ARRARARARRAGGHHHHH going mad
removing we from sentences. TORTURE MENTAL TORTURE
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@ -941,7 +941,6 @@ ISSN={1530-2059},}
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YEAR = "1988"
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YEAR = "1988"
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}
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}
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@book{DBLP:books/ph/KernighanR88,
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@book{DBLP:books/ph/KernighanR88,
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author = {Brian W. Kernighan and
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author = {Brian W. Kernighan and
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Dennis Ritchie},
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Dennis Ritchie},
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@ -1136,6 +1135,14 @@ ISSN={0098-5589},}
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}
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}
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@MISC{microchipreliability,
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author = "Microchip",
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title = "Microchip: Reliability Data Search Engine: Annual Product Reliability Reports",
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howpublished = "Microchip Inc. http://www.microchip.com/reliabilityreport/Default.aspx",
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year = "2013"
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}
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@MISC{javaarea,
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@MISC{javaarea,
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author = "Sun~Micro~Systems",
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author = "Sun~Micro~Systems",
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title = "Java Area Operations",
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title = "Java Area Operations",
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@ -24,11 +24,11 @@ are examined in the context of two sources of information that define failure mo
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To introduce the concept of FMEA, a simple example is given, using a hypothetical four to twenty milli-amp ({\ft}) %milli-amp
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To introduce the concept of FMEA, a simple example is given, using a hypothetical four to twenty milli-amp ({\ft}) %milli-amp
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reader.
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reader.
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%
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%
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The four main current FMEA variants are described and we develop %conclude by describing concepts
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The four main current FMEA variants are described %and we develop %conclude by describing concepts
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the concepts
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the concepts
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that underlie the usage and philosophy of FMEA.
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that underlie the usage and philosophy of FMEA discussed.
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%
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%
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We return to the overall process of FMEA and model it using UML.
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The overall process of FMEA is then reviewed and modelled using UML.
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%
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%
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By using UML
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By using UML
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the entities needed to implement FMEA
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the entities needed to implement FMEA
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@ -95,11 +95,12 @@ function that they perform.
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We begin FMEA with the basic, or starting components.
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We begin FMEA with the basic, or starting components.
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%
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%
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These components are the sort we buy in or consider as pre-assembled modules.
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These components are the sort bought in or considered as pre-assembled modules.
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We term these the {\bcs}; they are considered ``atomic'' i.e. they are not broken down further.
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These are termed {\bcs}; they are considered ``atomic'' i.e. they are not broken down further.
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%
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%
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Firstly we need to know how these can fail, so our first relationship
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The first requirement for a {\bc} is to define the ways in which it can fail,
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is between a {\bc} and its failure modes, see figure~\ref{fig:component_fm_rel}.
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this relationship %between a {\bc} and its failure modes,
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is shown in figure~\ref{fig:component_fm_rel}.
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\fmmdglossBC
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\fmmdglossBC
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%DIAGRAM of Base components and failure modes
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%DIAGRAM of Base components and failure modes
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@ -114,8 +115,8 @@ is between a {\bc} and its failure modes, see figure~\ref{fig:component_fm_rel}.
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The next stage is analysis, that is reasoning applied to the system in the event of
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The next stage is analysis, that is reasoning applied to the system in the event of
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a given failure mode.
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a given failure mode.
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%
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%
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To perform this we need to know how a failure
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To perform how a failure
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mode, considering its effect on other components in the system,
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mode, after considering its effect on other components in the system,
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will translate to a system level symptom/failure.
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will translate to a system level symptom/failure.
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%
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%
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The result of FMEA is to determine system level failures,
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The result of FMEA is to determine system level failures,
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@ -147,17 +148,23 @@ of this chapter.
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\fmmdglossBC
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\fmmdglossBC
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\label{sec:determine_fms}
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\label{sec:determine_fms}
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\fmodegloss
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\fmodegloss
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In order to apply any form of FMEA we need to know the ways in which
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In order to apply any form of FMEA the ways in which
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the {\bcs} we are using can fail. In practise, this part of the process is guided by
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the {\bcs}\footnote{A good introduction to hardware and software failure modes may be found in~\cite{sccs}[pp.114-124].} %used
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the standards to which we are seeking to conform.% to.
