APPLICATION NOTE: AN Mechanical Switch Extended Life Test Report

Transcription

1 APPLICATION NOTE: AN TITLE: Mechanical Switch Extene Life Test Report Reference: RF Mechanical Switch, RF Relay Switch Report Date: August, Report Issue by: Report Reviewe by: Report Status: Te Heil Harvey Kaylie Initial Release File Name File Date 4/30/2015 3:01:00 PM No. Pages 20 s:\users\hkoffice\te_heil_ntwk\projects_ntwk\projects - archive\mechanical switches_ \life test report\mechanical switch life test report_4an.oc AN Rev.: D M (04/15/15) File: AN83001.oc Sheet 1 of 20 This ocument an its contents are the property of Mini-Circuits.

2 Ee &^ WD W e e e e W ^ W ^h W> ^ e De Z>h e Z>h Z^ e Z&^ e AN Rev.: D M (04/15/15) File: AN83001.oc Sheet 2 of 20 This ocument an its contents are the property of Mini-Circuits.

3 Ee &^ WD W 1 Purpose To valiate the extene life performance of the Mini-Circuits Mechanical Switch Prouct line in the efine environment uner efine operating conitions. 2 Scope: D^Wey> D^Wey> D^ey> 3 Backgroun: Prior to eveloping our Mechanical Switch, Mini-Circuits purchase a significant quantity of mechanical switches for use in our prouction test facilities. These switches utilize a combination of springs an solenois to accomplish the switching. Most operate for less than 1 million cycles, or approximately 50 ays in our prouction environment. This turnover prompte Mini-Circuits to evelop our own esign to aress the short operating life, long lea times, an high cost of using commercially available Mechanical Relay switches. 4 Design Approach Design Objective: Develop a long life mechanical switch Design Criteria: 1. Eliminate the use of any springs 2. Select combinations of materials base upon compatibility an ability to mate with limite wear. 3. Simplicity of esign with the minimum number of components possible 4. Cost effectiveness to meet internal an external market emans 5 Tests Performe 5.1 Life Testing In a prouction test environment, a failure is very important. When using commercially available mechanical relays, we observe a number of cases where goo proucts faile as a result of a ba switch in our test system. It was commonly believe that a mechanical switch has faile when it fails to switch states (was close when expecte to be open, or open when expecte to be close), i.e. AN Rev.: D M (04/15/15) File: AN83001.oc Sheet 3 of 20 This ocument an its contents are the property of Mini-Circuits.

4 Ee &^ WD W catastrophic failure. We learne that a mechanical switch will actually show many cycles of egrae performance prior to reaching catastrophic failure. For customer use purposes, the number of faile switching cycles is a more meaningful criteria for etermining the failure of a mechanical switch. For example, many commercially available mechanical switches are specifie at one-million cycle life expectancy; however, we have seen that these switches often exhibit faile performance starting at 800K cycles. In a test environment, every faile performance cycle can mean a rejecte goo DUT. To etermine if a switch has faile life test, we efine Life Test Failure as an accumulation of iniviual cycle performance failures. The failure criteria of any one performance cycle is one that measures DC resistance exceeing 240 milliohms. That is equivalent to an increase in RF insertion loss at low frequencies of 0.021B (see chart below). The Mini-Circuits criteria for Mechanical Switch Life Test Failure is a unit which passes both of the following conitions: 1. First 10 cumulative cycle failures occurs at greater than 5 million total switch cycles (equals 2 DPPM) - an - 2. Cumulative of 1000 cycle failures occurs at greater than 10 million total switch cycles Loss (B) Spec Contact resistance (Ohms) &&& 5.2 Sleep Moe Testing Sleep testing valiates the ability of a mechanical switch to remain in a fixe state for an extene perio of time, an still switch reliably to another state when energize. This parameter is a result of applications where mechanical relay switches are use to switch-in reunant paths in the event of a failure in the main path. A switch functioning in this moe is often referre to as operating in sleep moe. AN Rev.: D M (04/15/15) File: AN83001.oc Sheet 4 of 20 This ocument an its contents are the property of Mini-Circuits.

