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ECE 3000: Engineering Seminar

ECE 3000: Engineering Seminar. Engineering Failures. 1) Toyota Recalls (2009). Issue: Pedals trapped/stuck causing unintended acceleration or braking issues. Impact: ~20.5m vehicles recalled. 2) Hall of Shame: Samsung.

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ECE 3000: Engineering Seminar

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  1. ECE 3000: Engineering Seminar Engineering Failures

  2. 1) Toyota Recalls (2009) • Issue: Pedals trapped/stuck causing unintended acceleration or braking issues. • Impact: • ~20.5m vehicles recalled

  3. 2) Hall of Shame: Samsung https://www.sammobile.com/2016/08/24/samsung-galaxy-note-7-explodes-while-charging-using-a-usb-type-c-converter/

  4. 2) Samsung’s Galaxy Note 7 are on Fire! (2016) • https://www.extremetech.com/mobile/243198-samsung-reveals-root-cause-galaxy-note-7-failures-fires • Samsung’s version of the story: • Battery had manufacturing defect – electrodes were prone to bending. > Causing short circuit and fire. • Recalled > Had 2 battery manufacturers- switched to only one> New batteries prone to welding defect causing positive and negative electrodes to short at welding point. • Second recall !! > Note 7 off market. • Impact: • $5.3 billion cost to Samsung! • 96 battery overheating reports (per US Consumer Product Safety Commision) • Per Samsung: • 13 report of Burns. • 47 reports of property damage.

  5. 2) Burnt Note7 - Video • http://www.dailymail.co.uk/sciencetech/article-3774896/Samsung-DIDN-T-officially-recall-Galaxy-Note-7-Consumer-Reports-slams-phonemaker-failing-make-exploding-battery-issue-official.html

  6. 3) Takata Airbags (2004?/2008 – 2017) 2019?? • May shoot metal fragments, upon/during inflation! • Impact: • Chrysler, Honda, Toyota, Nissan, Ford, BMW, GM, Subaru, Volkswagen, Mercedes Benz, Ferrari, Mazda, Mitsubishi, Audi, Jaguar, Tesla. • ~42 million vehicles affected in US • Honda: 11 deaths & 184 injuries in US • Interesting: • Only 12% of recalled cars repaired in America, vs 70% recalled repaired in Japan (huge difference in the no. of cars?) • Orbital testing results: “it was the combination of these three factors—the use of ammonium nitrate, the construction of Takata’s inflator assembly, and the exposure to heat and humidity—that made the inflators vulnerable to rupture.” • Cause: • Improper storage of propellant causes increased pressure • Humidity? Rust? • Welding issue? • DPM - High passing rate?

  7. 4) VW TDI Fiasco • Promise: clean Diesel, Failure: 40x times NOx emissions! • Impact: • Public health and enviorment • Law enforcement and EPA • Bad publicity and failure for approval of future vehicles • Cause: • Activated ECU controls during testing to mask their true NOx emissions • In real-world driving, ECU controls were off • Corporate greed • Software realignment • Defeat device

  8. More engineering disasters Most Famous • https://10mosttoday.com/10-most-famous-engineering-disasters/ Architectural Failures • https://www.youtube.com/watch?v=M6wP93cvnSA EE/ECE related Failures • https://www.youtube.com/watch?v=qgusHewRFgA • https://en.wikipedia.org/wiki/Capacitor_plague Learning from Failures (Technical issues) • https://www.tms.org/Communities/FTAttachments/material_disasters_Nik_Chawla.pdf • https://www.journals.elsevier.com/engineering-failure-analysis/recent-articles

  9. Assignment • Please do a case study on an engineering failure that was reported in the past 5 years. • Summarize the event (what happened), what was the impact (on both customer and engineer/organization side) and how the organization responded to it (fix?). • Share your thoughts on what was the cause of the failure. • What can be learnt from this failure and how can it be avoided in the future?

  10. References • http://www.engineering.com/DesignerEdge/water/ArticleID/5301/Five-Biggest-Engineering-Disasters.aspx • https://www.extremetech.com/mobile/243198-samsung-reveals-root-cause-galaxy-note-7-failures-fires • https://www.usatoday.com/story/tech/2016/10/14/samsung-note-7-recall-cost-least-53-billion/92040942/ • https://blog.caranddriver.com/massive-takata-airbag-recall-everything-you-need-to-know-including-full-list-of-affected-vehicles/ • https://www.theatlantic.com/business/archive/2011/05/who-was-really-at-fault-for-the-toyota-recalls/238076/

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