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can fail must be clearly defined.
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%
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%
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\footnote{A good introduction to hardware and software failure modes may be found in~\cite{sccs}[pp.114-124].}
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In practise, this part of the process is guided by
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the particular standard
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which is being conformed to. %we are seeking to conform.% to.
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%
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%
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Typically, when choosing components for a design, we look at manufacturers' data sheets
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Standards may differ in their definitions for the {\fms} of {\bcs}.
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The reasons for these differences are examined below using two example components.
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%
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%
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Typically, when choosing components for a design, engineers will look at manufacturers' data sheets
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which describe functionality, physical dimensions,
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which describe functionality, physical dimensions,
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environmental ranges, tolerances and by `reading~between~the~lines'
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environmental ranges, tolerances and by `reading~between~the~lines'
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in some cases can indicate how a component may fail/misbehave
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in some cases can indicate how a component may fail/misbehave.
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under given conditions.
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%under given conditions.
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%
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%
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How %base
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How %base
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components could fail internally, is not of interest to an FMEA investigation.
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components could fail internally, is not of interest to an FMEA investigation.
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@ -168,8 +175,10 @@ A large body of literature exists giving guidance for the determination of comp
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For this study FMD-91~\cite{fmd91} and the gas burner standard EN298~\cite{en298} are examined.
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For this study FMD-91~\cite{fmd91} and the gas burner standard EN298~\cite{en298} are examined.
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%Some standards prescribe specific failure modes for generic component types.
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%Some standards prescribe specific failure modes for generic component types.
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In EN298 failure modes for most generic component types are listed, or if not listed,
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In EN298 failure modes for most generic component types are listed, or if not listed,
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are determined using a procedure where we consider
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are determined using a procedure:
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all pins open and then all adjacent pins shorted.
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typically of the form of examining scenarios such as
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`all~pins~open' and then `all~adjacent~pins~shorted'~\cite{en298}[A.1 note e].
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%a procedure where failure scenarios of all pins OPEN and all adjacent pins shorted
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%a procedure where failure scenarios of all pins OPEN and all adjacent pins shorted
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%are examined.
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%are examined.
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%
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%
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@ -185,9 +194,18 @@ component {\fms} suitable for use in FMEA.
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A third document, MIL-1991~\cite{mil1991} provides overall reliability statistics for
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A third document, MIL-1991~\cite{mil1991} provides overall reliability statistics for
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component types, but does not detail specific failure modes.
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component types, but does not detail specific failure modes.
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%
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%
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Using MIL1991 in conjunction with FMD-91 we can determine statistics for the failure modes
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Using MIL1991 in conjunction with FMD-91 statistics can be determined for the failure modes
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of component types.
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of component types.
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%
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%
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As these documents are now a little old, the results
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from them can be on the conservative side.
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\frategloss
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\fmmdglossFIT
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%
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A FIT value for a micro-processor
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may be determined at around 100 using these documents for instance, but
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FIT claims for modern integrated micro-controllers are typically less than five~\cite{microchipreliability}.
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%
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The FMEA variant\footnote{EN61508 (and related standards) are based on the FMEA variant Failure Mode Effects and Diagnostic Analysis (FMEDA)}
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The FMEA variant\footnote{EN61508 (and related standards) are based on the FMEA variant Failure Mode Effects and Diagnostic Analysis (FMEDA)}
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used for European standard EN61508~\cite{en61508}
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used for European standard EN61508~\cite{en61508}
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requires statistics for Meantime to Failure (MTTF) for all {\bc} failure modes.
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requires statistics for Meantime to Failure (MTTF) for all {\bc} failure modes.
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@ -211,22 +229,25 @@ requires statistics for Meantime to Failure (MTTF) for all {\bc} failure modes.
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\section{Determining the failure modes of Components.}
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\section{Determining the failure modes of Components.}
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\fmodegloss
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\fmodegloss
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The starting point in the FMEA process are the failure modes of the components
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The starting points in the FMEA process are the failure modes of the {\bcs}.
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we would typically find in a production parts list, which we can term the {\bcs}.
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%s
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%Typically found in a production parts list, which are termed the {\bcs}.
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%
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%
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In order to define FMEA we must start with a discussion on how these failure modes are chosen.
