A HALT-Simulation Combined Fault Diagnosis and Optimization Method for Electronic Module

As the basic units of electronic systems, electronic module is essential for the normal operation of the electronic system. The method to stimulate the failure of electronic modules, locate the weak parts and optimize the modules, is the concern for both of the industry and academia. Taking a power module as an example, this paper provides a new method to accurately locate the weak parts of electronic modules and improve the design of the module, which helps to find out the exact point of the fault and optimize the design of the module. First, use the high-acceleration vibration chamber, QualMark Typhoon 2.5, to carry out random vibration test on the power module, recording the output signal changes in real time, which helps to determine whether the power supply module has failed. Then, build the finite element simulation model of the power module and carry out random vibration simulation to obtain the stress distribution. According to the actual fault state and the circuit simulation of the power module, determine the weak parts of the module and verify the analysis results by the physical failure injection test. Finally, analyze the effects of different shapes of solder joint and solder dosage on the stress distribution and anti-vibration performance of power module's weak parts. And give an optimization scheme to improve its reliability under vibration stress.