Before or during design and development phase of any electrical and electronic circuit, often, it is not possible to predict the reliability of the product. This results into either overdesign of the product due to excessive safety margin or poor design due to lack of understanding of duty cycle as well as the product use cases and failure modes. Specially, in the electronic product this is the acute problem as the state of technology is still evolving. Thus, design engineers cannot depend on historical data. To support the design engineer to optimize design as well as to speed up the design life cycle; reliability prediction model is required for electronic product.IEC-62380 is the reliability prediction method of electronic component, printed circuit boards, optical cards, and equipment. It is consisted of the series of mathematical model to predict the failure rate that affected by duty cycle, thermal cycling, environmental condition, various electrical stresses, quality levels and various others parameter. These factors called as the pie (π) factor in reliability analysis. In practical environment these factors are not in our controlled they are continuously varied; these variations are adopted using the Monte Carlo simulation (MCS). In this work reliability prediction and modeling is studied for controlled power supply, which is used in automotive application. The output of the modeling is failure in time (fit’s), mean time to failure (MTTF), mean time between failure (MTBF), b10 life, and failure contributor. With this output we optimize the design up to the expected reliability levels.
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