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In order to define FMEA, a discussion on how these failure modes are defined and
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their relationship to particular standards is presented below.
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%
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%
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In this section we pick %look in detail at
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%In this section we pick %look in detail at
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two common electrical components as examples, and examine how
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Two common electrical components are used as examples,
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the two chosen sources of {\fm} information define their failure mode behaviour.
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and examined against two sources of {\fm} information. % define their failure mode behaviour.
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We look at the reasons why some known failure modes % are omitted, or presented in
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%specific but unintuitive ways.
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%We compare the US. military published failure mode specifications wi
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can be found in one source but not in the others and vice versa.
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%
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%
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Finally we compare and contrast the failure modes determined for these components
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These definitions for a given generic component may not always agree.
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%
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The reasons why some {\fms}
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can be found in one source but not in the others and vice versa, are discussed.
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%
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Finally the failure modes determined %for these components
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from the FMD-91~\cite{fmd91} reference source and from the guidelines of the
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from the FMD-91~\cite{fmd91} reference source and from the guidelines of the
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European burner standard EN298~\cite{en298}.
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European burner standard EN298~\cite{en298} are compared and contrasted.
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\subsection{Failure mode determination for generic resistor.}
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\subsection{Failure mode determination for generic resistor.}
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\label{sec:resistorfm}
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\label{sec:resistorfm}
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@ -238,14 +259,14 @@ The resistor is a ubiquitous component in electronics, and is therefore a good c
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%
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%
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FMD-91\cite{fmd91}[3-178] lists many types of resistor
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FMD-91\cite{fmd91}[3-178] lists many types of resistor
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and lists many possible failure causes.
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and lists many possible failure causes.
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For instance for {\textbf{Resistor,~Fixed,~Film}} we are given the following failure causes:
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For instance for {\textbf{Resistor,~Fixed,~Film}} the following failure causes are given:
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\begin{itemize}
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\begin{itemize}
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\item Opened 52\%
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\item Opened 52\% ,
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\item Drift 31.8\%
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\item Drift 31.8\% ,
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\item Film Imperfections 5.1\%
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\item Film Imperfections 5.1\% ,
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\item Substrate defects 5.1\%
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\item Substrate defects 5.1\% ,
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\item Shorted 3.9\%
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\item Shorted 3.9\% ,
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\item Lead damage 1.9\%
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\item Lead damage 1.9\% .
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\end{itemize}
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\end{itemize}
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% This information may be of interest to the manufacturer of resistors, but it does not directly
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% This information may be of interest to the manufacturer of resistors, but it does not directly
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% help a circuit designer.
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% help a circuit designer.
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@ -253,27 +274,27 @@ For instance for {\textbf{Resistor,~Fixed,~Film}} we are given the following fai
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% against {\fms} that the resistor could exhibit.
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% against {\fms} that the resistor could exhibit.
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% We can determine these {\fms} by converting the internal failure descriptions
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% We can determine these {\fms} by converting the internal failure descriptions
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% to {\fms} thus:
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% to {\fms} thus:
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To make this useful for FMEA/FMMD we must assign each failure cause to symptomatic failure mode descriptor
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To make this useful for FMEA/FMMD each failure cause must be mapped to a symptomatic failure mode descriptor
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as shown below.
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as listed below:
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%
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%
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%and map these failure causes to three symptoms,
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%and map these failure causes to three symptoms,
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%drift (resistance value changing), open and short.
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%drift (resistance value changing), open and short.
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\begin{itemize}
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\begin{itemize}
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\item Opened 52\% $\mapsto$ OPENED
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\item Opened 52\% $\mapsto$ OPENED,
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\item Drift 31.8\% $\mapsto$ DRIFT
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\item Drift 31.8\% $\mapsto$ DRIFT,
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\item Film Imperfections 5.1\% $\mapsto$ OPEN
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\item Film Imperfections 5.1\% $\mapsto$ OPEN,
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\item Substrate defects 5.1\% $\mapsto$ OPEN
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\item Substrate defects 5.1\% $\mapsto$ OPEN,
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\item Shorted 3.9\% $\mapsto$ SHORT
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\item Shorted 3.9\% $\mapsto$ SHORT,
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\item Lead damage 1.9\% $\mapsto$ OPEN.
