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    Next Generation HALT and HASS

    Robust Design of Electronics and Systems

    AvKirk A. Gray,John J. Paschkewitz

    Inbunden, Engelska, 2016

    Del i serien Quality and Reliability Engineering Series

    1 146 kr

    Beställningsvara. Skickas inom 5-8 vardagar. Fri frakt över 249 kr.

    Beskrivning

    NEXT GENERATION HALT AND HASS ROBUST DESIGN OF ELECTRONICS AND SYSTEMS A NEW APPROACH TO DISCOVERING AND CORRECTING SYSTEMS RELIABILITY RISKS Next Generation HALT and HASS presents a major paradigm shift from reliability prediction-based methods to discovery of electronic systems reliability risks. This is achieved by integrating highly accelerated life test (HALT) and highly accelerated stress screen (HASS) into a physics of failure based robust product and process development methodology. The new methodologies challenge misleading and sometimes costly misapplication of probabilistic failure prediction methods (FPM) and provide a new deterministic map for reliability development. The authors clearly explain the new approach with a logical progression of problem statement and solutions. The book helps engineers employ HALT and HASS by demonstrating why the misleading assumptions used for FPM are invalid. Next, the application of HALT and HASS empirical discovery methods to quickly find unreliable elements in electronics systems gives readers practical insight into the techniques. The physics of HALT and HASS methodologies are highlighted, illustrating how they uncover and isolate software failures due to hardware–software interactions in digital systems. The use of empirical operational stress limits for the development of future tools and reliability discriminators is described. Key features: Provides a clear basis for moving from statistical reliability prediction models to practical methods of insuring and improving reliability.Challenges existing failure prediction methodologies by highlighting their limitations using real field data.Explains a practical approach to why and how HALT and HASS are applied to electronics and electromechanical systems.Presents opportunities to develop reliability test discriminators for prognostics using empirical stress limits.Guides engineers and managers on the benefits of the deterministic and more efficient methods of HALT and HASS.Integrates the empirical limit discovery methods of HALT and HASS into a physics of failure based robust product and process development process.

    Produktinformation

    • Utgivningsdatum:2016-05-13
    • Mått:163 x 236 x 20 mm
    • Vikt:504 g
    • Format:Inbunden
    • Språk:Engelska
    • Serie:Quality and Reliability Engineering Series
    • Antal sidor:296
    • Förlag:John Wiley & Sons Inc
    • ISBN:9781118700235

    Utforska kategorier

    • Elektronik och kommunikationer inom Naturvetenskap och teknik
    • Maskinteknik och material inom Naturvetenskap och teknik

    Mer om författaren

    Kirk A. Gray, Accelerated Reliability Solutions, LLC, Colorado, USA.John J. Paschkewitz, Product Assurance Engineering, LLC, Missouri, USA.

