System Reliability Assessment

(SRA)

Machine Deep learning algorithms, Artificial intelligence (AI), Automation and modern technology in business as concept.
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In transdisciplinary teams, we develop innovative, customer-oriented solutions for robust, energy-efficient and sustainable electronic systems. We ensure their reliability through application-specific system design, qualification, weak point analysis and optimization both at the system and technology level. Experimental and simulative methods are also developed and applied for this purpose. Reliability assessment and tamper detection of complex electronic systems is increasingly carried out using hybrid (grey-box) modeling approaches. Functional circuit structures are extended by physics-based model approaches and data-based, AI-supported evaluation methods (digital twin).

Taking advantage of our extensive technological expertise combined with the analytical resources of Fraunhofer IZM, we also carry out failure and root cause analysis of electronic assemblies or power electronic modules. To evaluate the reliability and robustness of electronic assemblies and systems, we cover a wide range of defined stress tests and develop target-oriented stress scenarios on the basis of application-specific mission profiles.
 

Application-specific system evaluation

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Our primary task is to control the management activities for achieving reliable products and processes throughout the entire product lifecycle. Ensuring reliability starts within the innovation phase. Within the product development phase, careful consideration must be given regarding the influences of production and operation. Moreover functionality and availability should be ensured during operation.

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Reliability: simulation, test and optimization

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Reliability: simulation, test and optimization cover the development and application of experiments and simulations which make it possible to "Design for Reliability". The basis is provided by life-time models determined in accelerated tests.

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Corrosion, electrochemical migration, moisture diffusion

A large number of failures of electronic assemblies can be proven to be due to the influence and effect of humidity. Electronic systems are increasingly exposed to changing climatic environmental influences. At the same time, progressive miniaturization is leading to smaller structural dimensions and consequently smaller packages. Smaller dimensions in the packages also result in smaller diffusion paths for external loads caused by moisture.

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Condition monitoring of electronics

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Condition Monitoring Concepts

The highest levels of availability and lowest failure rates are key requirements for durable and high quality products and main criteria for increasing sustainability. Concepts for condition monitoring are based on the identification and intelligent and efficient recording of relevant system parameters and simultaneous evaluation and calculation of reliability purposes. By means of intelligent interpretation of field data it is possible to determine the condition and the remaining life-time of electrical, electronic and mechatronic systems (E/E/M).

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Analytical, Numerical and Experiment-Based Assessment of Electromigration in Electrical Contacts

One factor limiting the reliability of increasingly miniaturized electronic systems is failure due to electromigration. This current- and temperature-induced mechanism displaces atoms in the conducting material, leading to defects in the electrical traces and solder joints.
Any investigation of electromigration as part of optimized, model-based evaluation has to take into account the effects of interdependent parameters.  

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Design assessment and optimisation for reliability

HIGH PERFORMANCE COMPUTING CLUSTER ALLOWS EXTENSIVE RELIABILITY-ANALYSIS
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Already in the early stages of the design process for a new product, FEM analysis can be used to compare alternatives quickly and to optimise the design in terms of reliability and durability. When selecting suitable technologies for a new product, FEM makes it possible at an early stage to take into account the effects of the production process itself and of use over the operating life of the product.

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Corrosion, electrochemical migration, moisture diffusion

A large number of failures of electronic assemblies can be proven to be due to the influence and effect of humidity. Electronic systems are increasingly exposed to changing climatic environmental influences. At the same time, progressive miniaturization is leading to smaller structural dimensions and consequently smaller packages. Smaller dimensions in the packages also result in smaller diffusion paths for external loads caused by moisture.

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Thermal Characterisation

Infrared thermography can be used for non-destructive and contact-free measurements of heat radiation from the surface. High-resolution measurements can register very small objects (10µm per pixel) and rapid transient processes (up to approx. 3kHz).

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Vibration Measurements and Tests

Key elements of vibration measurements and tests are

  • Vibration analyses and tests
  • Design and characterisation of fixtures
  • Vibration measurements
  • Registering vibrations at individual measurement points and on surfaces with a scanning laser vibrometer.
  • Test conditions Vibration measurements and tests

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Reliability evaluation with FEM

teaser image - Zuverlässigkeitsbewertung mit FEM
© Fraunhofer IZM

To identify weak points in the early stages of development, or to obtain the optimum geometry under consideration of external loads, finite element simulation (FE) are applied. By means of so-called multiphysics simulations, e.g. thermo-mechanical, electro-thermal, and electro-mechanical couplings can be considered. In addition, moisture diffusion and swelling can be calculated.