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\item Lead damage 1.9\% $\mapsto$ OPEN.
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\end{itemize}
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\end{itemize}
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%
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%
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We note that the main causes of resistor value drift are overloading. % of components.
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Note that the main causes of resistor value drift are overloading. % of components.
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This is borne out in the FMD-91~\cite{fmd91}[232] entry for a resistor network where the failure
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This is borne out in the FMD-91~\cite{fmd91}[232] entry for a resistor network where the failure
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modes do not include drift.
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modes do not include drift.
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%
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%
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If we can ensure that our resistors will not be exposed to overload conditions, the
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If it is ensured that our resistors will not be exposed to overload conditions, the
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probability of drift (sometimes called parameter change) occurring
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probability of drift (sometimes called parameter change) %occurring
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is significantly reduced, enough for some standards to exclude it~\cite{en298,en230}.
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is significantly reduced, enough for some standards to exclude it~\cite{en298,en230}.
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@ -328,8 +349,8 @@ The differences in resistor failure modes between FMD-91 and EN298 are that FMD-
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include the failure mode DRIFT. EN298 does not include this, mainly because it imposes circuit design constraints
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include the failure mode DRIFT. EN298 does not include this, mainly because it imposes circuit design constraints
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that effectively side step that problem.
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that effectively side step that problem.
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%
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%
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For this study we will take the conservative view from EN298, and consider the failure
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For this study the conservative view from EN298 is taken, and the failure
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modes for a generic resistor to be both OPEN and SHORT. We use the function $fm$
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modes for a generic resistor taken to be both OPEN and SHORT. The function $fm$ is used
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to return a set of failure modes,
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to return a set of failure modes,
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i.e.
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i.e.
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\label{ros}
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\label{ros}
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@ -348,7 +369,7 @@ $$ fm(R) = \{ OPEN, SHORT \} . $$
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The operational amplifier (op-amp) %is a differential amplifier and
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The operational amplifier (op-amp) %is a differential amplifier and
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is very widely used in nearly all fields of modern analogue electronics.
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is very widely used in nearly all fields of modern analogue electronics.
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%
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%
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Only one of two sources of information on {\bc} {\fms} we are comparing
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Only one of two sources of information on {\bc} {\fms} being compared
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has an entry specific to operational amplifiers (FMD-91).
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has an entry specific to operational amplifiers (FMD-91).
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%
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%
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EN298 does not specifically define the
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EN298 does not specifically define the
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@ -358,16 +379,17 @@ components types not specifically listed in it.
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%
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%
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Operational amplifiers are typically packaged in dual or quad configurations---meaning
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Operational amplifiers are typically packaged in dual or quad configurations---meaning
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that a chip will typically contain two or four amplifiers.
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that a chip will typically contain two or four amplifiers.
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For the purpose of example for EN298, we look at
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%
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For the purpose of example for EN298, %we look at
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a typical op-amp designed for instrumentation and measurement, the dual packaged version of the LM358~\cite{lm358}
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a typical op-amp designed for instrumentation and measurement, the dual packaged version of the LM358~\cite{lm358}
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(see figure~\ref{fig:lm258}).
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(see figure~\ref{fig:lm258}) is examined.
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%
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%
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With the results from both sources of {\fm} definition %
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With the results from both sources of {\fm} definition %
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%we compare
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%we compare
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the failure mode definitions for FMD-91 and EN298
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the failure mode definitions for FMD-91 and EN298
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relating to operational amplifiers are compared.
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relating to operational amplifiers are compared.
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\paragraph{ Failure Modes of an Op-Amp according to FMD-91 }
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\paragraph{Failure Modes of an Op-Amp according to FMD-91.}
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\fmodegloss
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\fmodegloss
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%Literature suggests, latch up, latch down and oscillation.
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%Literature suggests, latch up, latch down and oscillation.
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For Op-Amp failures modes, FMD-91\cite{fmd91}{3-116] states,
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For Op-Amp failures modes, FMD-91\cite{fmd91}{3-116] states,
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@ -382,38 +404,40 @@ Again these are mostly internal causes of failure, more of interest to the compo
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than a test engineer % designer
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than a test engineer % designer
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looking for the symptoms of failure.
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looking for the symptoms of failure.
