Reliability test and failure analysis of high power LED packages

A new type application specific light emitting diode （LED） package （ASLP） with freeform polycarbonate lens for street lighting is developed, whose manufacturing processes are compatible with a typical LED packaging process. The reliability test methods and failure criterions from different vendors are reviewed and compared. It is found that test methods and failure criterions are quite different. The rapid reliability assessment standards are urgently needed for the LED industry. 85℃/85 RH with 700 mA is used to test our LED modules with three other vendors for 1000 h, showing no visible degradation in optical performance for our modules, with two other vendors showing significant degradation. Some failure analysis methods such as C-SAM, Nano X-ray CT and optical microscope are used for LED packages. Some failure mechanisms such as delaminations and cracks are detected in the LED packages after the accelerated reliability testing. The finite element simulation method is helpful for the failure analysis and design of the reliability of the LED packaging. One example is used to show one currently used module in industry is vulnerable and may not easily pass the harsh thermal cycle testing.

Novel Accelerating Life Test Method and Its Application by Combining Constan Stress and Progressive Stress

Constant stress accelerated life tests(ALTs) can be applied to obtain a high estimation accuracy of reliability measure?ments, but these are time?consuming tests. Progressive stress ALTs can yield failures more quickly but cannot guaran tee the estimation accuracy of reliability measurements. In this paper, a progressive?constant combination stress ALT is proposed to combine the merits of both tests. The optimal plan, in which the design variables are the initial pro?gressive stress level, the progressive stress ramp rate, the sample allocation proportion of the progressive stress and the constant stress level, is determined using the principle of minimizing the asymptotic variance of the maximum likelihood estimator of the natural log reliable life for the connectors. A comparison between the optimal PCCSALT plan and the CSALT plan with the same sample size and estimation accuracy shows that the test time is reduced by 13.59% by applying the PCCSALT.

Accelerated Degradation Reliability Modeling and Test Data Statistical Analysis of Aerospace Electrical Connector

As few or no failures occur during accelerated life test,it is difficult to assess reliability for long-life products with traditional life tests.Reliability assessment using degradation data of product performance over time becomes a significant approach.Aerospace electrical connector is researched in this paper.Through the analysis of failure mechanism,the performance degradation law is obtained and the statistical model for degradation failure is set up; according to the research on statistical analysis methods for degradation data,accelerated life test theory and method for aerospace electrical connector based on performance degradation is proposed by improving time series analysis method,and the storage reliability is assessed for Y11X series of aerospace electrical connector with degradation data from accelerated degradation test.The result obtained is basically consistent with that obtained from accelerated life test based on failure data,and the two estimates of product＇s characteristic life only have a difference of 8.7%,but the test time shortens about a half.As a result,a systemic approach is proposed for reliability assessment of highly reliable and long-life aerospace product.

Aging effect and test-retest reliability of the sinusoidal harmonic acceleration test and velocity step test using nanotorque rotatory chair

Introduction:Rotatory chair testing has been used to evaluate horizontal canal function.Frequently used tests include sinusoidal harmonic acceleration test(SHAT)and velocity step test(VST).Objectives:Assessment of age effect on the SHAT and VST and assessment of test-retest reliability of the parameters of those two tests.Methods:A prospective study was performed on 100 subjects with no ear or vestibular complaints and normal vestibular evaluation.They were divided into two groups;Group A:below 50 years of age and Group B:50 years of age or above.SHAT was presented at frequencies 0.02,0.04,0.08,0.16,0.32,0.64 Hz with a peak velocity of 60°/s.VST was performed using a maximum velocity of 100°/s with acceleration and deceleration of 200°/s2.Thirty subjects were tested twice to assess reliability.Results:Study participants ranged in age from 20 to 67 years.Regarding group A,the mean age was30.92±7.31 and 55.36±4.61 for group B.No significant differences were found in SHAT parameters between the two groups.As well,there was no significant difference in VST per-rotatory time constant,however,post-rotatory time constant was significantly longer for Group B(P value<0.05).Intraclass correlation coefficient(ICC)values showed moderate to good reliability(ICC 0.5800.818)for SHAT parameters for the lower frequencies and indicated moderate reliability for VST time constant(ICC 0.5090.652).Conclusions:Age has no significant effect on the parameters of SHAT and VST.Test-retest reliability is generally good for both tests.

