「燒機」測試:電源轉換器燒到面目全非…

作者 : Paul Breed,EDN

這200個電源轉被連接到系統上,並在70℃下進行48小時的燒機測試。但就在36小時後,200個電源轉換器的主電橋都燒掉了,電源部份就算沒熔化也燒到所剩無幾⋯

我的公司最近剛完成了一項時間緊迫的專案,這項「急件」是要將一批堅固的電源轉換器出貨給一家系統整合商,讓他們能將這些電源轉換器整合於強固型電腦中,以便供應給第一次波斯灣戰爭(Persian Gulf War)的沙漠風暴行動中使用。這些電源轉換器必須能在40-400Hz頻率下採​​用100-300V的任何標準電壓以及28V直流(DC)電壓供電,並在1500W下連續10分鐘以類似UPS (不斷電)的備用電池,提供乾淨、穩定的117V、60Hz交流電(AC)輸出。

我們剛好就有一款符合該規格的商品,但還欠缺這家客戶所要求的堅固性和抗惡劣環境性能。為了滿足客戶的需求,我們努力地對其機械和散熱設計進行了升級。在經歷每週加班工作長達80小時的三個月之後,這項任務終於完成了。

最難通過的測試是在滿負載、85℃下進行24小時測試。我們第一次就通過了這項測試,但仍繼續測試10%的產品以確保符合要求。一切都很順利,於是便將全部200個電源轉換器交貨給這家整合商。然後我得到了一週的休假,這是我應得的。

等到客戶收到了這200個電源轉換器後,便將它們連接到系統上,並在70℃下進行48小時的燒機測試。很遺憾地,就在36小時後,200個電源轉換器全部都發生了災難性的故障。於是,我的老闆把我從休假中召喚回來,然後送我上飛機,要我到現場去把問題找出來。

我到了客戶那兒發現,每個電源轉換器的主電橋都燒掉了,電源部份就算沒熔化也都燒到幾乎所剩無幾。我心事重重地回到家,並反覆思量究竟出了什麼問題。接著,我們帶了自家的工程套件去做測試,並在高達70℃的溫度下執行,然而當它進行到36小時,真的又冒煙燒毁了。這些元件都在兩小時內完全達到了熱平衡,但它們究竟如何區別出24小時與36小時之間的差別?

…繼續閱讀請連結EDN Taiwan網站

 

 

 

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