零件熱應力〈Thermal Stress〉的把關

一般來說有三種不同的應力測試方式可以判斷或是推估電源供應器的產品可靠度或是輸出穩定度，分別是熱應力〈Thermal Stress〉測試、電壓應力〈Voltage Stress〉測試、電流應力〈Current Stress〉。為了揭開灰色地帶的神秘面紗，本文將介紹有關熱應力的部分，還有除了客戶指定的要求外，全漢企業是針對下面幾項重要零件項目以及熱應力的測定結果要求來測試產品如下表：

Device(零件品項)	Type(類別)	Category(分類)	Derating Thermal(額定降溫值)
Capacitor(電容器)	–	–	90%
MOSFET(場效電晶體)	–	Main Switch(主要開關)	85%
		Small Signal(小信號開關)
Diode(二極體)	–	–
IC(控制IC)	–	–
Photo Coupler(光耦合器)	–	–
Inductor(電感)	Transformer(電壓器)	–	85%
	Choke(扼流器)	–	90%

產品可靠度與輸出穩定度一直是電源供應器選擇的重點之一，然大多數的廠商無法有效提出相關的數據來佐證他們的產品比他牌廠商在產品可靠度與輸出穩定度上有優勢，因此讓許多不肖的品牌廠商有灰色地帶去操作電源供應器的零件選用；且大部分的消費者不會經常性地讓電腦設備在電源供應器滿載下使用，也不會讓電腦處於環境溫度超過40℃或甚至於在50℃〈高階產品的耐溫設定〉的條件下使用，不肖業者因此偷料或是讓零件在超過100%的額定條件下使用。我們剛剛提到多數的消費者不會滿載使用，通常產品不會在買回來一年內壞掉，也因此讓這些不肖業者有空間操作，而當消費者使用一段時間發生問題後往往也過保固期限，或是自認倒楣不去追究。

除了定義重要的零件測試標準外，我們的測試條件也很嚴苛，規定產品要在申請安規的最高耐溫條件下且不同滿載條件下測定這些零組件，以下是我們一個80 Plus Gold的650W產品內部設定的測試條件：

• AC Input (交流輸入電壓): 90Vac/115Vac/230Vac/264Vac
• Frequency (交流輸入頻率): 47Hz/60Hz/50Hz/63Hz
• Ambient Temperature (環境溫度): 40℃

Loading(負載)	+5V	+12V	-12V	+3.3V	+5Vsb
FL1(滿載條件1)	20A	42.85A	0.3A	6.05A	2.5A
FL2(滿載條件2)	10.8A	43.9A	0.3A	20A	0A
FL3(滿載條件3)	0.1A	54.16A	0A	0A	0A
SB Mode(待機模式)	*	*	*	*	2.5A

輸入以及輸出條件設定好後，公司內規會選用這個產品所有報備安規的風扇中散熱能力最差的那顆風扇做測定，因為使用條件最差的都可以符合公司規定時，選用散熱條件最好的風扇一定可以讓測試結果表現得更好，同樣的這顆650W金牌產品的風扇設定如下表：

Fan Type(風扇類型)	Input Voltage (輸入電壓)	Load (負載)	Fan Voltage(Vdc) (風扇設定電壓)
FAN, MIDDLE,0.3A,12V,120*25,27dB, 55-68cfm,1800rpm,SLEEVE,2PIN, 150mm,CONNECT,D12SM-12,YATE LOON/NICE FULL	90Vac/47HZ	FL1	11.44
		FL2	11.44
		FL3	11.44
	115Vac/60Hz	FL1	11.44
		FL2	11.44
		FL3	11.44
	230Vac/50Hz	FL1	11.44
		FL2	11.44
		FL3	11.44
	264Vac/63Hz	FL1	11.44
		FL2	11.44
		FL3	11.44

下面幾個表格是根據全漢企業的設定條件下所測得的數據，所有測項都符合內部標準，我們更規定研發單位所有的新機種一定要通過這個關卡才可以安排產品的試產，最後試產沒有問題才可以量產產品。

(UNIT:℃)