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%
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%
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We need to translate these failure causes within the Op-Amp into {\fms}.
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These failure causes within the Op-Amp need to be translated to symptomatic {\fms}.
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%
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%
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We can look at each failure cause in turn, and map it to potential {\fms} suitable for use in FMEA
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Each failure cause is examined in turn, and mapped to potential {\fms} suitable for use in FMEA
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investigations.
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investigations.
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\paragraph{Op-Amp failure cause: Poor Die attach.}
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\paragraph{Op-Amp failure cause: Poor Die attach.}
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The symptom for this is given as a low slew rate. This means that the op-amp
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The symptom for this is given as a low slew rate.
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will not react quickly to changes on its input terminals.
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%
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This means that the op-amp will not react quickly to changes on its input terminals.
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%
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This is a failure symptom that may not be of concern in a slow responding system like an
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This is a failure symptom that may not be of concern in a slow responding system like an
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instrumentation amplifier. However, where higher frequencies are being processed,
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instrumentation amplifier. However, where higher frequencies are being processed,
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a signal may be lost entirely.
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a signal may be lost entirely.
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We can map this failure cause to a {\fm}, and we can call it $LOW_{slew}$.
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This failure cause can be mapped to a symptomatic {\fm} called $LOW_{slew}$.
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\paragraph{No Operation - over stress.}
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\paragraph{No Operation - over stress.}
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Here the OP-Amp has been damaged, and the output may be held HIGH or LOW, or may be
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Here the OP-Amp has been damaged, and the output may be held HIGH or LOW, or may be
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effectively tri-stated, i.e. not able to drive circuitry in along the next stages of
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effectively tri-stated, i.e. not able to drive circuitry in along the next stages of
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the signal path: we can call this state NOOP (no Operation).
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the signal path: this {\fm} is termed NOOP (no Operation).
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%
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%
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We can map this failure cause to three {\fms}, $LOW$, $HIGH$, $NOOP$.
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This failure cause thus maps to three {\fms}, $LOW$, $HIGH$, $NOOP$.
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\paragraph{Shorted inputs: $V_+$ to $V_-$.}
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\paragraph{Shorted inputs: $V_+$ to $V_-$.}
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Due to the high intrinsic gain of an op-amp, and the effect of offset currents,
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Due to the high intrinsic gain of an op-amp, and the effect of offset currents,
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this will force the output HIGH or LOW.
|
this will force the output HIGH or LOW.
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We map this failure cause to $HIGH$ or $LOW$.
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This failure cause maps to $HIGH$ or $LOW$.
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|
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\paragraph{Open input: $V_+$.}
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\paragraph{Open input: $V_+$.}
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This failure cause will mean that the minus input will have the very high gain
|
This failure cause will mean that the minus input will have the very high gain
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of the Op-Amp applied to it, and the output will be forced HIGH or LOW.
|
of the Op-Amp applied to it, and the output will be forced HIGH or LOW.
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||||||
We map this failure cause to $HIGH$ or $LOW$.
|
This failure cause maps to $HIGH$ or $LOW$.
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||||||
|
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||||||
\paragraph{Collecting Op-Amp failure modes from FMD-91.}
|
\paragraph{Collecting Op-Amp failure modes from FMD-91.}
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||||||
We can define an Op-Amp, under FMD-91 definitions to have the following {\fms}.
|
An Op-Amps' failure mode behaviour, under FMD-91 definitions will have the following {\fms}.
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||||||
\begin{equation}
|
\begin{equation}
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||||||
\label{eqn:opampfms}
|
\label{eqn:opampfms}
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||||||
fm(OpAmp) = \{ HIGH, LOW, NOOP, LOW_{slew} \}
|
fm(OpAmp) = \{ HIGH, LOW, NOOP, LOW_{slew} \}
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||||||
@ -425,15 +449,20 @@ We can define an Op-Amp, under FMD-91 definitions to have the following {\fms}.
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|||||||
EN298 does not specifically define OP\_AMPS failure modes; these can be determined
|
EN298 does not specifically define OP\_AMPS failure modes; these can be determined
|
||||||
by following a procedure for `integrated~circuits' outlined in
|
by following a procedure for `integrated~circuits' outlined in
|
||||||
annex~A~\cite{en298}[A.1 note e].
|
annex~A~\cite{en298}[A.1 note e].