Efficient Method for Accelerated Reliability Qualification Testing

Based on the theoretical inference and experiment verification,a method was proposed to carry out the accelerated reliability qualification testing. First,theoretical inference was used to get the acceleration coefficients of super Gauss vibration stress and temperature stress. Then, by applying these coefficients, an accelerated reliability qualification testing curve was obtained from the standard tests. Finally,the actual experiment on a digital marine control device was carried out under the proposed testing method.The experiment result shows that the proposed method can reduce the total experiment time and improve the efficiency of the reliability qualification test.

New method of online testing and data processing for LED lamps

In order to achieve quick and accurate lifetime prediction of LED lighting products under the testing time of 2 000 h, a method of online testing of luminous flux is proposed under the condition of temperature stress.Exponential fitting of lumen maintenance, the Bayesian estimation of failure probability, the Weibull distribution of lifetime and the Arrhenius model of the decay rate are used in combination to acquire the distribution of failure probability over time at the ambient temperatures of 25 ℃. The lifetime test of the same lamps based on the Energy Star standard under the testing time of 6 000 h is also implemented to verify the effectiveness of the method. The errors of lifetimes acquired with the proposed method are 7%, 4%, 3% and 1% at the failure probabilities of 62. 3%, 10%, 5% and 1%,respectively.

IEC 62059 Standards' Application in Reliability Prediction and Verification of Smart Meters

This article introduces the current situation of the smart then describes the relationship of meter reliability characteristics meter＇s reliability and the failure mechanisms at first, and combined with its Bathtub Curve. It also introduces both the feasible failure tree model for meter lifecycle prediction based on actual experiences and meter reliability prediction methodology by SN 29500 norms based on this model. This article also brings forward that it is necessary that the ＂Learning Factor＂ shall be adopted in meter reliability prediction for new materials, new process, and customized parts by referring to GJB/Z299C. Thereafter, this article also tries to apply IEC 62059 and JB/T 50070 to introduce the feasible method for the lifecycle prediction result verification by accelerated lifecycle test. Furthermore, the article also explores ways to increase the firmware reliability in smart meter.

Step-stress Accelerated Degradation Test Modeling and Statistical Analysis Methods

In order to get a rapid assessment on the storage reliability of high-reliable and long-life products within the storage period, accelerated degradation test data with a large amount of reliability information of product is adopted. Conducting a constant-stress accelerated degradation test（CSADT） is generally very costly as it requires a large sample size and long time for test. To overcome this problem, it is necessary to carry out research on modeling and statistical analysis methods of step-stress accelerated degradation test （SSADT）. Taking electrical connectors as the object, a research is conducted on statistical model and assessment method for SSADT. On the basis of mixed-effect degradation path model, the statistical model of SSADT for electrical connectors is presented, the maximum likelihood method for SSADT data based on mixed-effect degradation model is proposed. SSADT accelerated by temperature stress is conducted to Y11X-1419 type of electrical connectors, and the storage reliability is assessed with the SSADT data. Compared with the result obtained from accelerated life test, the reliability estimation of 32-year storage period for electrical connectors obtained from S SADT data only have a difference of 0.869%, which validates the accuracy of the degradation model and the feasibility of the test data statistic analysis method put forward.

Consistency check of degradation mechanism between natural storage and enhancement test for missile servo system

Reliability enhancement testing(RET) is an accelerated testing which hastens the performance degradation process to surface its inherent defects of design and manufacture. It is an important hypothesis that the degradation mechanism of the RET is the same as the one of the normal stress condition. In order to check the consistency of two mechanisms, we conduct two enhancement tests with a missile servo system as an object of the study, and preprocess two sets of test data to establish the accelerated degradation models regarding the temperature change rate that is assumed to be the main applied stress of the servo system during the natural storage. Based on the accelerated degradation models and natural storage profile of the servo system, we provide and demonstrate a procedure to check the consistency of two mechanisms by checking the correlation and difference of two sets of degradation data. The results indicate that the two degradation mechanisms are significantly consistent with each other.

Design of Accelerated Life Test Plans——Overview and Prospect

Accelerated life test(ALT) is currently the main method of assessing product reliability rapidly, and the design of efficient test plans is a critical step to ensure that ALTs can assess the product reliability accurately, quickly, and economically. With the promotion of the national strategy of civil-military integration, ALT will be widely used in the research and development(R&D) of various types of products, and the ALT plan design theory will face further challenges. To aid engineers in selecting appropriate theories and to stimulate researchers to develop the theories required in engineering, with focus on the demands for theory research that arise from the implementation of ALT, this paper reviews and summarizes the development of ALT plan design theory. The development of the theory and method for planning optimal ALT for location-scale distribution, which is the most applied and mature theory of designing the optimal ALT plan, are described in detail. Taking this as the center of radiation, some problems that ALT now faces, such as the verification of the statistical model, limitation of sample size, solutions of resource limits, optimization of the test arrangement, and management of product complexity, are discussed, and the general ideas and methods of solving these problems are analyzed. Suggestions for selecting appropriate ALT plan design theories are proposed, and the urgent solved theory problems and opinions of their solutions are proposed. Based on the principle of convenience for engineers to select appropriate methods according to the problems found in practice, this paper reviews the development of optimal ALT plan design theory by taking the engineering problems arising from the ALT implementation as the main thread, provides guidelines on selecting appropriate theories for engineers, and proposes opinions about the urgent solved theory problems for researchers.