Location	SPEC	FL1								Result
		90V	Derating (%)	115V	Derating (%)	230V	Derating (%)	264V	Derating (%)
QS203	175	77.99	44.6	77.41	44.2	77.3	44.2	77.26	44.1	Pass
QS201	175	87.51	50	86.5	49.4	86.24	49.3	85.97	49.1	Pass
QS103	175	63.66	36.4	62.68	35.8	62.23	35.6	62.21	35.5	Pass
CS106	105	64.21	61.2	63.85	60.8	63.56	60.5	63.53	60.5	Pass
FL1	130	77.59	59.7	60.32	46.4	49.28	37.9	48.38	37.2	Pass
FL3	130	92.86	71.4	70.85	54.5	56.33	43.3	54.95	42.3	Pass
BD1	150	93.11	62.1	80.44	53.6	62.55	41.7	60.59	40.4	Pass
C6	105	51.19	48.8	48.73	46.4	46.11	43.9	45.47	43.3	Pass
L1	130	107.93	83	89.45	68.8	67.99	52.3	61.32	47.2	Pass
Q201	150	79.39	52.9	71.7	47.8	65.54	43.7	65.39	43.6	Pass
Q202	150	72.11	48.1	65.43	43.6	60.07	40	59.98	40	Pass
D6	175	73.18	41.8	65.5	37.4	57.97	33.1	57.41	32.8	Pass
Q1	150	85.02	56.7	70.03	46.7	57.85	38.6	57.26	38.2	Pass
L201	130	75.28	57.9	71.72	55.2	68.93	53	68.48	52.7	Pass
T3	130	44.16	34	43.56	33.5	43.15	33.2	43.35	33.3	Pass
T201	130	80.97	62.3	80.1	61.6	79.7	61.3	78.98	60.8	Pass
T101	130	72.37	55.7	71.41	54.9	70.92	54.6	70.37	54.1	Pass
LS801	130	62.76	48.3	62.34	48	62.26	47.9	62.45	48	Pass
LS802	130	52.46	40.4	52.18	40.1	52.05	40	52.26	40.2	Pass
CS202	105	66.64	63.5	66.27	63.1	66.49	63.3	66.57	63.4	Pass
CS805	105	53.19	50.7	52.8	50.3	52.81	50.3	53.06	50.5	Pass
CS213	105	47.14	44.9	46.77	44.5	46.85	44.6	47.09	44.8	Pass
QS805	175	62.19	35.5	61.81	35.3	61.73	35.3	62.09	35.5	Pass
QS806	175	52.54	30	52.19	29.8	52.18	29.8	52.37	29.9	Pass
QS803	175	64.34	36.8	64.01	36.6	63.89	36.5	64.2	36.7	Pass
QS804	175	61.74	35.3	61.19	35	61.32	35	61.45	35.1	Pass
IC101	125	67.15	53.7	66.45	53.2	66.18	52.9	66.3	53	Pass
IC801	150	53.59	35.7	53.25	35.5	53.23	35.5	53.42	35.6	Pass
D2	150	60.55	40.4	55.08	36.7	49.38	32.9	48.58	32.4	Pass
LS101	130	50.76	39	50.2	38.6	50.01	38.5	50.04	38.5	Pass
LS201	130	65.48	50.4	65.1	50.1	65.05	50	65.24	50.2	Pass
R36	150	84.77	56.5	69.52	46.3	53.97	36	52.35	34.9	Pass
L2	130	77.61	59.7	67.27	51.7	57.03	43.9	55.85	43	Pass
CT201	130	50.93	39.2	48.85	37.6	47.2	36.3	47.28	36.4	Pass
AMB	—	40	—	40	—	40	—	40	—	—

 