5 Ee &^ WD W Mini-Circuits has, an continues to test switches in this moe of operation. Sets of 10 switches are store in a fixe state over a perio a four (4) years. At specific intervals, switches are remove an teste for their ability to switch after the perio of inactivity. 6 Switch Tune-Up Even though the life of the Mini-Circuits switches is far greater than any other switch on the market toay, even our switches will fail at some point. Mini-Circuits unique construction makes it very practical to clean the switch contact assembly enabling switch performance recovery for extening the switch life to well over 100 million cycles. Mini-Circuits also valiate the effectiveness of the tune-up on our mechanical switches, subjecting switches to extene life testing with tune-ups after any switch reache 1000 cumulative faile cycles. We achieve a total life cycle of greater than 300 million cycles. 7 Prouction Life Testing It is a Mini-Circuits internal quality requirement that each prouction lot of Mechanical RF Switches be subjecte to sample life testing prior to Lot Acceptance. On each prouction lot, a minimum of two (2) switches are ranomly selecte an subjecte to the same DC life test as outline above. All units are require to pass the First Failure an the Cumulative Failure criteria for lot acceptance. Data is recore on all lots an a sample summary is inclue herein Prouction Life Test ata is use in this report as basis for Life Testing. (referre herein in TEST 1: Life Testing - without Tune-Up) AN Rev.: D M (04/15/15) File: AN83001.oc Sheet 5 of 20 This ocument an its contents are the property of Mini-Circuits.

6 Ee &^ WD W e 8 Test Summary 8.1 TEST 1: Life Testing (without Tune-Up) Seventy-five(75) switches teste over a perio of 1 year Moel: MSP2T-18XL an MSP2TA-18XL Test Results Units Min Avg Max First Failure Occurs at 1000 Cum Failures Occur at Cycle Number Cycle Number 5,096,137 18,798,751 44,252,850 10,476,000 33,045,867 83,526,000 Table 1 Life Test Results 8.2 TEST 2: Extene Life Testing after Tune-ups Five (5) switches teste Test Results: All units excee 300 million cycles after Unit No. No. Cycles Achieve No. Tune-Ups Req million million million million million 20 Table 2 Extene Life Test Results Testing terminate after 300 Million Cycles (units show no permanent wear an continue to operate) 8.3 TEST 3: Sleep Moe Testing 20 units teste (10 units MSP2T-18, 10 units MSP2T-18XL) All units energize in State 1 Units Energize to State 2 over 4 years All units successfully switche to State 2 AN Rev.: D M (04/15/15) File: AN83001.oc Sheet 6 of 20 This ocument an its contents are the property of Mini-Circuits.

7 Ee &^ WD W e 9 Test Methos an Conitions 9.1 Life Tests (Tests 1 an Tests 2): KE l PORT X to PORT Y l & /^& m ^&Z && & 9.2 Sleep time test Mini-Circuits switches have passe four year sleep time test. Sleep Time efines the perio over which switch is not energize an hence not switche. &D,Z& D^We D^Wey> Z& Z& & D. AN Rev.: D M (04/15/15) File: AN83001.oc Sheet 7 of 20 This ocument an its contents are the property of Mini-Circuits.

8 Ee &^ WD W e 10 Detaile Test Results Test 1: Life Tests (without Tune-Up) 10.1 TEST PROCESS TEST 1 Life Test (without Tuneup) Life Test Data is erive from results of Prouction Life Test process, performe as follows: ^Z WZKh/KE^^D>z E^Y ^, lz&^ />zzs/t ^>^t/,^&kz >/&^&ZKD WZKh/KE>K /^^t/,z> KhE&/Z^ &/>hz^md z>^ z^ EK >/ZYh/WDE Z^/^E D^hZDE /^K>E &/>hz^ m z^ /^ K>E ^t/,z>^ mdz>^ EK ZhED,E/> ^t/,>/&^ ^K&tZ EK /^K>E ^t/,z>^ mdz>^ z^ z^ WZK^^/E' >/&^&/>hz^ DKs ^t/,^ W ZKZZ^/^E &/>hzm EK EK/&zE'/EZ/E' ^DE'Z &/E>Zs/t ^/'EY^, WWZKsWZKh/KEZhE EK /^ K>EK &/>hz^ m z^ ^KW^ ^Zs/D/EE KE&/>hE/ Z^K<&KZ^ WZDE Figure 2 Prouction Life Testing Process Flow AN Rev.: D M (04/15/15) File: AN83001.oc Sheet 8 of 20 This ocument an its contents are the property of Mini-Circuits.

