Failure Analysis and Troubleshooting in Electronics

No one likes it, everyone experiences it, you will experience it again – failure. From everyday fails to spectacular ones, it’s something that is just a part of existence. And it isn’t a human experience alone, even the things we design to be as near to faultless as we can experience failings. The key thing that sets us above the rest is our ability to learn from all mistakes, analyse, and strive to improve. But as an electronics company, we won’t waste your time by waxing philosophical – we’ll focus on the tangible: failure analysis and troubleshooting in electronics.

We all know that electronics are intertwined with almost every aspect of our existence, and 99% of us are entirely reliant on systems far outside of our control that govern our survival. From consumer gadgets like smart watches to industrial control systems that monitor the machines grinding up wheat to become the food we eat.

Despite advances in design and manufacturing, electronic circuits and systems can still experience failures. There are a lot of causes of these failures – for example, component degradation, design flaws or even external factors like environmental temperature. Learning how and why the failures happened will hopefully help us learn to prevent them again in the future.

In this blog, we’ll explore the process of failure analysis and troubleshooting in electronics. We provide insights into diagnosing issues, discuss common faults and offer practical solutions that can help ensure reliable performance.

What is failure analysis in electronics?

Failure analysis, like any system analysis, involves the systematic investigation of the components or systems to determine the root cause; in this case, they would be electronic components or systems. The goal of the investigation is to identify where the fault lies – design error, manufacturing defect, or external stress. By understanding the mechanics behind the failure, an engineer can implement corrective actions and plot plans to prevent a future issue from re-occurring.

How does troubleshooting differ from this? Failure analysis occurs during the design and testing phases, troubleshooting occurs when the system is actually live. It’s mainly a lexical difference as the functionality is the same, though long-term use of a system can present unforeseen issues that need to be identified, isolated and corrected whilst the system is still live.

Together, failure analysis and troubleshooting form the backbone of effective maintenance strategies in the electronics industry

Common causes of failure

Now that we’ve identified how and why an electronic system can fail, let’s take a deeper look at some of those reasons:

• Component degradation: Over time, components such as capacitors and resistors may degrade due to factors like ageing or exposure to harsh environments. This one is probably the hardest to prevent because nothing is impervious to degradation and decay.
• Solder joint failures: Poor soldering techniques or thermal cycling can lead to cracks in solder joints, and these cracks cause massive problems for the connectivity of the device.
• Overloading and overheating: Excessive current or prolonged high temperatures can damage sensitive components, leading to thermal runaway or complete system failure if not addressed.
• Design flaws: Inadequate design margins, improper component selection or insufficient protection circuits are just some of the design flaws that can cause problems for devices, and eventually cause failure. Always work with an experienced team to reduce these as much as possible.
• Environmental factors: Humidity, vibration, and electromagnetic interference are all examples of external factors that can cause failures in electrical systems. But there are far more than just these. One unusual one we have encountered was a species of almost microscopic ant in the Amazon jungle that was attracted to something within the device. When enough ants entered the space, they formed a connection and shorted the device… a pretty hard one to factor against!

Understanding these causes is the first step in diagnosing and rectifying issues in electronic systems.

Diagnostic techniques and tools

When it comes to actually diagnosing electronic failures, there is a wide range of different tools we at TAD have at our disposal. What we think is the most important, however, is making sure you take a systematic approach to your diagnostics. Here are some common diagnostic techniques and tools we use day-to-day:

• Visual inspection: Carefully examining the board/device can reveal obvious issues such as burnt components, cracked solder joints or corrosion on circuit boards. We always make sure to inspect our boards beneath a microscope to check for faults that the human eye just can’t see.
• Multimeters and oscilloscopes: Multimeters allow for quick measurements of voltage, current and resistance, while oscilloscopes provide a visual representation of signals, making it easier to spot small fluctuations and identify errors during testing.
• Thermal imaging: Infrared cameras help identify hotspots on a circuit board, which visually show components that may be overheating. Working out why a component is overheating can then be completed, the component replaced and the board retested to see if the issue persists.
• Network analysers: In systems involving communication protocols, network analysers can help diagnose issues with data transmission.

There is also a variety of software we use at TAD that helps us troubleshoot devices, such as circuit simulation software. These are just some of the techniques we use to diagnose issues, and when combined, they provide a comprehensive and robust approach to troubleshooting.

A methodical approach to troubleshooting

You now know why errors can occur, what causes them and some of the diagnostic tools companies like TAD use to diagnose and troubleshoot. But as mentioned above, the systematic troubleshooting process is critical to making sure it is tested thoroughly and follows a set plan. This not only saves on time in the long run, but also increases the likelihood of quickly identifying the true cause of the failure. We recommend using the following process and steps in your device testing:

1. Initial assessment: Start by gathering as much information as possible. Look at error logs, user reports and operating conditions leading up to the failure.
2. Visual and physical inspection: Check for any visible signs of damage or wear. This step is crucial and can often reveal the culprit without the need for complex instruments.
3. Electrical testing: Use a multimeter to verify that power supplies and ground connections are within expected ranges. Check continuity to rule out open circuits.
4. Signal analysis: Employ an oscilloscope to examine the signal integrity of key nodes within the circuit. Look for anomalies such as unexpected noise or signal distortion.
5. Isolation and replacement: Once a suspect component is identified, replace it or isolate it from the system to see if the fault persists. This method of ‘divide and conquer’ helps narrow down the issue.
6. Documentation: Record every step of the process. Detailed documentation ensures that once the problem is resolved, future troubleshooting becomes more efficient.

Following these steps at every step in the production timeline – including once the device is active and being used – will make it easier to diagnose problems accurately and avoid unnecessary downtime.

A lot of issues with electronics fall into common patterns – like the ones identified in the ‘common causes of failure’ section. Each scenario demands a different set of tools and approaches, but a methodical, structured and well-documented process will make identifying and troubleshooting far less problematic.

Preventative measures and best practices

Whilst we recommend the testing and troubleshooting outlined above, it’s a bit of a no-brainer that preventing failures from being able to occur in the first place should be an objective. Engineers can adopt a number of ‘best practices’ to help reduce the risk of failures, such as:

• Robust design practices: Incorporate redundancy, over-voltage protection and appropriate safety margins in the design phase.
• Regular maintenance: Make sure to schedule regular inspections and testing to catch potential issues before they get worse.
• Environmental controls: Ensure that your electronic systems only operate within their specified environmental conditions. Your engineers should outline the temperature, humidity and electromagnetic interference tolerances of any systems they design for you. Rigidly stick to these where possible to ensure both the lifespan of the system matches the figure you were given, and that any potential environmentally caused faults are reduced.
• Quality control: Implement rigorous testing protocols during manufacturing to catch defects early.

Employing these preventative measures can greatly enhance the longevity and reliability of your electronic systems, and hopefully reduce the number of headaches and downtime you suffer from systems functioning as they should.

Failure analysis and troubleshooting conclusion

Failure analysis and troubleshooting in electronics require a careful balance of technical knowledge, systematic testing and practical experience. By understanding common causes, utilising the right diagnostic tools and adopting a methodical approach, engineers can not only resolve issues but also prevent future failures. In an industry where reliability is critical, investing time and resources in effective troubleshooting strategies is key to maintaining performance and reducing downtime.

If you are facing challenges with electronic system failures or need assistance in refining your troubleshooting processes, TAD Electronics is here to help. Contact us today to discover how our expertise can make a difference in your projects. Or read more here!