Exploration of a Statistically Accurate and Energy Efficient Accelerated Testing Methodology

本基础研究的目的是探索一种新的加速测试（AT）方法，以提高AT实验的可靠性估计精度，同时最大限度地减少其总能耗。AT的基本思想是将产品的测试单元暴露在比正常操作条件更恶劣的环境中，以加速故障的发生。然而，AT经常消耗大量的能量。为了避免在广泛的产品开发过程中浪费能源，本研究将通过将控制理论纳入复杂的实验设计来增加我们的知识，这些实验设计需要新的工具来共同处理统计估计精度，控制器设计和通过计算机模拟的能量评估。该方法将确定各种应力载荷与总能耗之间的相互关系，建立一个通用框架，以促进最佳实验设计和节能过程，并提供能够跟踪各种应力载荷的先进控制策略。为了验证该方法，将研究焊点的长期可靠性，这在微电子工业中是相当具有挑战性的，并且对数百万应用至关重要。如果成功，这项研究将改变目前在开发高可靠性产品（或材料）方面的可靠性测试实践，这些产品（或材料）不断面临着对时间和节能技术日益增长的需求。考虑到美国和全世界正在开发的数以百万计的产品，在开发过程的每个阶段减少可靠性测试的能量将最终导致大量的能源节约。这项研究补充了世界范围内积极寻求新能源的可持续性努力。研究结果亦会加强可靠性工程、设备及控制、统计及节能技术的教育和知识传播。此外，研究结果将通过出版物、讲习班和行业合作得到广泛传播。此外，该项目将招募少数民族和女性学生，K-12教师和学生将接触到最前沿的研究经验。

The objective of this fundamental research is to explore a new accelerated testing (AT) methodology that improves the reliability estimation accuracy of an AT experiment while minimizing its total energy consumption. The basic idea of AT is to expose test units of a product to harsher-than-normal operating conditions to expedite failures. However, AT often consumes significant amounts of energy. To avoid the waste of energy in a wide spectrum of product development processes, this research will increase our knowledge by incorporating control theory into such complex experimental designs that require new tools to jointly handle statistical estimation accuracy, controller design, and energy assessment via computer simulation. The methodology will determine the interrelationship between various stress loadings and total energy use, establish a generic framework to facilitate the optimum experimental design and energy reduction process, and provide advanced control strategies capable of following various stress loadings. To validate the methodology, the long-term reliability of solder joints will be studied, which is quite challenging in the microelectronics industry and is essential for millions of applications. If successful, this research will change the current reliability testing practices in developing highly reliable products (or materials) that are continually faced with increasing needs for time- and energy-saving technologies. Considering millions of products being developed in the U.S. and the world, energy reduction in reliability testing for each stage of a development process will eventually lead to substantial energy savings. This research complements the world-wide sustainability efforts in actively seeking new energy resources. The research findings will also enhance education and knowledge dissemination in reliability engineering, equipment and control, statistics, and energy-saving technologies. Moreover, the results will be broadly disseminated through publications, workshops, and industry collaborations. Furthermore, minority and female students will be recruited in this project and K-12 teachers and students will be exposed to cutting edge research experiences.