9 Ee &^ WD W e 10.2 DC Resistance Measurement DC Resistance is measure at each switching cycle for each Port on Life Test units. Data is collecte an reviewe on a aily basis. Life Test Units are teste to failure; i.e. Greater than 1000 Cumulative cycles with DC Resistance >240mΩ. Typical DC Life test ata on a single unit is presente below in Figure 3 below. &/Z^&/>eDz>^ z>&/>d Figure 3 Sample Life Test Data one Switch AN Rev.: D M (04/15/15) File: AN83001.oc Sheet 9 of 20 This ocument an its contents are the property of Mini-Circuits.

10 Ee &^ WD W Unit Data Distribution Test 1: Life Tests (without Tune-Up) &&WZ e e h E D^>Z && D Figure 4 Switch First Failures Recore Cycle - Distribution &WZ D^>Z e e h E D Figure 5 Switch 1000 Cumulative Failures Recore Cycle - Distribution AN Rev.: D M (04/15/15) File: AN83001.oc Sheet 10 of 20 This ocument an its contents are the property of Mini-Circuits.

11 Ee &^ WD W 10.4 DETAILED TEST DATA Test 1: Life Tests (without Tune-Up) LIFE TEST REPORT DATA First Failure 1000 Cum Fail No. Runs Moels: MSP2T-18XL Min 5,096,137 10,476,000 MSP2TA-18XL Max 44,252,850 83,526,000 Time Perio 01/18/08 Average 18,798,751 33,045,867 01/12/09 STDEV 9,675,126 15,422,011 CT Run No. Run Number Moel No. Unit No. Run DATE Run Qty Release Date Life Test Qty No. Failures at First Failure 1000 Cum Fail TEST STOP N59890 MSP2T-18XL /18/ Jan ,172,114 37,203, N59890 MSP2T-18XL /18/ ,759,979 22,325, N59890 MSP2T-18XL /18/ ,564,880 25,691, N61840 MSP2T-18XL /14/ Feb ,939,466 42,849, N61840 MSP2T-18XL /14/ ,195,716 47,836, N61840 MSP2T-18XL /14/ ,601,417 43,353, N73210 MSP2T-18XL /20/ Feb ,659,367 29,580, N73210 MSP2T-18XL /20/ ,911,046 28,223, N73210 MSP2T-18XL /20/ ,601,417 35,472, N76230 MSP2T-18XL /14/ Mar ,499,055 13,823, N76230 MSP2T-18XL /14/ ,703,742 40,925, N76230 MSP2T-18XL /14/ ,582,758 20,902, N82720 MSP2T-18XL /26/ Apr ,165,115 10,643, N82720 MSP2T-18XL /26/ ,864,775 45,414, N82720 MSP2T-18XL /26/ ,325,529 41,480, N73210 MSP2T-18XL /27/ Apr ,563,929 22,676, N73210 MSP2T-18XL /27/ ,376,513 60,545, N73210 MSP2T-18XL /27/ ,379,073 24,012, N79510 MSP2T-18XL /28/ Apr ,822,783 18,334, N79510 MSP2T-18XL /28/ ,054,932 44,704, N79510 MSP2T-18XL /28/ ,693,321 32,055, N73210 MSP2T-18XL /01/ May ,457,105 50,239, N73210 MSP2T-18XL /01/ ,262,282 29,609, N73210 MSP2T-18XL /01/ ,555,303 71,963, N92790 MSP2T-18XL /02/ May ,252,850 64,260, N92790 MSP2T-18XL /02/ ,608,347 58,286, N92790 MSP2T-18XL /02/ ,252,419 83,526, * N97820 MSP2T-18XL /24/ Jul ,817,045 47,478, N97820 MSP2T-18XL /24/ ,753,600 48,740, N97820 MSP2T-18XL /24/ ,990,051 50,000, * N01200 MSP2TA-18XL /30/ Jul ,483,701 32,275, N01200 MSP2TA-18XL /30/ ,578,121 43,830, N01210 MSP2TA-18XL /09/ Jul ,459,922 44,584, N01210 MSP2TA-18XL /09/ ,809,803 35,989, N01210 MSP2TA-18XL /09/ ,115,307 37,028, N01220 MSP2TA-18XL /23/ Aug ,599,736 50,000, * N01220 MSP2TA-18XL /23/ ,523,486 42,901, N01220 MSP2TA-18XL /23/ ,463,694 44,729, N01230 MSP2TA-18XL /30/ Aug ,344,686 32,790, N01230 MSP2TA-18XL /30/ ,342,293 25,843, N01230 MSP2TA-18XL /30/ ,364,154 34,155, N05490 MSP2T-18XL /05/ Aug ,055,732 42,004, N05490 MSP2T-18XL /05/ ,870,088 50,000, * N05490 MSP2T-18XL /05/ ,649,155 50,000,000 3* N05510 MSP2T-18XL /06/ Aug ,331,892 49,241, N05510 MSP2T-18XL /06/ ,598,369 40,208, N05510 MSP2T-18XL /06/ ,385,306 50,000, * N05520 MSP2T-18XL /10/ Sep ,737,191 25,619, N05520 MSP2T-18XL /10/ ,399,379 22,772, N01240 MSP2TA-18XL /10/ Sep ,411,508 16,835, N01240 MSP2TA-18XL /26/ Oct ,015,585 22,434, N01240 MSP2TA-18XL /26/ ,049,030 20,737, N07280 MSP2T-18XL /03/ Oct ,992,340 20,782, N07280 MSP2T-18XL /03/ ,702,337 20,412, N07280 MSP2T-18XL /03/ ,454,447 17,736, N07290 MSP2TA-18XL /15/ Oct ,348,571 12,029, N07290 MSP2TA-18XL /15/ ,653,387 18,824, N07290 MSP2TA-18XL /15/ ,633,372 13,499, N07300 MSP2TA-18XL /18/ Nov ,676,884 20,444, N07300 MSP2TA-18XL /18/ ,326,921 30,748, N07300 MSP2TA-18XL /18/ ,986,248 24,187, N07300 MSP2TA-18XL /18/ ,867,459 19,616, N12090 MSP2T-18XL /20/ Nov ,609,451 26,409, N12090 MSP2T-18XL /20/ ,387,139 28,144, N12090 MSP2T-18XL /20/ ,946,303 32,946, N07310 MSP2TA-18XL /03/ Dec ,812,588 13,833, N07310 MSP2TA-18XL /03/ ,556,473 11,139, N14600 MSP2T-18XL /16/ Dec ,416,966 31,190, N14600 MSP2T-18XL /16/ ,334,380 16,385, N14600 MSP2T-18XL /16/ ,337,631 29,561, N14600 MSP2T-18XL /16/ ,230,600 32,696, N07320 MSP2TA-18XL /08/ Jan ,794,741 14,478, N07320 MSP2TA-18XL /08/ ,244,288 14,138, N07320 MSP2TA-18XL /08/ ,096,137 10,476, N05520 MSP2T-18XL /12/ Jan ,523,567 12,648, * Life Test terminate prior to 1000 cycle failures for units exceeing 50 million cycles - Change institute May Table 3 Life Test Data (without Tune-up) Details 75 Switches ^& AN Rev.: D M (04/15/15) File: AN83001.oc Sheet 11 of 20 This ocument an its contents are the property of Mini-Circuits.

12 Ee &^ WD W 11 Detaile Test Results Test 2: Extene Life Tests (with Tune-Up) 11.1 TEST PROCESS TEST 2 Extene Life Test (with Tuneup) ^Z WZ&KZDWZKh/KE >/&^ ^>&KhZ ^t/,^&kz ye>/&^ &ZKDWZKh/KE >/&^ KE,^t/, WZ&KZD lz&^ ZhEWZKh/KE>/& ^WZK'ZD ZKZz> hehw /^K>E &/>hz^ m WZ&KZDD,E/> ^t/,hehw WZKhZ WZ&KZD lz&^ W^^ he/ W^^ &/> &/> ZKZEz>^ &/E>&/>hZ ^KW Figure 6 Extene Life Test Data (with Tune-up) Process Flow AN Rev.: D M (04/15/15) File: AN83001.oc Sheet 12 of 20 This ocument an its contents are the property of Mini-Circuits.

