Abstract
This chapter is an overview of the concepts behind electrical, thermal, and mechanical stresses in power conversion. The corresponding best practices and trade-offs in component selection and design so as to achieve realistic reliability targets in commercial designs is discussed. The emerging power conversion standard, IPC-9592, is introduced. Part 1 of the chapter focuses on developing a thorough understanding of power component ratings underlining which of those ratings are relevant and/or potentially called into question in different locations inside a power converter. The relevance of topology is also highlighted alongwith ways to avoid over-design. Part 2 goes into stress derating principles and the calculation and estimation of failure rates, life expectancy, and MTBF. Demonstrated reliability testing using Chi-square tables and reliability predictions based on the philosophy of MIL-HDBK-217F are presented. Accelerated life/stress testing and HALT and HASS are explained. Warranty costs calculations are provided. Part 3 concludes this chapter with a detailed analysis of life estimates of aluminum electrolytic capacitors.
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