tunnel, the lights can be switched on without any intervention by the driver.

For Windshield wipers working operation Click this Link.

Light Sensors:

Automatic lighting of the headlights is controlled by a passive light sensor. It measures available light using a set of photo-electric cells.

The light sensor comprises three lenses that focus the light onto three photo-electric cells. This allowed “the luminous space” surrounding the vehicle into several zones through the directivity of each basic lens cell pair.

• Lens 1: Measure total ambient light
• Lens 2: Intersect Front source of light
• Lens 3: Distinguish Road Condition (Like brighter sunny weather condition or Dark tunnel)

By comparing the information gathered by these three devices, the system computer determines the situation with which the vehicle is confronted and commands the headlights in consequence.