13 Ee &^ WD W 11.2 TEST RESULTS TEST 2 Extene Life Test (with Tuneup) Run: E39070 Start Date: October 19 th, 2006 En: March 3 r 2008 Tune-up # Switch# Table 4 - Cumulative Number of Cycles Complete (in millions) prior to Each Tune-up AN Rev.: D M (04/15/15) File: AN83001.oc Sheet 13 of 20 This ocument an its contents are the property of Mini-Circuits.

14 Ee &^ WD W 12 Detaile Test Results Test 3: Sleep Testing 12.1 TEST PROCESS TEST 3 Sleep Test ^Z ^>tez ^t/,^&kz^>w ^&ZKDWWZKs WZKh/KE>K D^We D^Wey> KE,^t/, ^, KE,^t/,,^t/,/E E K ^KZ'/E&/y D ^KE,^t/, ^ ^hw l EZ'/^t/, / KE,^t/, ^>^t/, :/E ^ ^ ^hw t e ^ KE,^t/, l, hwke^w/&/ D/E/E^ EZ'/^t/, / E ^ ^hw e ^ ^,h> KE,^t/, ^ :/E K Z EZ'/^t/, t D l, D/E/E^ ^ ^hw / E ^ Z :/E K WZ&KZDZKZ KE,^t/, z WZ&KZDZKZ EZ'/^t/, ^ ^hw t D ^ D/E/E^ l, lz&^ :/E KE,^t/, z ^ lz&^ EZ'/^t/, E Z D/E/E^ :/E ^ ^hw K l WZ&KZDZKZ ^ KE,^t/, t D / z Z D/E/E^ EZ'/^t/, l t/y WZ/K lz&^ ^ ^hw / WZ&KZDZKZ KE,^t/, t z ^ :/E EZ'/^t/, Z /D t/y WZ/K lz&^ ^ ^hw t l WZ&KZDZKZ D/E/E^ /D :/E / z lz&^ EZ'/^t/, D/E/E^ ^ ^hw l t/y WZ/K WZ&KZDZKZ :/E t / EZ'/^t/, ^ ^hw /D lz&^ l t/y WZ/K WZ&KZDZKZ D/E/E^ :/E t EZ'/^t/, ^ ^hw / /D D/E/E^ :/E EZ'/^t/, t/y WZ/K lz&^ WZ&KZDZKZ t D/E/E^ :/E ^ ^hw /D t/y WZ/K lz&^ D/E/E^ EZ'/^t/, /D WZ&KZDZKZ ^ ^hw :/E t/y WZ/K lz&^ WZ&KZDZKZ WZ&KZDZKZ EZ'/^t/, D/E/E^ ^ ^hw /D t/y WZ/K lz&^ lz&^ :/E WZ&KZDZKZ EZ'/^t/, ^ ^hw D/E/E^ /D lz&^ :/E EZ'/^t/, t/y WZ/K WZ&KZDZKZ D/E/E^ :/E ^ ^hw /D t/y WZ/K ^KW lz&^ D/E/E^ EZ'/^t/, ^ ^hw /D WZ&KZDZKZ :/E EZ'/^t/, ^KW lz&^ WZ&KZDZKZ D/E/E^ ^ ^hw :/E lz&^ WZ&KZDZKZ EZ'/^t/, D/E/E^ ^ ^hw ^KW lz&^ :/EEZ'/^t/, ^KW WZ&KZDZKZ D/E/E^ :/E lz&^ WZ&KZDZKZ D/E/E^ ^KW ^KW lz&^ WZ&KZDZKZ lz&^ WZ&KZDZKZ ^KW lz&^ ^KW ^ Z z l / t ^KW ^KW &/E>ZWKZ Figure 7 Sleep Test Process Flow AN Rev.: D M (04/15/15) File: AN83001.oc Sheet 14 of 20 This ocument an its contents are the property of Mini-Circuits.

