VLM Industries

Aerospace

Tomorrow’s systems are being asked to perform at higher altitudes, fly faster, with more fuel efficiency, and carry more payload. Still, we expect our aerospace systems to be ready every time we need them. To this end, to be more accurate, maintenance should be conditioned-based rather than based on arbitrarily pre-planned schedules. In fact, our VLM system can predict maintenance with even greater accuracy than physical testing might indicate.

VEXTEC has conducted aerospace research and development for systems such as aircraft, helicopters, missiles, and rockets. We have also participated in the design and development of onboard sub-systems like prognosis reasoners, electronics, structures, and turbine engine components. VEXTEC has an internationally renowned reputation for excellence in lifing and fatigue analysis within the aerospace industry. Our engineers and scientists are currently working on aerospace systems of the future – concepts that will impact security and transportation globally.

Automotive

Conventionally, vehicle quality estimates have been based on prototype testing, a slow, expensive, and not particularly accurate process. The physical testing of a statically significant number of integrated prototype vehicles prior to launch is generally not practicable; therefore true vehicle reliability becomes apparent only when it’s too late: after the vehicles are fielded.

But Virtual Life Management analysis can successfully replace the high cost of physical testing with low cost virtual testing, while providing management with unprecedented information about product behavior. The VLM system can also be used to assess TCO benefits and how they can be engineered into vehicle systems prior to their arrival on the dealership’s showroom floor.

Heavy Industry

Heavy equipment manufacturers are faced with a daunting scenario. They are being charged with accommodating an unprecedented collection of complex new demands from every constituency. Their customers want more durable products at increased levels of performance. EPA mandates are now coming into play, and raw material prices are going through the roof. On top of all this, competitive pressures mandate lower overall costs and higher warranty coverages.

Working with VEXTEC, the top industrial suppliers can view product cost, performance and durability as completely linked issues. VLM simulations are being used to develop life expectancy actuarial analysis of design and material changes, warranty offerings, and the widest possible range of customer usage scenarios BEFORE the fact. With our Virtual Life Management system, VEXTEC has become a key enabling technology within the diesel engine, component, and turbocharger specialty markets, to name just a few.

Electronics

The electronics industry is constantly seeking to improve processing capability within smaller real estate frameworks. Operating environments are often harsh – imposing dramatic cycling under extreme temperatures and high vibratory loadings. We have become a mobile society and we carry our electronics with us. We drop devices, spill coffee on them and, still, we expect them to work! Yet, the way our electronics are built must change – because regulatory bodies have mandated it. For more than 30 years, electronics wires, devices, etc have been constructed from lead-based interconnects. Now, the industry has been told to shift to lead-free materials – and this changes everything.

VEXTEC VLM  technology is giving electronics companies the computational modeling they need to make informed decisions about performance, reliability and cost trade-offs, to enable them to build the electronic systems of the future.

Electronics: Interconnect Issues

Electronics are reliant on the integrity of interconnects or solder bonds. The reliability of interconnects is a concern because it is widely expressed that fracture failures in solder joints account for up to 70% of failures in electronic digital devices.

Conventionally, the reliability of electronic devices is assessed using empirically-based models. Experimental conditions are systematically varied through testing and a mathematical relationship is “fit” to the data. This is supposed to represent the influence of the conditions to the time or cycles to failure. The problem is there is so much variation in the time or cycles to failure that device life can only be conveyed in the form of a statistical average, such as mean time to failure (MTTF) or the mean time between failures (MTBF). This gives no information beyond that single point number and there is no measure of the real world probabilistic variation that exists in the manufactured product lot.

The old “MTBF view” of reliability is a hold-over from the days when computing power was expensive. The true failure mechanisms for computational modeling may have been understood by reliability specialists as conceptually desirable, but implementing them was completely beyond the tools of the time. Such ideas could not make their way into common practice, because there was no practical way for engineers to take advantage of them. No longer.

Our VLM system probabilistically models fatigue damage (dislocations, slip bands, small cracks and long cracks) and the damage interaction with material microstructural features (crystallographic planes, phase boundaries, grain boundaries) to simulate damage accumulation for lead and lead-free interconnects on a cycle by cycle basis. By taking into account such parameters as loading, temperature and microstructure, the VLM system can simulate real world conditions with a very high degree of accuracy.