Evaluation of operational reliability and life cycle of key components of automotive equipment under conditions of intensive operation

Abstract

Herein, the reliability analysis of several critical automotive components operating under intensive conditions have been reported. Understanding failure mechanisms under high-stress environments compared to nomal operating conditions has been addressed. Real-world data failures have been collected. Weibull distribution of the failure data of several components where some are considered as wear sensitive components (like brake pads, tires and pistons) and fatigue-sensitive components like transmission and shock absorbers were modelled. Reliability quantification was based on incorporating Weibull parameters for shape (β) and characteristic life (η). The results showed a significant difference between normal and intensive regimes. Under intensive operational conditions, the characteristic life parameter eta decreased by 46% for brake pads, 44 % for tires, and 99% for piston engines. The failure modes classification indicated that wear was responsible of 52% of the failure cases. The main causes of failure were originating from intensive service, poor lubrication, and the non-respect of maintenance protocols, amplifying fatigue accumulation in key automotive components. These findings suggest incorporating predictive maintenance strategies based on Weibull parameters to mitigate such failures