Application of Diagnostics and Prognostics Techniques to Qualification Against Wear-Out Failure

Abstract

QUALIFICATION IS A PROCESS THAT DEMONSTRATES WHETHER A PRODUCT MEETS OR EXCEEDS SPECIFIED REQUIREMENTS. TESTING AND DATA ANALYSIS PERFORMED WITHIN A QUALIFICATION PROCEDURE SHOULD VERIFY IF PRODUCTS SATISFY THOSE REQUIREMENTS, INCLUDING RELIABILITY REQUIREMENTS. MOST OF THE ELECTRONICS INDUSTRY QUALIFIES PRODUCTS USING PROCEDURES DICTATED WITHIN QUALIFICATION STANDARDS. A REVIEW OF COMMON QUALIFICATION STANDARDS REVEALS THAT THOSE STANDARDS DO NOT CONSIDER CUSTOMER REQUIREMENTS OR THE PRODUCT PHYSICS-OF-FAILURE IN THAT INTENDED APPLICATION. AS A RESULT, QUALIFICATION, AS REPRESENTED IN THE REVIEWED QUALIFICATION STANDARDS, WOULD NOT MEET OUR DEFINITION OF QUALIFICATION FOR RELIABILITY ASSESSMENT.

THIS THESIS PROVIDES AN APPLICATION-SPECIFIC APPROACH FOR DEVELOPING A QUALIFICATION PROCEDURE THAT ACCOUNTS FOR CUSTOMER REQUIREMENTS, PRODUCT PHYSICS-OF-FAILURE, AND KNOWLEDGE OF PRODUCT BEHAVIOR UNDER LOADING. THIS THESIS PROVIDES A REVAMPED APPROACH FOR DEVELOPING A LIFE CYCLE PROFILE THAT ACCOUNTS FOR LOADING THROUGHOUT MANUFACTURING/ASSEMBLY, STORAGE AND TRANSPORTATION, AND OPERATION. THE THESIS ALSO DISCUSSES IDENTIFYING VARIATIONS IN THE LIFE CYCLE PROFILE THAT MAY ARISE THROUGHOUT THE PRODUCT LIFETIME AND METHODS FOR ESTIMATING LOADS. THIS UPDATED APPROACH FOR DEVELOPING A LIFE CYCLE PROFILE SUPPORTS BETTER FAILURE PRIORITIZATION, TEST SELECTION, AND TEST CONDITION AND DURATION REQUIREMENT ESTIMATION.

ADDITIONALLY, THIS THESIS INTRODUCES THE APPLICATION OF DIAGNOSTICS AND PROGNOSTICS TECHNIQUES TO ANALYZE REAL-TIME DATA TRENDS WHILE CONDUCTING QUALIFICATION TESTS. DIAGNOSTICS TECHNIQUES IDENTIFY ANOMALOUS BEHAVIOR EXHIBITED BY THE PRODUCT, AND PROGNOSTICS TECHNIQUES FORECAST HOW THE PRODUCT WILL BEHAVE DURING THE REMAINDER OF THE QUALIFICATION TEST AND HOW THE PRODUCT WOULD HAVE BEHAVED IF THE TEST CONTINUED. AS A RESULT, COMBINING DIAGNOSTICS AND PROGNOSTICS TECHNIQUES CAN ENABLE THE PREDICTION OF THE REMAINING TIME-TO-FAILURE FOR THE PRODUCT UNDERGOING QUALIFICATION. SEVERAL ANCILLARY BENEFITS RELATED TO AN IMPROVED TESTING STRATEGY, PARTS SELECTION AND MANAGEMENT, AND SUPPORT OF A PROGNOSTICS AND HEALTH MANAGEMENT SYSTEM IN OPERATION ALSO ARISE FROM APPLYING PROGNOSTICS AND DIAGNOSTICS TECHNIQUES TO QUALIFICATION.