Reliability design and case study of refrigerator parts subjected to repetitive loads under consumer usage conditions

When newly designed refrigerator parts failed due to repetitive loads under consumer usage conditions in the field, a general method for reliability design was proposed. A newly designed refrigerator compressor system that brings greater energy efficiency to side-by-side (SBS) refrigerators was studied. The laboratory failure mode and mechanism of the compressor was a stopping nose due to design flaws. The data on the failed products in the field, accelerated life tests (ALT) and corrective action plans were used to identify the key control parameters for the mechanical compressor system. The missing controllable design parameters of the compressor system in the design phase were the gap between the frame and the upper due to the stator frame shape. After a tailored series of accelerated life tests with corrective action plans, the B1 life of the new compressor system is now guaranteed to be over 10 years with a yearly failure rate of 0.1%.

► When newly designed refrigerator parts failed due to repetitive loads, a general method for reliability design was proposed.
► A newly designed refrigerator compressor system was studied.
► The laboratory failure mode and mechanism of the compressor was a stopping nose due to design flaws.
► After accelerated life tests with corrective action plans, B1 life of the compressor system is guaranteed to be over 10 years.