product reliability testing: environmental, mechanical and ... · pdf filemike brown...
TRANSCRIPT
![Page 1: PRODUCT RELIABILITY TESTING: Environmental, Mechanical and ... · PDF fileMike Brown Laboratory Manager Presenter Herb Schueneman President & CEO Presenter PRODUCT RELIABILITY TESTING:](https://reader034.vdocuments.us/reader034/viewer/2022051320/5ab7fb807f8b9a684c8c3ce2/html5/thumbnails/1.jpg)
Mike Brown Laboratory Manager
Presenter
Herb Schueneman President & CEO
Presenter
PRODUCT RELIABILITY TESTING: Environmental, Mechanical and Packaging
Case study: 19” Rackmount Switch
June 2015
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2
Overview
• Background
– Why Test?, DOE, Product Classifications
• Environmental tests
– Temperature, Humidity, Altitude
• Mechanical tests
– Mechanical Shock, Vibration, Handling
• Shipping / Packaging Tests
– Drop, Compression, Vibration
• Conclusions and Questions
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Why Test?
• Products will be subjected to hazards – Shipment
– Storage extremes
– Operating environment
– Rough handling, installation
• Regulatory / Certification Requirements – Safety (Optical, Acoustic, Electrical, Fire)
– EMI/EMC
– Product Functionality
• Customer Satisfaction, Warranty, Liability
3
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Establishing the Test Plan
4
• Design of Experiments (DoE)
– Characterize environments DUT will see
• Define test inputs to cover all hazards – Environmental, Mechanical, Shipping
• Consider unique / combined environments
– Determine acceptance criteria / inspections
– Start small (EVT, DVT, Final Production)
• Test temperature and mechanical handling
– Test to level vs. testing to failure
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Product Classifications
5
• Example: Rackmount network switch
Handheld Product Small Product Large Product
Smaller units a user will carry by hand or their
person
A single user can install / move without assistance.
(usually <100 pounds)
Requires two or more people or mechanical lift
to install / move. (usually >100 lbs)
Ships single parcel and freight (unitized load)
Ships single parcel and freight (unitized load)
Ships as freight only
Moderate Environment Severe Environment
General office or server farm environment. Moderate operating
environment.
Consumer product, could be used anywhere, could be in used in extreme
temperature conditions.
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Non-Operational Temperature
6
• Define temperature range – Storage temperatures
• -40°C to +85°C (Severe) • -30°C to +60°C (Moderate)
– Shipping conditions • Cold, Tropical, Desert • -40°C, 40°C/90%RH, 60°C/30%RH
– Static extremes, cyclic and shock tests – Standards: IEC 60068-2-1 (Cold), IEC 60068-2-2 (Hot), IEC 60068-2-14 (Thermal Cycle), IEC 60068-2-78 (Humidity), ASTM D4332 (Shipping)
• Common issues / results – Thermal expansion / contraction – Oxidation / Corrosion – Exceeding material limits, mechanical failures
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Operating Temperature Setup
7
• Instrument components of interest
– Internal temp sensors or externally mounted
– Define maximum allowable operating temperatures
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Operating Temperature / Humidity
• Test conditions – Cold: 0°C
– Hot/Wet: 40°C / 90%RH • Dew point and condensation
– Hot/Dry: 40°C / 20%RH
• Test plan – Operate at each condition for 12 – 24 hours
– Power cycle unit on / off
• Common Issues / Results – Electrical problems (often caused by condensation)
– Component overheating 8
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Operating Temperature / Humidity
9
0
5
10
15
20
25
30
35
40
45
50
0 1 2 3 4 5 6 7 8 9 10
Tem
pe
ratu
re (
C)
Elapsed Time (hours)
Operating Temperature Rise
Unit Heatsink (°C)
Chamber Air (°C)
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Non-Operating Altitude
• Define environment (shipment, storage)
– Usually tested to 14,000, 16,000 or 40,000-ft equivalent
– Only applicable for sealed volumes, potted parts, etc.
• Common tests
– 1 hour duration at low pressure
– ASTM D6653, IEC 60068-2-13
• Common results
– Expanded/imploded parts
10
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Operating Altitude
• Define environment (end use)
– Usually tested to 10,000 or 14,000-ft equivalent
– Low air pressure greatly reduces effectiveness of convective cooling
• Common tests
– 12-24 hour duration at low pressure
– IEC 60068-2-13
• Common results
– Unit overheating
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Operating Altitude - Data
39
40
41
42
43
44
45
0 1 2 3 4 5 6
Tem
pe
ratu
re (
C)
Elapsed Time (hours)
Low Pressure (Altitude)
Unit Heatsink (°C)
Chamber Air (°C)
14,000ft Sea Level 10,000ft
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Other Environmental Tests
• Ultraviolet (UV) Light
– ASTM G154 (UV only) or G155 (Full Spectrum)
– Materials selection or comparative testing
– Fading, legibility, brittle plastics
• Corrosive Atmosphere
– ASTM B117
– Corrosion of metals, dissimilar metals uncoated parts
• Water Spray / Ingress Protection
– IEC 60529
– Depends on application 13
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Other Environmental Test Considerations
14
• Typical input vs. worst case scenario
• Operating Inputs
– High / Low Nominal Voltage
• Safety
– Do safety cut outs work (thermal)
– Does the device fail safely?
