An overall methodology for reliability prediction of mechatronic systems design with industrial application

•A ten-step methodology for reliability prediction of mechatronic systems design.•Qualitative and quantitative analysis for reliability evaluation using PN and RBD.•A dependency matrix proposal, based on the collateral and functional interactions.•Models consider mission profile, deterioration, interactions and influent factors.•Application and validation of the methodology on the “Smart Actuator” of PACK’AERO.

We propose in this paper an overall ten-step methodology dedicated to the analysis and quantification of reliability during the design phase of a mechatronic system, considered as a complex system. The ten steps of the methodology are detailed according to the downward side of the V-development cycle usually used for the design of complex systems. Two main phases of analysis are complementary and cover the ten steps, qualitative analysis and quantitative analysis. The qualitative phase proposes to analyze the functional and dysfunctional behavior of the system and then determine its different failure modes and degradation states, based on external and internal functional analysis, organic and physical implementation, and dependencies between components, with consideration of customer specifications and mission profile. The quantitative phase is used to calculate the reliability of the system and its components, based on the qualitative behavior patterns, and considering data gathering and processing and reliability targets. Systemic approach is used to calculate the reliability of the system taking into account: the different technologies of a mechatronic system (mechanics, electronics, electrical .), dependencies and interactions between components and external influencing factors. To validate the methodology, the ten steps are applied to an industrial system, the smart actuator of Pack'Aero Company.