ENGINEERING DESIGN HANDBOOK

1 AMC PAMPHLET AMCP 706-196 ENGINEERING DESIGN HANDBOOK DEVELOPMENT GUIDE FOR reliability PART TWO DESIGN . FOR reliability HEADQUARTERS, US ARMY MATERIEL COMMAND JANUARY 1976 AMCP 706-196 DEPARTMENT OF THE ARMY HEADQUARTERS US ARMY MATERIEL COMMAND 5001 EISENHOWER AVENUE, ALEXANDRIA, VA 22333 AMC PAMPHLET 5 January 1976 NO. 706-196 ENGINEERING DESIGN HANDBOOK ~ DESIGN FOR reliability TABLE OF CONTENTS Paragraph Page IZST OF ILLUSTRATIONS vi LISTOFTABLES viii PREFACE ix CHAPTER 1. INTRODUCTION 1-0 List of Symbols 1-1 1-1 General 1-1 1-2 System ENGINEERING 1-2 1-3 System Effectiveness 1-4 1-4 The Role cf reliability 1-7 1-5 The Role of Maintainability 1-9 Relationship to reliability 1-10 DESIGN Guidelines 1-10 Prediction 1-12 DESIGN Review 1-12 Availability 1-13 1-6 The Role of Safety 1-13 Relationships to reliability 1-14 System Hazard Analysis 1-14 Trade-offs 1-15 1-7 Summary 1-16 CHAPTER 2.

2 THE ENVIRONMENT 2-1 Introduction 2-1 Military Operations 2-1 Predicting Environmental Conditions 2-1 2-2 Effects of the Environment 2-3 2-2-1 General Categories 2-3 Combinations of Natural Environmental Factors 2-3 Evaluation of Environmental Characteristics 2-3 Combinations 2-3 Practical Combinations .. 2-7 AMCP 706-196 TABLE OF CONTENTS Paragraph Page Combinationsof Induced Environmental Factors 2-8 Environmental Analysis 2-8 2-3 Designing for the Environment 2-8 Temperature Protection 2-14 Shock and Vibration Protection * . 2-15 Moisture Protection 2-17 Sand and Dust Protection 2-17 Explosion Proofing 2-18 Electromagnetic-Radiation Protection 2-19 2 4 Operations Research Methods 2-19 CHAPTER 3. MEASURES OF reliability 3-0 List of Symbols 3-1 3-1 Introduction 3-1 3-2 Probabilities cf Success and Failure 3-1 3-3 Failure Distributions 3-2 3-4 Failure Rate 3-3 3-5 Time-to-Failure 3-5 3-6 Time Between Failures 3-5 3-7 Fraction Defective 3-6 CHAPTER 4.

3 MODEL BUILDING AND ANALYSIS 4-0 List cf Symbols 4-1 41 Introduction 4-1 4-2 Model Building 4-2 4-3 Analysis 4-9 4-4 Simulation 4-9 General Description cf a Simulation Program 4-9 4-5 Computer Programs 4-16 CHAPTER 5. ALLOCATION OF reliability REQUIREMENTS 5-0 List of Symbols 5-1 5-1 Introduction 5-1 5-2 Systems Without Repair 5-2 Equal Allocation 5-3 Proportional Complexity 5-3 Simple-Modular Complexity 5-3 Detailed Complexity 5-8 Feasibility-of-Objectives Allocations 5-9 Redundant Systems 5-13 Redundant Systars with Constraints 5-13 Simple Redundancy Allocation with a Single Constraint 5-20 Dynamic Programming Allocation 5-20 Minimization of Effort Algorithm 5-20 5-3 Systems with Repair .- 5-23 1 AMCP 706-196 TABLE OF CONTENTS Paragraph Page An Elementary Approach to Steady-State Availability.

