It Failed, But Why? What You Can Do with More Data

A common failure scenario while burst testing a tube assembly is that there is a failure at or near the tube to fitting junction. What was the failure sequence during the last few milliseconds of the test? Did the tube split before separating from the fitting? Was the tube expanding or being extruded from the fitting? Was it a gradual failure or was it instantaneous? These questions can be answered through the interpretation of the collected data, but not all test systems are measured equally when it comes to test control and data management.

How Do You Remove the Guess Work?

You have tested your component using the correct Industry Standards, and have followed the prescribed test parameters, but now what? Your component failed within the expected parameters, but why did it fail? What can you do to determine the actual reason for the failure and what do you do to improve your component or reduce manufacturing costs?

These questions are commonly asked during the testing phase of new products and can go unanswered or sometimes simply ignored. Genuen’s Test as Service (TaaS) offerings employ Real-Time-Controller-Based Systems, which can be utilized to answer your questions with more data than provided by PLC-based test systems.

In this blog post, we’ll be looking at the advantages of data produced by Real-Time-Controller-Based Systems and what you can do with this data.

Note: Burst testing scenarios are used throughout this post to illustrate the benefits of Real-Time-Controller-Based Systems; however, these benefits can be applied to any kind of testing.

It Failed, But Why? What You Can Do with More Data

Advantages of Real-Time Data

Most test as a service providers offer testing on PLC-based systems. While these systems are capable of performing the test, the data captured is limited by the PLC’s scan time. This sample rate can be greater than 40 milliseconds. Yet, while a PLC-based system can capture that a part has failed and at what pressure failure occurred, operators are left asking what really happened, from data-point to data-point, during that missed 39 milliseconds?

Using a test scenario with a ramp rate of 20,000 PSI/second, the captured data point could have an error as high as ±780 PSI (or a 4% error).

Test systems utilizing Real-Time Data can better provide the answer to what was happening during the test just before and during the component’s failure. By collecting data using data sample rates of up to 1,000 Hz, an informed decision can be made about what really happened rather than basing decisions upon a hit-or-miss period before the actual failure.

Discover What’s Happening Between Point A and Point B

Real-Time data collection enables you to know what’s happening, along with adjustable capture rates, between two sample points. With Genuen’s Real-Time-Controller-Based TaaS systems, an entire slope can be recorded, specific portions of the pressure curve, or just a definable “snapshot period” leading up to the failure.

Example of “snapshot” periods of a Proof to Burst Test

Know What Happened During the Exact Moment of Failure

With high data sample rates enabled by Real-Time-Controller-Based Systems, you can see exactly what happened just before or even during the moment of failure. Higher data sample rates also allow you to measure the expansion rate, elongation rate, and their overall percentages in relationship to the applied pressure of components.

Having this data can help you to determine the mode of failure to find its root cause. Was the failure the result of a gradual increase in leakage? Or was the failure instantaneous? Access to more data allows you to utilize Comparative and Condition Based Monitoring models to refine your components throughout the development and manufacturing processes. With this data you can better analyze possible modifications to the design to prevent future failures.

Better Visualization

Real-Time-Controller-Based Systems provide you with more information, so you can use precise data to make informed evaluations. Our available data package content varies from base CSV files to fully plotted data curves to meet your specific requirements. With the addition of photographs, commentary and observations from technicians, and even time-linked video to data packages, Genuen can provide you with the correct amount of data to make informed decisions.

An example of a burst test report showing the entire curve

Use Your Data to Make Predictions

While more data may not always be better, with an expert interpretation, more data can be a powerful tool to determine your failure analysis and predict how your component will respond to other stimuli. This can result in reduced concept-to-production times, lowered manufacturing costs, longer product life, improved performance, and documented specification conformance. This additional data can be easily obtained by utilizing Genuen’s Real-Time Based TaaS test platforms without the requiring you to update your current test systems or purchase additional equipment.

Learn more about Genuen's TaaS offerings to determine how more data can expedite your test processes and assist in making informed decisions.