Multiple Objective Test Design for Accelerated Destructive Degradation Tests

Accelerated destructive degradation tests(ADDTs)are powerful to provide reliability information in the degradation processes with destructive measurements.In order to carry out an ADDT efficiently,both the estimation precision of parameters and the test cost should be considered.On the basis of the given degradation model and failure criterion,a multiple-objective optimization model for the design of ADDTs is proposed.Under constrains of the maximum measurement time,the total sample size and the number of stress levels,a comprehensive target function is suggested to reflect both the precision of lifetime estimation and total cost,and the optimal test plan is obtained,which is composed by optimal choices for samples size,measurement frequency,and the number of measurements at each stress level.A real example is illustrated to demonstrate the implementation of the proposed approach.

Multiple dependent reliability estimation of large range MEMS accelerometers in high temperature environment

In the past,only one performance parameter was considered in the reliability estimation of micro-electro-mechanical system (MEMS) accelerometers,resulting in a one-sided reliability evaluation. Aiming at the failure condition of large range MEMS accelerometers in high temperature environment,the corresponding accelerated degradation test is designed. According to the degradation condition of zero bias and scale factor,multiple dependent reliability estimation of large range MEMS accelerometers is carried out. The results show that the multiple dependent reliability estimation of the large range MEMS accelerometers can improve the accuracy of the estimation and get more accurate results.

Challenges in Qualitative Accelerated Testing of WSN Hardware

Internet of Things (IOT) is a conceptual vision to connect things in order to create a ubiquitous computing world. In order to create such an ever-present network, a simple, reliable, and cost-effective technology is crucial. Wireless sensor network (WSN) is an important wireless technology that has wide variety of applications and provides unlimited future potentials for IOT. Since WSNs in IOT will be used in varying and challenging applications and environments, reliability and reliability testing of WSN hardware becomes extremely important. In accelerated reliability testing, test stresses are increased to cut down the time required to obtain a weakening effect similar to one resulting from normal service conditions in the field. This paper introduces three common difficulties that engineers may experience in qualitative accelerated testing of WSN devices: 1. Challenges in use of standard accelerated tests, 2. Challenges in component-level testing, and 3. Challenges in testing of prototypes. The paper will also introduce examples from real life reliability research and accelerated tests to clarify the presented challenges.

Reliability Design of Ice-Maker System Subjected to Repetitive Loading

Parametric Accelerated Life Testing (ALT) was used to improve the reliability of ice-maker system with a fractured helix upper dispenser in field. By using bond graphs and state equations, a variety of mechanical loads in the assembly were analyzed. The acceleration factor was derived from a generalized life-stress failure model with a new load concept. To reproduce the failure modes and mechanisms causing the fracture, new sample size equation was derived. The sample size equation with the acceleration factor also enabled the parametric accelerated life testing to quickly reproduce early failure in field. Consequently, the failure modes and mechanisms found were identical with those of the failed sample. The design of this testing should help an engineer uncover the design parameters affecting the reliability of fractured helix upper dispenser in field. By eliminating the design flaws, gaps and weldline, the B1 life of the redesign of helix upper dispenser is now guaranteed to be over 10 years with a yearly failure rate of 0.1% that is the reliability quantitative test specifications (RQ).

电连接器用聚氨酯胶密封件贮存可靠性统计模型的加速试验验证与评估

针对电连接器用聚氨酯胶密封件在长贮条件下的寿命评估问题,从机理层面分析了聚氨酯胶密封件内聚破坏和边界破坏导致性能下降的原因。依据从机理层面建立的电连接器用聚氨酯胶密封件贮存可靠性统计模型,利用聚氨酯胶密封件温湿度综合应力加速退化试验数据,综合应用粒子群优化算法和回归分析、AD检验及拟合优度等检验方法,从数据统计层面验证了电连接器用聚氨酯胶密封件失效物理方程和退化轨迹模型的合理性。利用扫描电镜和能谱分析验证了失效机理分析的正确性。最后,利用所建模型评估了电连接器用聚氨酯胶密封件在贮存环境下的可靠寿命。