4 5-23 Failure Rate and Repair Rate Allocation orSeries Systems 5-25 A Simple Technique for Allocating Steady-State Availability to Series Systems 5-26 Failure and Repair Rate Allocations -v for Redundant Systems 5-26 reliability with Repair and Instantaneous Availability 5-32 CHAPTER6. HUMAN FACTORS 6-0 List of Symbols 6-1 6-1 Introduction 6-1 6-2 DESIGN and Production 6-1 6-3 Human ENGINEERING 6-2 6-4 Human Performance reliability 6-3 The Relationship Between Human Factors and reliability 6-4 Human Factors Theory 6-4 Man/Machine Allocation and reliability 6-5 Interactions and Trade-offs 6-8 THERP (Technique for Human Error Rate Prediction) 6-9 CHAPTER 7. CAUSE-CONSEQUENCE CHARTS 7-1 Introduction 7-1 7-2 Generation 7-2 System Definition 7-6 Fault Tree Construction 7-6 7-3 Minimal Cut Sets 7-7 Finding the Minimal Cut Sets 7-7 Modifications for Mutually Exclusive Events 7-12 7-4 Failure Probability 7-15 CHAPTER 8.

5 FAILURE MODES AND EFFECTS ANALYSIS 8-0 ListofSymbols 8-1 8-1 Introduction 8-1 8-2 Phasel 8-2 8-3 Phase2 8-2 8-4 Computer Analysis 8-13 CHAPTER 9. MODELS FOR FAILURE 9-0 ListofSymbols 9-1 9-1 Introduction 9-1 iii a AMCP 706-196 TABLE OF CONTENTS Paragraph Page 9-2 Deterministic Stress-Strength 9-2 Tensile Strength 9-2 Safety Factors. Load Factors, and Margin of Safety 9-5 9-3 Probabilistic StressTStieng v, ., -.. 9-6 1 g 1 Computing Probability 5i Failure - | 9-32 Probabilistic Safety Margin 9-11 94 Simple Cumulative Damage 9-12 9-5 Severity Levels for Electronic Equipment 9-12 9-6 Other Models 9-18 CHAPTER 10. PARAMETER VARIATION ANALYSIS 10-0 List of Symbols 10-1 10-1 Introduction 10-1 10-2 Descriptions of Variability 10-2 10-3 Sources of Variability 10-5 104 Effects of Variability 10-6 10-5 Worst-Case Method 10-8 10-6 Moment Method 10-9 10-7 Monte Carlo Method 10-15 10-8 Method Selection 10-17 10-9 Computer Programs 10-17 10-91 A General Program 50-17 ECAPandNASAP 10-17 CHAPTER 11.

6 DESIGN AND PRODUCTION REVIEWS 11-1 Introduction 11-1 11-2 Organizingfor the Reviews 11-2 Review Board Chairman 11-2 DESIGN Group 114 Other Review Team Members 114 11-2-4 Followup System 114 11-3 Review Cycles 11-5 Technical Exchange Phase 11-5 Internal DESIGN Review Meeting/Agreement Phase H-5 Army Involvement in Internal Eteskp. Review H*" DESIGN Data Package Phase 11-5 Change Data Package 11-5 11-3,6 Performance Specification Changes 11-5 Government Response 11-6 Unsatisfactory DESIGN Data 11-6 Army/Contractor Review Meeting 11-6 Standard Review 11-S Subcontractor DESIGN Review 11-6 114 Minimum Requirements in Conceptual-Phase Review .. 11-6 11-5 Minimum Requirements for Developmental-Phase Review.

7 11-7 11-6 Checklists H-8 IV AMCP 706-196 TABLE OF CONTENTS Paragraph Page APPENDIX A. DESIGN DETAIL CHECKLISTS A_i Introduction ". A-l A-2 Propulsion Systems A-l ^_3 Fuel/Propellant System A-l A 4 Hydraulic Systems A-5 Pressurization and Pneumatic Systems _ . Electrical/Electronic Systems A-3 A-7 Vehicle Control Systems A-5 A-8 Guidance and Navigation Systems A-6 ^.9 Communication Systems A-7 A-10 Protection Systems A-ll Fire Extinguishing and Suppression Sysbsn A-8 A-12 Crew Station Systems A9 A-13 Ordnance and Explosive Systsns A-ll APPENDIX B. reliability DATA SOURCES B-l Introduction B-l B-2 GIDEP. Government-Industry Data Exchange Program .El Introduction B-l Functions B2 ENGINEERING Data Bank B-2 Failure Experience Data Bank B2 Failure Rate Data Bank (FARADA) Metrology Data Bank B-3 Operations B-3 Cost Savings B-4 B-3 reliability Analysis Center A DOD Electronics Information Center B 4 B^ Army Systems B5 The Amy Equipment Record System (TAERS) B-5 The Army Maintenance Management Systsii (TAMMS)Including Sample Data Collection E5 B-5 Precautions in Use JB-6 B-6 Partial Listing of Data Banks in Operation B-7 B-7 Discontinued or Transferred Activities B-15 APPENDIX C.