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System Reliability

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The safeguarding of the reliability begins in early design phases of the development process of a system. Existing systems can be optimized based on statistical methods.

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Self-validation of complex electronic systems in safety-critical mobility applications based on grey-box models

SesiM

The project SesiM employs novel hybrid modeling approaches based on physical models and AI methods to enable condition monitoring of complex electronic systems. The approach is initially demonstrated on mobility applications in automotive and railway technology.

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Independent testing programme assessing the lifetime of consumer products

PROMPT

In May 2019, the EU’s PROMPT project was launched to tackle e-waste: the aim is to establish an independent test program to evaluate the service life of consumer goods.

Waste generation of electrical and electronic equipment has soared in the past decades. In the EU, discarded equipment such as fridges, computers, printers, and coffee machines are one of the fastest growing waste streams, rising by 3-5% per year. This development is not only putting a strain on the environment but also on consumers’ budgets.

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Logo PROMPT (Premature Obsolescence Multi-Stakeholder Product Testing Program)

Power4re

The inverters used for grid feed-in in solar parks and frequency converters in wind turbines (hereafter simplified: converters) are exposed to particularly challenging operating and environmental conditions. Today, they are among the most frequently failing plant components and thus cause considerable costs in some cases. In power4re, material, process and structural optimizations as well as protection concepts for converter components are developed to meet the high demands of these two applications.

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KorSikA

The KorSikA team is adding to our current understanding of the corrosion behaviour of power electronics in offshore wind farm applications, focusing in particular on sintered joints.

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Skizze - Projekt KorSikA
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Condition Monitoring for Wind Turbines

AMWind

Making power electronics more reliable used to mean going back to the drawing board and optimizing materials, structures, and processes. For real reliability in regular operations, modern condition monitoring concepts are offering their operators a new choice.

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Projekt Am Wind: Zustandsüberwachung für Windkraftanlagen | Foto: H&M Ingenieurbüro GmbH&Co. KG
© H&M Ingenieurbüro GmbH&Co. KG

Energy Autarkic Wireless Sensors for Condition Monitoring

ECoMoS

Condition monitoring systems (CMS) catch machine malfunction before operation grinds to halt and have played no small part in the success of German mechanical and plant engineering over the last decade. In the project ECoMos (Energy Autarkic Condition Monitoring System), we are extending wireless sensor technology to include condition monitoring of entire manufacturing plants.

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Robust Design of New Electronic Components for Electromobility Applications

RESCAR 2.0

Project partners from every stage of electrical and electronic controls development are cooperating in the German federal ministry for education and research (BMBF) program “Key Technologies for Electromobility (STROM I)” to develop new approaches to the design of robust semiconductor components. The project covers the entire supply and manufacture chain, from automotive manufacturers, to producers of control systems, through to semiconductor manufacturers.

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Active Power Cycling Lab

Quality assurance of power electronics is an essential factor in product reliability. The active power cycling test provides instant lifetime data for power modules. The corresponding area of application (e.g. wind energy, photovoltaics, automotive) determines the corresponding test parameters and procedures. We offer comprehensive consultation to find the right test method with regard to the specific mission profiles.

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Corrosion Analysis Lab

A large number of failures of electronic components are proven to be caused by the influence of moisture. In general, the exposure of electronics to moisture presents a major challenge for any system. In order to qualify and analyze these defects better, the focus in our laboratory is on the electrochemical characterization of materials and their composites with regard to their corrosion behavior depending on the electrolyte exposure occurring in the application.

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Corrosion Analysis Lab | Environmental & Reliability Engineering
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Electronics Condition Monitoring Lab

Vibration measurement and test with electronic components, if required in combination with humidity and temperature stressing, contactless vibration measurements with laser vibrometer, and in-situ monitoring of the failure of electronic components.

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image - Electronics Condition Monitoring
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Thermal and Environmental Analysis Lab

We offer thermal investigations of both - the materials and the systems. In order to be able to characterize thermal interface materials (TIM), a system was set up for determine heat conductivity and thermal resistance depending on the resistance relative to compression force. Infrared measurement techniques measure temperatures without any contact to detect errors in systems or components.

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