导弹整机贮存寿命加速试验建模与评估技术

针对多失效模式、多失效机理、小子样导弹整机产品贮存寿命加速试验与评估面临的难题,提出整机贮存寿命加速试验建模方法,通过建立基于竞争失效的整机贮存寿命模型,综合考虑零部组件产品的贮存寿命信息,开展整机加速因子综合计算;提出基于试验长度因子的小子样整机贮存可靠度评估方法,通过加长试验时间达到利用小子样验证高贮存可靠度的目的。最后给出典型伺服机构加速试验案例分析,证明方法的有效性。该方法可为开展小子样整机产品贮存寿命加速试验与寿命评估提供一种新的技术途径。

小样本加速寿命试验设计与评估方法

针对工程上加速寿命试验仍然存在时间长、试样多的问题,提出一种小样本加速寿命试验设计与评估方法。该方法只需在两个加速应力水平下进行加速寿命试验,即可对产品在正常使用应力水平下高置信度、高可靠度的可靠寿命进行评估。文中首先利用工程上常用的线性加速模型(如阿伦尼斯模型、逆幂律模型和指数模型等)建立了正常使用应力水平下可靠寿命的单侧置信下限与两个加速应力水平下的可靠寿命置信限之间的数学关系式,给出了正常使用应力水平下高置信度、高可靠度的可靠寿命单侧置信下限评估方法。然后分别对指数分布、两参数Weibull分布和对数正态分布的定数截尾加速寿命试验情况进行了详细讨论,给出了相应的正常使用应力水平下高置信度、高可靠度的可靠寿命单侧置信下限计算公式。该方法计算简单,而且对完全数据、不完全数据以及各种分布均适用。大量工程算例和Monte Carlo模拟验证表明,与需要在多个加速应力水平下进行寿命试验的传统方法相比,本文方法不但可以节省大量试样和试验时间,而且理论上更加严谨,精度更高。

基于恒定应力加速寿命试验的SF_(6)气体密度表可靠性研究

SF_(6)气体密度表作为电网体系中一次设备的重要监测设备,其可靠性关乎变电设备的安全运行。为了确保SF_(6)气体密度表的可靠运行,有必要对其可靠性和寿命进行评估,而恒定应力加速寿命试验方法是结构复杂机械产品可靠性评估的有效方法之一。文章分析了SF_(6)气体密度表的加速应力和正常应力水平,确定了多应力加速寿命试验方案,利用Weibull寿命-应力模型综合估计了SF_(6)气体密度表的中位寿命、特征寿命、可靠寿命、平均寿命及相应的失效率,得到了其正常应力下可靠度曲线,为SF_(6)气体密度表生产制造和使用维护提供了理论依据和数据参考。

航天地面电源加速寿命试验研究

以某航天地面电源为研究对象,开展加速寿命试验研究。首先,介绍了加速寿命试验的特点、目的和优点;然后,阐述了加速试验的方法和流程;最后,对加速寿命试验的结果进行了分析。结果表明,与传统的可靠性试验相比,加速寿命试验可有效降低试验成本、提升试验效率,具有绝对优势。

对冲式冲击试验机的设计及其动力特性的研究

为了对舰船内部电子设备进行高加速度冲击检测,提高冲击试验机的检测能力,对传统的冲击试验机进行了结构上的改进,提出了一种新型的对冲式冲击试验机,并对设计参数及其动力特性进行了研究。首先,介绍了对冲式冲击试验机的机械结构和控制原理,建立了设备的运动学模型,将试验动作划分成了四个过程(分别为蓄能、释放、碰撞与刹车阶段),并对各阶段进行了数学建模分析,确定了最大能量碰撞点;然后,建立了实体模型,使用ANSYS软件对其进行了计算机仿真,评估了结构稳定性,预测了其冲击加速度;最后,通过多次试验检测了动力特性,在不同位置下重复测试了该设备碰撞点位置与产生的冲击加速度大小,采集了加速度与位移信号,对信号进行了降噪滤波处理与微分计算,验证了设备性能的可靠性。研究结果表明:该试验机结构简单、操作容易,可重复试验;每次试验中碰撞点距理想位置分布数据散度在30 mm以内,数据稳定可靠,符合设计需求,控制方法合理;通过调节试验台与冲击台的释放位置可以改变冲击产生的加速度大小,在极限位置释放时最高能产生2 000 g左右的冲击加速度,满足各种元器件对耐冲击测试的试验要求。