TDK Lambda Magazine | May 2021

This detailed and precise process of Product Evaluation ends with hundreds of test pages per product - and even more. For example, the GENESYS+ 5kW reliability file has about 1,000 test pages. Extreme Scenarios Another procedure, called Component Derating, involves testing that helps us define the terms of use of each component. For each type of electronic component (such as MOSFET, Diode Resistor) the derating is determined with its main parameters: working voltage, working current, internal temperature and more. Through this procedure, a series of extreme scenarios are tested, in order to investigate the product’s functionality beyond its natural conditions. The thermal testing procedure is particularly critical - and also quite long, because it tests the durability of each component under any condition. One of the methods that are applied is to attach thermocouples to the power components. The process begins with testing common circuits for all models in the series, and continues with testing the unique circuits for each model. All tests are performed under extreme conditions: maximal external temperature, maximal power and minimal input voltage - in order to simulate the most difficult working conditions. The Weak Spot The E. CAP LIFE procedure addresses one of the most common problems in Electronics. Even if a product is still working, the electrolytic capacitors inside it age - and tend to show a decrease in performance. In this procedure we monitor each and every capacitor in the product - based on thermal measurements and Ripple calculations. Each of the capacitors is exposed to high temperatures in order to predict its lifespan. The smaller the diameter of the capacitor, the shorter its life. Therefore, in this procedure we place emphasis on testing the small and sensitive capacitors. According to the company’s standards, we must ensure - after measurements in extreme conditions - the maximal lifespan that characterizes our products. Initiated Bugs In the next stages, the components and the entire product undergo additional testing. In a series of tests called AB NORMAL we create a series of initiated faults. For example, power circuits will be disconnected and will undergo short - intentionally. The goal: to identify the components that were damaged in the crash, and to make sure that a rare

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