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Assumptions accompanying exponential failure models are often not met in the standard sequential probability ratio test (SPRT) of many products. However, for most of the mechanical products, Weibull distribution conforms to their life distributions better compared to other techniques. The SPRT method for Weibull life distribution is derived in this paper, which enables the implementation of reliability compliance tests for gearboxes. Using historical failure data and condition monitoring data, a life prediction model based on hidden Markov model (HMM) is established to describe the deterioration process of gearboxes, then the predicted remaining useful life (RUL) is transformed into failure data that is used in SPRT for further analysis, which can significantly save on testing time and reduce costs. Explicit expression for the distribution of RUL is derived in terms of the posterior probability that the system is in the unhealthy state. The predicted and actual values of the residual life are compared, and the average relative error is 3.90 %, which verifies the validity of the proposed residual life prediction approach. A comparison with other life prediction and SPRT methods is given to elucidate the efficacy of the proposed approach.

Reliability sequential compliance method for a partially observable gear system subject to vibration monitoring