Location	SPEC	FL2								Result
		90V	Derating (%)	115V	Derating (%)	230V	Derating (%)	264V	Derating (%)
QS203	175	79.41	45.4	79.03	45.2	78.73	45	78.86	45.1	Pass
QS201	175	88.37	50.5	87.54	50	87.17	49.8	87.22	49.8	Pass
QS103	175	59.64	34.1	58.84	33.6	58.37	33.4	58.38	33.4	Pass
CS106	105	61.44	58.5	61.02	58.1	60.86	58	60.86	58	Pass
FL1	130	76.77	59.1	59.75	46	48.71	37.5	48.16	37	Pass
FL3	130	92.52	71.2	70.34	54.1	56.15	43.2	54.83	42.2	Pass
BD1	150	93.03	62	80.51	53.7	62.52	41.7	60.7	40.5	Pass
C6	105	50.95	48.5	48.62	46.3	46.06	43.9	46.07	43.9	Pass
L1	130	107.97	83.1	89.5	68.8	68.01	52.3	64.82	49.9	Pass
Q201	150	80.11	53.4	72.34	48.2	66.01	44	65.77	43.8	Pass
Q202	150	72.65	48.4	65.95	44	60.47	40.3	60.33	40.2	Pass
D6	175	73.35	41.9	65.6	37.5	58.09	33.2	57.5	32.9	Pass
Q1	150	85.31	56.9	70.33	46.9	58.03	38.7	57.39	38.3	Pass
L201	130	75.88	58.4	72.32	55.6	69.61	53.5	69.67	53.6	Pass
T3	130	44.05	33.9	43.5	33.5	43.19	33.2	43.24	33.3	Pass
T201	130	82.14	63.2	81.25	62.5	80.84	62.2	80.87	62.2	Pass
T101	130	63.03	48.5	62.14	47.8	61.41	47.2	61.6	47.4	Pass
LS801	130	56.12	43.2	55.85	43	55.62	42.8	55.73	42.9	Pass
LS802	130	66.42	51.1	66.13	50.9	66.04	50.8	66.06	50.8	Pass
CS202	105	68.07	64.8	67.94	64.7	67.92	64.7	68.03	64.8	Pass
CS805	105	59.86	57	59.65	56.8	59.55	56.7	59.63	56.8	Pass
CS213	105	47.51	45.2	47.39	45.1	47.35	45.1	47.49	45.2	Pass
QS805	175	68.06	38.9	67.84	38.8	67.7	38.7	67.8	38.7	Pass
QS806	175	62.14	35.5	61.9	35.4	61.79	35.3	61.95	35.4	Pass
QS803	175	63.75	36.4	63.59	36.3	63.46	36.3	63.56	36.3	Pass
QS804	175	58.38	33.4	58.09	33.2	58	33.1	58.12	33.2	Pass
IC101	125	60.24	48.2	59.55	47.6	59.21	47.4	59.34	47.5	Pass
ICS801	150	54.02	36	53.79	35.9	53.78	35.9	53.91	35.9	Pass
D2	150	60.45	40.3	55	36.7	49.32	32.9	48.88	32.6	Pass
LS101	130	49.03	37.7	48.69	37.5	48.44	37.3	48.52	37.3	Pass
LS201	130	67.69	52.1	67.44	51.9	67.3	51.8	67.29	51.8	Pass
R36	150	84.79	56.5	69.72	46.5	53.95	36	52.71	35.1	Pass
L2	130	77.65	59.7	67.32	51.8	56.93	43.8	56	43.1	Pass
CT201	130	51	39.2	48.91	37.6	47.2	36.3	47.22	36.3	Pass
AMB	—	40	—	40	—	40	—	40	—	—

 

Location	SPEC	FL3								Result
		90V	Derating (%)	115V	Derating (%)	230V	Derating (%)	264V	Derating (%)
QS203	175	77.13	44.1	76.79	43.9	76.67	43.8	76.84	43.9	Pass
QS201	175	85.24	48.7	84.51	48.3	84.19	48.1	84.33	48.2	Pass
QS103	175	56.88	32.5	56.26	32.1	55.73	31.8	55.88	31.9	Pass
CS106	105	57.92	55.2	57.54	54.8	57.4	54.7	57.51	54.8	Pass
FL1	130	71.32	54.9	57.97	44.6	47.19	36.3	46.85	36	Pass
FL3	130	86.15	66.3	68.78	52.9	54.61	42	53.84	41.4	Pass
BD1	150	91.41	60.9	79.81	53.2	61.92	41.3	60.31	40.2	Pass
C6	105	50.78	48.4	48.52	46.2	45.97	43.8	46.05	43.9	Pass
L1	130	106.33	81.8	88.71	68.2	67.78	52.1	64.74	49.8	Pass
Q201	150	78.58	52.4	71.33	47.6	65.26	43.5	65.13	43.4	Pass
Q202	150	71.55	47.7	65.25	43.5	60.02	40	59.86	39.9	Pass
D6	175	72.37	41.4	65.17	37.2	57.73	33	57.28	32.7	Pass
Q1	150	83.64	55.8	69.57	46.4	57.58	38.4	57.16	38.1	Pass
L201	130	74.85	57.6	71.52	55	68.74	52.9	68.95	53	Pass
T3	130	43.84	33.7	43.35	33.3	42.97	33.1	43.21	33.2	Pass
T201	130	80.35	61.8	79.64	61.3	79.06	60.8	79.56	61.2	Pass
T101	130	60.38	46.4	59.55	45.8	58.94	45.3	59.15	45.5	Pass
LS801	130	48.3	37.2	48.02	36.9	47.91	36.9	48.01	36.9	Pass
LS802	130	47.17	36.3	47.01	36.2	46.88	36.1	47.06	36.2	Pass
CS202	105	66.52	63.4	66.32	63.2	66.19	63	66.49	63.3	Pass
CS805	105	48.42	46.1	48.37	46.1	48.17	45.9	48.4	46.1	Pass
CS213	105	46.76	44.5	46.7	44.5	46.52	44.3	46.74	44.5	Pass
QS805	175	49.46	28.3	49.31	28.2	49.19	28.1	49.35	28.2	Pass
QS806	175	46.58	26.6	46.47	26.6	46.27	26.4	46.49	26.6	Pass
QS803	175	49.06	28	48.92	28	48.74	27.9	48.93	28	Pass
QS804	175	48.23	27.6	48.08	27.5	47.8	27.3	48	27.4	Pass
IC101	125	54.92	43.9	54.4	43.5	54.03	43.2	54.25	43.4	Pass
IC801	150	49.17	32.8	49.02	32.7	48.86	32.6	49.01	32.7	Pass
D2	150	59.86	39.9	54.85	36.6	49.13	32.8	48.82	32.5	Pass
LS101	130	46.19	35.5	45.81	35.2	45.56	35	45.74	35.2	Pass
LS201	130	66.39	51.1	66.16	50.9	66	50.8	66.18	50.9	Pass
R36	150	83.47	55.6	69.2	46.1	53.74	35.8	52.59	35.1	Pass
L2	130	76.59	58.9	66.89	51.5	56.69	43.6	55.82	42.9	Pass
CT201	130	50.53	38.9	48.6	37.4	46.93	36.1	47	36.2	Pass
AMB	—	40	—	40	—	40	—	40	—	—