    Innehållsförteckning

    • Series Editor’s Foreword xiPreface xivList of Acronyms xviIntroduction 11 Basis and Limitations of Typical Current Reliability Methods and Metrics 51.1 The Life Cycle Bathtub Curve 71.1.1 Real Electronics Life Cycle Curves 91.2 HALT and HASS Approach 111.3 The Future of Electronics: Higher Density and Speed and Lower Power 131.3.1 There is a Drain in the Bathtub Curve 141.4 Use of MTBF as a Reliability Metric 161.5 MTBF: What is it Good For? 171.5.1 Introduction 171.5.2 Examples 181.5.3 Conclusion 241.5.4 Alternatives to MTBF for Specifying Reliability 251.6 Reliability of Systems is Complex 261.7 Reliability Testing 281.8 Traditional Reliability Development 33Bibliography 342 The Need for Reliability Assurance Reference Metrics to Change 362.1 Wear‐Out and Technology Obsolescence of Electronics 362.2 Semiconductor Life Limiting Mechanisms 372.2.1 Overly Optimistic and Misleading Estimates 422.3 Lack of Root Cause Field Unreliability Data 432.4 Predicting Reliability 482.5 Reliability Predictions – Continued Reliance on a Misleading Approach 502.5.1 Introduction 512.5.2 Prediction History 522.5.3 Technical Limitations 532.5.4 Keeping Handbooks Up‐to‐Date 542.5.5 Technical Studies – Past and Present 592.5.6 Reliability Assessment 622.5.7 Efforts to Improve Tools and Their Limitations 632.6 Stress–Strength Diagram and Electronics Capability 632.7 Testing to Discover Reliability Risks 682.8 Stress–Strength Normal Assumption 692.8.1 Notation 702.8.2 Three Cases 712.8.3 Two Normal Distributions 732.8.4 Probability of Failure Calculation 732.9 A Major Challenge – Distributions Data 732.10 HALT Maximizes the Design’s Mean Strength 752.11 What Does the Term HALT Actually Mean? 78Bibliography 833 Challenges to Advancing Electronics Reliability Engineering 863.1 Disclosure of Real Failure Data is Rare 863.2 Electronics Materials and Manufacturing Evolution 89Bibliography 914 A New Deterministic Reliability Development Paradigm 924.1 Introduction 924.2 Understanding Customer Needs and Expectations 954.3 Anticipating Risks and Potential Failure Modes 984.4 Robust Design for Reliability 1044.5 Diagnostic and Prognostic Considerations and Features 1104.6 Knowledge Capture for Reuse 1104.7 Accelerated Test to Failure to Find Empirical Design Limits 1124.8 Design Confirmation Testing: Quantitative Accelerated Life Test 1134.9 Limitations of Success Based Compliance Test 1144.10 Production Validation Testing 1154.11 Failure Analysis and Design Review Based on Test Results 116Bibliography 1205 Common Understanding of HALT Approach is Critical for Success 1225.1 HALT – Now a Very Common Term 1235.2 HALT – Change from Failure Prediction to Failure Discovery 1245.2.1 Education on the HALT Paradigm 1255.3 Serial Education of HALT May Increase Fear, Uncertainty and Doubt 1305.3.1 While You Were Busy in the Lab 1325.3.2 Product Launch Time – Too Late, But Now You May Get the Field Failure Data 1326 The Fundamentals of HALT 1346.1 Discovering System Stress Limits 1346.2 HALT is a Simple Concept – Adaptation is the Challenge 1356.3 Cost of Reliable vs Unreliable Design 1366.4 HALT Stress Limits and Estimates of Failure Rates 1376.4.1 What Level of Assembly Should HALT beApplied? 1376.4.2 HALT of Supplier Subsystems 1386.5 Defining Operational Limit and Destruct Limits 1386.6 Efficient Cooling and Heating in HALT 1396.6.1 Stress Monitoring Instrumentation 1396.6.2 Single and Combined Stresses 1406.7 Applying HALT 1426.7.1 Order of HALT Stress Application 1436.8 Thermal HALT Process 1446.8.1 Disabling Thermal Overstress Protection Circuits 1456.8.2 HALT Limit Comparisons 1466.8.3 Cold Thermal HALT 1486.8.4 Hot Thermal HALT 1506.8.5 Post Thermal HALT 1516.9 Random Vibration HALT 1526.10 Product Configurations for HALT 1556.10.1 Other Configuration Considerations for HALT 1566.11 Lessons Learned from HALT 1576.12 Failure Analysis after HALT 1597 Highly Accelerated Stress Screening (HASS) and Audits (HASA) 1617.1 The Use of Stress Screening on Electronics 1617.2 ‘Infant Mortality’ Failures are Reliability Issues 1637.2.1 HASS is a Production Insurance Process 1647.3 Developing a HASS 1677.3.1 Precipitation and Detection Screens 1687.3.2 Stresses Applied in HASS 1727.3.3 Verification of HASS Safety for Defect Free Products 1737.3.4 Applying the SOS to Validate the HASS Process 1747.3.5 HASS and Field Life 1777.4 Unique Pneumatic Multi‐axis RS Vibration Characteristics 1777.5 HALT and HASS Case History 1797.5.1 Background 1797.5.2 HALT 1807.5.3 HASS (HASA) 1817.5.4 Cost avoidance 183Bibliography 1847.6 Benefits of HALT and HASS with Prognostics and Health Management (PHM) 1847.6.1 Stress Testing for Diagnosis and Prognosis 1857.6.2 HALT, HASS and Relevance to PHM 186Bibliography 1898 HALT Benefits for Software/Firmware Performance and Reliability 1908.1 Software – Hardware Interactions and Operational Reliability 1908.1.1 Digital Signal Quality and Reliability 1938.1.2 Temperature and Signal Propagation 1948.1.3 Temperature Operational Limits and Destruct Limits in Digital Systems 1978.2 Stimulation of Systematic Parametric Variations 1988.2.1 Parametric Failures of ICs 1998.2.2 Stimulation of Systematic Parametric Variations 201Bibliography 2059 Design Confirmation Test: Quantitative Accelerated Life Test (ALT) 2079.1 Introduction to Accelerated Life Test 2079.2 Accelerated Degradation Testing 2119.3 Accelerated Life Test Planning 2129.4 Pitfalls of Accelerated Life Testing 2159.5 Analysis Considerations 216Bibliography 21710 Failure Analysis and Corrective Action 21810.1 Failure Analysis and Knowledge Capture 21810.2 Review of Test Results and Failure Analysis 22010.3 Capture Test and Failure Analysis Results for Access on Follow‐on Projects 22110.4 Analyzing Production and Field Return Failures 222Bibliography 22211 Additional Applications of HALT Methods 22311.1 Future of Reliability Engineering and HALT Methodology 22311.2 Winning the Hearts and Minds of the HALT Skeptics 22511.2.1 Analysis of Field Failures 22511.3 Test of No Fault Found Units 22611.4 HALT for Reliable Supplier Selection 22611.5 Comparisons of Stress Limits for Reliability Assessments 22811.6 Multiple Stress Limit Boundary Maps 23011.7 Robustness Indicator Figures 23511.8 Focusing on Deterministic Weakness Discovery Will Lead to New Tools 23511.9 Application of Limit Tests, AST and HALT Methodology to Products Other Than Electronics 236Bibliography 238Appendix: HALT and Reliability Case Histories 239A.1 HALT Program at Space Systems Loral 240A.2 Software Fault Isolation Using HALT and HASS 243A.3 Watlow HALT and HASS Application 253A.4 HALT and HASS Application in Electric Motor Control Electronics 256A.5 A HALT to HASS Case Study – Power Conversion Systems 261Index 268
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