• Acceptance Criteria
– Cosmetic, functional, safety
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Questions
15
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Mechanical Testing - Setup
• Why use Accelerometers?
– Resonance search
– Characterize response to mechanical excitations
– Characterize response to operating components (fans)
• Typical Test Setup
– 1 Accelerometer on chassis
– 1 to 4 Accelerometers on components of interest
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Mechanical Testing - Setup
• Choose most rigid practical chassis location
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Mechanical Testing - Setup
• Mounting accelerometer
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Mechanical Testing - Setup
• Component Accelerometer
– Sensitive components / spring-mass systems
– Use appropriate adhesion method!
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Mechanical Testing - Setup
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Mechanical Testing - Setup
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Mechanical Testing - Setup
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Mechanical Testing - Orientations
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Operating / Non-Operating Sine Vibration
• Reasons to test – Non-operating: Resonance Search – Operating: Unique and Severe Use Environments (Stress Test)
• Typical Test – All tests: X, Y, Z axis – Resonance search: 2 sweeps – Stress test: 10 sweeps / resonant dwell – 0.1G to 5.0G constant acceleration – Frequency Domain: 5-500Hz – Test Standards
• ASTM D3580, ASTM D5112, IEC 60068-2-6
• Common Issues / Results – Unit shut down or operating errors – Unsupported / surface mount component failure – Critical component resonance / failure
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Sine Vibration Control
profile(f)
control(f)
500.00 5.00 10.00 100.00
10.0000
0.0100
0.1000
1.0000
Frequency (Hz)
gn
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Sine Vibration Response - Chassis
Chassis
Chassis
500.00 5.00 10.00 100.00
100.0000
0.0100
0.1000
1.0000
10.0000
Frequency (Hz)
(gn)/(gn)
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Sine Vibration Response - PCB
PCB
PCB
500.00 5.00 10.00 100.00
100.0000
0.0100
0.1000
1.0000
10.0000
Frequency (Hz)
(gn)/(gn)
PCB: 171.2734 Hz, 25.1815 (gn)/(gn) PCB: 216.4476Hz, 21.3627 (gn)/(gn) dx = -45.1742Hz, dy = 3.8188 (gn)/(gn)
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Operating / Non-Operating Random Vibration
• Reasons to test – Non operating: Resonance Search / Shipment – Operating: End use environment
• Typical Tests – All tests: X, Y, Z axes tested / 10-60 minutes per axis – Non-operating: 5Hz to 500Hz up to 5 Grms – Operating: 5Hz to 500Hz up to 1 Grms
• Test Standards – ASTM D3580, ASTM D5112, IEC 60068-2-64
• Common Issues / Results – Operational issues – Unsupported / surface mount component failure – Critical component resonance / failure
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Non-Operating Random Vibration Example: 1.35 Grms, 2-500 Hz
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Random Vibration Control
control(f)
profile(f)
500.00 2.00 10.00 100.00
0.1000
1.00E-04
0.0010
0.0100
Frequency (Hz)
(gn)²/Hz
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Random Vibration Response - Chassis
Chassis
500.00 2.00 10.00 100.00
100.0000
0.0100
0.1000
1.0000
10.0000
Frequency (Hz)
((gn)²/Hz)/((gn)²/Hz)
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Random Vibration Response - PCB
PCB
500.00 2.00 10.00 100.00
100.0000
0.0100
0.1000
1.0000
10.0000
Frequency (Hz)
((gn)²/Hz)/((gn)²/Hz)
PCB: 170.6250 Hz, 20.5499 ((gn)²/Hz)/((gn)²/Hz) PCB: 216.8750Hz, 19.1423 ((gn)²/Hz)/((gn)²/Hz) dx = -46.2500Hz, dy = 1.4077 ((gn)²/Hz)/((gn)²/Hz)
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Operating Mechanical Shock
• Typical Test
• Half-sine duration (0.5ms – 18ms)
• Peak G level (6-50G’s)
• X, Y, Z axes both directions
• Test Standards
• ASTM D3332, IEC 60068-2-27
• Common Issues / Results
• Unsupported / surface mount component failure
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Non-Operating Mechanical Shock
• Typical Test • Half-sine duration (0.5ms – 18ms)
• Will see ‘shock’ in shipment
• Peak G level (6-50G’s)
• X, Y, Z axes both directions
• Consider using trapezoidal pulse shape
• Test Standards • ASTM D3332, IEC 60068-2-27
• Common Issues / Results • Unsupported / surface mount component failure
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Non Operating Mechanical Shock Example: 40G’s, 11ms, Half-Sine
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Mechanical Shock - Control
control(t)
profile(t)
22 -11 -8 -4 0 4 8 12 16 20
50.0000
-50.0000
-40.0000
-30.0000
-20.0000
-10.0000
0
10.0000
20.0000
30.0000
40.0000
Time (Milliseconds)
gn
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Mechanical Shock Response - Chassis
Chassis
input3(t)
22 -11 -8 -4 0 4 8 12 16 20
50.0000
-50.0000
-40.0000
-30.0000
-20.0000
-10.0000
0
10.0000
20.0000
30.0000
40.0000
Time (Milliseconds)
gn
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Mechanical Shock Response - PCB
PCB
input4(t)_c0
22 -11 -8 -4 0 4 8 12 16 20
50.0000
-50.0000
-40.0000
-30.0000
-20.0000
-10.0000
0
10.0000
20.0000
30.0000
40.0000
Time (Milliseconds)
gn
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Manual Handling
• Simulate Installation Drop
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Mechanical Cycling
40
• All moving mechanical components should be evaluated • For Network Switch
• AC Cord / LAN Connections • ~100 cycles • Define cycle force, speed, duration • Inspect periodically • Test by hand or by machine
• Test Standards • Various
• Common Issues / Results • Quick wear out • Change in actuation or insertion/removal force
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Questions
41
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Shipping
42
• Every product will be shipped!