 

Location	SPEC	SB mode				Result
		90V	Derating (%)	264V	Derating (%)
QS203	175	41.14	23.5	41.08	23.5	Pass
QS201	175	42.77	24.4	42.72	24.4	Pass
QS103	175	48.31	27.6	48.29	27.6	Pass
CS106	105	50.28	47.9	50.32	47.9	Pass
FL1	130	42.83	32.9	42.8	32.9	Pass
FL3	130	43.44	33.4	43.45	33.4	Pass
BD1	150	42.6	28.4	42.55	28.4	Pass
C6	105	41.03	39.1	41.05	39.1	Pass
L1	130	40.42	31.1	40.44	31.1	Pass
Q201	150	40.46	27	40.46	27	Pass
Q202	150	40.41	26.9	40.43	27	Pass
D6	175	40.67	23.2	40.68	23.2	Pass
Q1	150	40.46	27	40.48	27	Pass
L201	130	40.66	31.3	40.69	31.3	Pass
T3	130	40.37	31.1	40.3	31	Pass
T201	130	41.47	31.9	41.49	31.9	Pass
T101	130	60.12	46.2	60.14	46.3	Pass
LS801	130	42.22	32.5	42.24	32.5	Pass
LS802	130	41.3	31.8	41.29	31.8	Pass
CS202	105	41.64	39.7	41.64	39.7	Pass
CS805	105	41.46	39.5	41.48	39.5	Pass
CS213	105	40.96	39	40.99	39	Pass
QS805	175	41.85	23.9	41.85	23.9	Pass
QS806	175	41.53	23.7	41.56	23.7	Pass
QS803	175	41.96	24	41.98	24	Pass
QS804	175	42.35	24.2	42.36	24.2	Pass
IC101	125	58.77	47	58.83	47.1	Pass
IC801	150	41.54	27.7	41.55	27.7	Pass
D2	150	42.43	28.3	42.45	28.3	Pass
LS101	130	47.09	36.2	47.1	36.2	Pass
LS201	130	41.58	32	41.58	32	Pass
R36	150	41.05	27.4	41.04	27.4	Pass
L2	130	40.36	31	40.37	31.1	Pass
CT201	130	40.41	31.1	40.45	31.1	Pass
AMB	—	40	—	40	—	—

 

大家都知道電子零件的操作溫度是越低越好，通常零件的操作溫度與壽命成反比的關係，看完這報表是否對於全漢企業的商品比較安心呢？因為多數的零件在不同的滿載條件下操作溫度距離額定降溫值〈Derating〉都還有一段距離，我們也因此可以確定這個產品的可靠度以及輸出穩定度有一定的水準。大家是否對於全漢的實驗室設備好奇呢？我們有哪些設備去測試新產品？下面幾張照片讓大家認識一下我們的實驗室。