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试验（AT）方法，提高可靠性估计精度的AT实验，同时最大限度地减少其总能量消耗。AT的基本思想是将产品的测试单元暴露在比正常更苛刻的操作条件下，以加速故障。然而，AT通常消耗大量的能量。为了避免在广泛的产品开发过程中浪费能源，这项研究将增加我们的知识，将控制理论结合到这样复杂的实验设计，需要新的工具来共同处理统计估计精度，控制器设计，并通过计算机仿真的能源评估。该方法将确定各种应力载荷和总能量使用之间的相互关系，建立一个通用的框架，以促进最佳的实验设计和能量减少过程，并提供先进的控制策略，能够遵循各种应力载荷。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，并且对于数百万应用是必不可少的。如果成功，这项研究将改变目前的可靠性测试实践，开发高度可靠的产品（或材料），不断面临越来越多的时间和节能技术的需求。考虑到美国和世界上正在开发的数百万种产品，在开发过程的每个阶段减少可靠性测试的能源最终将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发展努力。研究结果还将加强可靠性工程、设备和控制、统计和节能技术方面的教育和知识传播。此外，研究结果将通过出版物、研讨会和行业合作广泛传播。此外，少数民族和女学生将在这个项目中招募和K-12教师和学生将接触到前沿的研究经验。

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.