8 ANNOTATED BIBLIOGRAPHY ON HUMAN FACTORS (from NT1S Government Reports Announcement) ] 1 ] 1 AMCP 706-196 | LIST OF ILLUSTRATIONS Figure Page f I 1-1 System Management Activities ' i i-3 1-2 Fundamental System ENGINEERING Process Cycle 1-4 1 1-3 Flow Diagram for a General Optimization Process ^_g ] 1-4 reliability /Maintainability Relationships 1-11 2-1 Latitudinal Distribution of Environmental Extremes.. 2-6 2-2 Semispatial Distribution of Environmental Extremes.. - ."*T . 2-7 2-3 Coirparison Between Temperature and Other Environmental Factors 2-7 2-4 Comparison of Heat Removal Methods 2-15 2-5 Environmental Situation Diagram 2-20 2-6 Algorithm for Program Performance.

9 2-21 2-7 Matrix of Interrelationships of Tasks - - 2-22 4-1 Example of reliability Block Diagrams and Up-state Rules .. 4-2 ILS Localizer Functional Block Diagram 4 3 ILS Localizer reliability Block Diagram 4_g TA 4 4 Progressive Expansion of reliability Block Diagram T 4-5 Sampling from a Distribution ** 5-1 Steady-state Availability vs the Ratio of Failure Rate to Re- pair Rate 5-2 Repair Rate to Failure Rate Ratio vs Unavailability {n = 2) .. 5-29 5-3 Repair Rate to Failure Rate Ratio vs Unavailability (n = 3) .. 5-29 5-4 Repair Rate to Failure Rate Ratio vs Unavailability (n = 4) .. 5-30 5-5 Repair Rate of Failure Rate Ratio vs Unavailability (n= 5).}

10 5-30 6-1 The Man/Machine Interaction 6-5 6-2 Predicting Man/Machine reliability 7-1 Fault Tree Logic Symbols 7-4 7-2 Fault Tree Event Symbols 7-3 Sample System 7-^4 First Treetop System Boundary Condition for Sample System 7-7 7-5 First Fault Tree for Sample System 1 7-8 7-6 Second Treetop System Boundary Condition for Sample System 7-9 7-7 Second Fault Tree for Sample System . 7-10 7-8 Sample System 2 7-13 7-9 Fault Tree for Sample System 2 7-14 7-10 Sample Fault Tree for Probability Evaluation 7-16 7-11 Boolean Equivalent of Sample Fault Tree Shown in Fig. 7-10 . 7.^7 7-12 Sample Fault Tree with Time-Dependent Probabilities .. 7-18 8-1 Typical System Symbolic Logic Block Diagram 8-3 8-2 Typical Unit Symbolic Logic Block Diagram 8-3 Failure Effects Analysis Form g_7 8-4 Symbolic logic Block Diagram of Radar Example 8-10 8-5 Determination of Preamplifier Criticality 8-11 9-1 Typical Tensile-test Diagrams 9-2 Aluminum Simple Uniaxial Tension 9-3 Typical Probability Density Function g of Stress f and Strength F ^ 9-4 Simply Supported Rectangular Plate Subject to Uniform Load P -'- 9-16 VI AMCP 706-196 LIST OF ILLUSTRATIONS Figure Page 9-5 Determination of Failure Rate XB as Related to Stress Ratio S forMIL-R-ll/4E Resistors, RC-22 9-21 9-6 Determination of Longevity Factor JIL for MIL-R-l 1 Resistors.