Investigating the Reliability of Heating, Ventilation, and Air Conditioning Systems Utilized in Passenger Vehicles

A Heating, Ventilation, and Air Conditioning (HVAC) system is often utilized in passenger vehicles to enhance the comfort of both the driver and the passengers. The reliability of an HVAC system refers to the probability that a component within the system will fulfil its intended function during a specified timeframe while operating according to the predefined operational and environmental conditions. Conducting a reliability analysis for the HVAC system of a passenger vehicle is crucial to ensure safety, comfort, cost-effectiveness, and a positive standing. A methodology for analyzing the reliability analysis of a HVAC system using field failure data were developed to identify the critical failure modes, components, and subsystems. A detailed Pareto analysis was applied at subsystem and failure mode levels in order to prioritize them accordingly to their failure frequency. The analysis showed that the A/C evaporator and blower front sides were observed to be the most critical subsystems, contributing to approximately 50% of all failures. Furthermore, the leakages at the joints and vibrations are the primary failure modes of the HVAC system. The Weibull++ software package (version 2021) was used to estimate the best-fit probability distributions for each subsystem and system reliability modelling using a Reliability Block Diagram. The results show that the exponential distribution fits well for several subsystem’s Time-To-Failure (TTF) data and show that the failures were random and due to external reasons.