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||||||
|
%
|
||||||
This demands that all open connections, and shorts between adjacent pins be considered as failure scenarios.
|
This demands that all open connections, and shorts between adjacent pins be considered as failure scenarios.
|
||||||
We examine these failure scenarios on the dual packaged $LM358$~\cite{lm358} %\mu741$
|
We examine these failure scenarios on the dual packaged $LM358$~\cite{lm358} %\mu741$
|
||||||
and determine its {\fms} in table ~\ref{tbl:lm358}.
|
and determine its {\fms} in table ~\ref{tbl:lm358}.
|
||||||
Collecting the op-amp failure modes from table ~\ref{tbl:lm358} we obtain the same {\fms}
|
%
|
||||||
that we got from FMD-91, listed in equation~\ref{eqn:opampfms}, except for
|
% Collecting the op-amp failure modes from table ~\ref{tbl:lm358} we obtain the same {\fms}
|
||||||
|
% that we got from FMD-91, listed in equation~\ref{eqn:opampfms}, except for
|
||||||
|
% $LOW_{slew}$.
|
||||||
|
%
|
||||||
|
Collecting the op-amp failure modes from table ~\ref{tbl:lm358} the same {\fms}
|
||||||
|
that we got from FMD-91 are obtained---listed in equation~\ref{eqn:opampfms}---except for
|
||||||
$LOW_{slew}$.
|
$LOW_{slew}$.
|
||||||
|
|
||||||
|
|
||||||
|
|
||||||
%\paragraph{EN298: Open and shorted pin failure symptom determination technique}
|
%\paragraph{EN298: Open and shorted pin failure symptom determination technique}
|
||||||
|
|
||||||
|
|
||||||
@ -636,11 +665,14 @@ Let us choose resistor R1 in the OP-AMP gain circuitry.
|
|||||||
\item \textbf{F - Failures of given component} The resistor (R1) could fail by going OPEN or SHORT (EN298 definition).
|
\item \textbf{F - Failures of given component} The resistor (R1) could fail by going OPEN or SHORT (EN298 definition).
|
||||||
\item \textbf{M - Failure Mode} Consider the component failure mode SHORT
|
\item \textbf{M - Failure Mode} Consider the component failure mode SHORT
|
||||||
\item \textbf{E - Effects} This will drive the minus input LOW causing a HIGH OUTPUT/READING
|
\item \textbf{E - Effects} This will drive the minus input LOW causing a HIGH OUTPUT/READING
|
||||||
\item \textbf{A - Analysis} The reading will be out of the normal range, and we will have an erroneous milli-volt reading
|
\item \textbf{A - Analysis} The reading will be out of the normal range, i.e. will have an erroneous milli-volt reading
|
||||||
\end{itemize}
|
\end{itemize}
|
||||||
|
|
||||||
\fmeagloss
|
\fmeagloss
|
||||||
|
|
||||||
|
%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%
|
||||||
|
%%%%%%%%%%%% WE removal project ends here today 08SEP2013 %%%%%%%%
|
||||||
|
%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%
|
||||||
|
|
||||||
The analysis above has given us a result for % one failure %scenario i.e.
|
The analysis above has given us a result for % one failure %scenario i.e.
|
||||||
one single component failure mode.
|
one single component failure mode.
|
||||||
@ -649,8 +681,10 @@ for each failure mode of all the components in the system under investigation.
|
|||||||
%
|
%
|
||||||
In theory we have had to look at the failure~mode
|
In theory we have had to look at the failure~mode
|
||||||
in relation to the entire circuit.
|
in relation to the entire circuit.
|
||||||
|
%
|
||||||
We have used intuition to determine the probable
|
We have used intuition to determine the probable
|
||||||
effect of this failure mode.
|
effect of this failure mode.
|
||||||
|
%
|
||||||
For instance we have assumed that the resistor R1 going SHORT
|
For instance we have assumed that the resistor R1 going SHORT
|
||||||
will not affect the ADC, the Microprocessor or the UART.
|
will not affect the ADC, the Microprocessor or the UART.
|
||||||
%
|
%
|
||||||
|
Loading…
Reference in New Issue
Block a user