• Common test inputs
• Environmental Conditioning
• Freefall Drop / Side Impact
• Compression
• Vehicle Vibration
• Other hazards
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Common Shipment Standards
43
• Small Parcel (less than 150 pounds)
• ISTA 2A or 3A
• ASTM D4169 (DC3 or DC13)
• ASTM D7386 (TS4)
• Freight (greater than 150 pounds, or on pallet)
• ISTA 2B, 3B, 3E
• ASTM D4169 (DC5 or DC6)
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Package Orientations
44
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Environmental Conditioning
45
• Simulate extreme environments in shipping
• ASTM D4332 Standard Conditions
• Cold (-30°C)
• Desert (60°C / 15% RH)
• Tropical (40°C / 90% RH)
• Stresses hygroscopic packaging (CFB)
• May cause condensation on EUT
• May cause tape or closures to come open
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Small Parcel Packaged Freefall Drop
• ISTA 2A parameters
• 10 drops: 1 corner, 3 edges, 6 faces
• Height based on weight (38”)
• Test equipment per: ASTM D5276
• Common Issues / Results
• Box denting, box failure, product damage
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Packaged Freefall Drop
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Packaged Freefall Drop - Chassis
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Packaged Freefall Drop - PCB
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Package Compression
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• Top load to simulate stacking in shipment • Top load based upon cubic volume above box in a
tractor trailer
• Sample compression formula (ISTA 2A) • Top load = Wt x (S – 1) x F x 1.4
• 415 lbs = 3.7 x (21 – 1) x 4 x 1.4
• Test equipment per ASTM D642
• Common issues / results • Box failure
• Damage to internal components
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Vehicle Vibration
• Simulates truck/aircraft shipment
• ISTA 2A
• 30 minutes base, 10 minutes top, side, end
• Test Equipment per: ASTM D4728
Common Issues / Results
• Components coming loose (SMT, large mass)
• Resonance
• Scuffing
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Vehicle Vibration
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Vehicle Vibration – ISTA 2A Profile
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profile(f) control(f)
200 1 10 100
0.1000
1.00E-05
0.0001
0.0010
0.0100
Frequency (Hz)
(gn)²/Hz
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Vehicle Vibration – Chassis Response
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Chassis (Z axis)
200 1 10 100
10.0000
0.1000
1.0000
Frequency (Hz)
Chassis (Z axis): 15.6250, 2.3483
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Vehicle Vibration – PCB response
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PCB (Z axis)
200 1 10 100
10.0000
0.0100
0.1000
1.0000
Frequency (Hz)
PCB (Z axis): 18.1250, 3.0485 PCB (Z axis): 173.7500, 4.1981 dx = -155.6250, dy = -1.1496 RMS= 14.5191, Power= 210.8054
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Parting Thoughts
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• Start by defining environment and regulatory requirements.
– Establish acceptance criteria
• Think about design and material choices first – Reference existing solutions!
• Start with small portions of the test plan – Test as early as possible, expect to have findings
– Take corrective action before finalizing tooling
• Don’t forget you have to ship it!
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Next Webinar: Packaging Dynamics Series
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#1: Overview and Definition of Terms – Jan 2015
#2: Defining & Quantifying the Distribution Environment Through Which All Products Must Travel – March 2015
#3: Determining the Vibration Sensitivity & Shock Fragility of Products; Test Methods, End Results, and Significant Insights –
#4: Dynamic Cushion Testing for Shock Absorption & Vibration Attenuation; Characteristics of Common Cushion Materials and Systems – July 2015
#5: Design and Testing of the Protective Package System; How We Know When the Job Was Done Correctly– Oct 2015
DONE !
DONE !
DONE !
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Questions
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About WESTPAK, INC.
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Two Locations:
San Jose Laboratory San Diego Laboratory
83 Great Oaks Boulevard 10326 Roselle Street
San Jose, CA 95119 San Diego, CA 92121
408-224-1300 858-623-8100
www.westpak.com
Contact Us
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THANK YOU !
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Mike Brown Laboratory Manager
Herb Schueneman President & CEO
Please feel free to Contact Us with any questions or assistance with your testing needs.