15 Ee &^ WD W 12.2 TEST RESULTS TEST 3 Sleep Tests DK>E ^E ^ W Z ^ W Z D^We Eee 2/12/05 W^^ W^^ Eee 4/12/05 W^^ e W^^ Eee 7/12/05 W^^ e W^^ Eee 10/12/05 W^^ W^^ Eee 1/12/06 W^^ W^^ Eee 7/12/06 W^^ W^^ Eee 1/12/07 W^^ W^^ Eee 7/12/07 W^^ W^^ Eeee 1/12/08 W^^ W^^ Eeee 1/12/09 W^^ W^^ D^Wey> N /18/2009 W^^ W^^ N /18/2009 W^^ e W^^ N /18/2009 W^^ e W^^ N /18/09 W^^ W^^ N /18/10 W^^ W^^ N /18/10 W^^ W^^ N /18/11 W^^ W^^ N /18/11 W^^ W^^ N /18/12 W^^ W^^ N /18/13 W^^ W^^ Table 5 Sleep Test Results EKDz>>KtWWE/y AN Rev.: D M (04/15/15) File: AN83001.oc Sheet 15 of 20 This ocument an its contents are the property of Mini-Circuits.

16 Ee &^ WD W e 13 Conclusion Due to the esign approach as outline in section 4, for all practical purposes, these switches o not wear out an have a lifetime far exceeing switches commercially available. They have the ability to be use in excess of 300 million cycles with perioic tune-up, meeting all electrical performance as outline in our catalog atasheet. AN Rev.: D M (04/15/15) File: AN83001.oc Sheet 16 of 20 This ocument an its contents are the property of Mini-Circuits.

17 Ee &^ WD W e 14 Appenix RF TEST DATA Typical Test Data taken on Switch, BEFORE an AFTER Sleep Test 14.1 BEFORE SLEEP TEST DATA Figure 8a RF TEST DATA - Before Sleep Test INSERTION LOSS RUN N S/N 0012 (D/C 0451) AN Rev.: D M (04/15/15) File: AN83001.oc Sheet 17 of 20 This ocument an its contents are the property of Mini-Circuits.

18 Ee &^ WD W e Figure 8b RF TEST DATA - Before Sleep Test ISOLATION RUN N S/N 0012 (D/C 0451) AN Rev.: D M (04/15/15) File: AN83001.oc Sheet 18 of 20 This ocument an its contents are the property of Mini-Circuits.

19 Ee &^ WD W e 14.1 AFTERSLEEP TEST DATA Figure 9 RF TEST DATA After Sleep Test INSERTION LOSS an ISOLATION N S/N 0012 (D/C 0451) AN Rev.: D M (04/15/15) File: AN83001.oc Sheet 19 of 20 This ocument an its contents are the property of Mini-Circuits.

20 Ee &^ WD W IMPORTANT NOTICE 2015 Mini-Circuits This ocument is provie as an accommoation to Mini-Circuits customers in connection with Mini-Circuits parts only. In that regar, this ocument is for informational an guieline purposes only. Mini-Circuits assumes no responsibility for errors or omissions in this ocument or for any information containe herein. Mini-Circuits may change this ocument or the Mini-Circuits parts reference herein (collectively, the Materials ) from time to time, without notice. Mini-Circuits makes no commitment to upate or correct any of the Materials, an Mini-Circuits shall have no responsibility whatsoever on account of any upates or corrections to the Materials or Mini-Circuits failure to o so. Mini-Circuits customers are solely responsible for the proucts, systems, an applications in which Mini-Circuits parts are incorporate or use. In that regar, customers are responsible for consulting with their own engineers an other appropriate professionals who are familiar with the specific proucts an systems into which Mini-Circuits parts are to be incorporate or use so that the proper selection, installation/integration, use an safeguars are mae. Accoringly, Mini-Circuits assumes no liability therefor. In aition, your use of this ocument an the information containe herein is subject to Mini-Circuits stanar terms of use, which are available at Mini-Circuits website at Mini-Circuits an the Mini-Circuits logo are registere traemarks of Scientific Components Corporation /b/a Mini-Circuits. All other thir-party traemarks are the property of their respective owners. A reference to any thir-party traemark oes not constitute or imply any enorsement, affiliation, sponsorship, or recommenation: (i) by Mini-Circuits of such thir-party s proucts, services, processes, or other information; or (ii) by any such thir-party of Mini-Circuits or its proucts, services, processes, or other information. AN Rev.: D M (04/15/15) File: AN83001.oc Sheet 20 of 20 This ocument an its contents are the property of Mini-Circuits.