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Transcript of Intro to Sherlock_Linkedin
© 2004 – 2010
Your Partner Throughout the Product Life Cycle
© 2004 - 2007© 2004 - 20109000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Who is DfR Solutions?
The Industry Leader in Quality-Reliability-
Durability of Electronics
50 Fastest Growing Companies in the Electronics Industry
- Inc Magazine
2012 Global Technology Award Winner
Best Design Verification Tool- Printed Circuit Design
© 2004 - 2007© 2004 - 20109000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
10 Years of Providing Solutions to the Electronics Marketplace
o DfR / DfM / DfT / DfS….. DfX
o Finite Element / Fluid Dynamics
o Physics of Failure Modeling
o FMEA / FTA
o 3rd Party Design Review
o Failure Analysis
o Root Cause Investigations
o Forensic Engineering
o Circuit Analysis
o Connector/Wiring Selection
o Analog/Power Design
o Material Characterization
o PCB / PCBA Onsite Audits
o Pottings and Coatings
o Software Risk Mitigation
End-to-End Quality and
Reliability Expertise
© 2004 - 2007© 2004 - 20109000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Results: Over 1000 Satisfied Customers
© 2004 – 2010
Sherlock Automated Design
Analysis™
© 2004 - 2007© 2004 - 20109000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
o Physics of Failure-based design reliability analysis tool
o Predicts product failure early in design process, quickly
and accurately
o Electronics-focused –
used across all
industries
What is Sherlock?
6
© 2004 - 2007© 2004 - 20109000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
o First released in 2011
o Over 65 Companies and 150 users worldwide
today
o Renewal rate exceeds 85%
o First specified for automotive supply chain in 2015
o Major global verticals served are Automotive,
Avionics, Aerospace and Defense, Medical Devices
Sherlock Worldwide
7
© 2004 - 2007© 2004 - 20109000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
o Greater Insight Earlier in New Product Development
o Introduces Modeling/Simulation Earlier in the NPI Process
o Eliminate Test Failures Due To Design
o Accelerates product qualification process with fewer respins
o Release Rev1, not Rev3
o Quantitative Tradeoff Analysis (no more Opinioneering)
o Select the right material the first time based on real cost/benefit analysis
o Ensure More Rapid Acceptance Of Newer, More Ground-Breaking Technologies
o Allows for first-to-market with no change in quality
Sherlock Value Proposition
© 2004 - 2007© 2004 - 20109000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
o Sherlock provides the Mechanical Analyst the ability to quickly and accurately develop intelligent 3D models of electronic assemblies
o Finite element simulations are post-processed to identify critical components and predict time to failure
Mechanical
9
© 2004 - 2007© 2004 - 20109000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
o Biggest risk in electronics manufacturing
is post-assembly flexure
o Current risk mitigations are insufficient
o Existing DfM tools only capture solder issues
o Strain measurements are laborious
o Supplier analyses often inaccurate
o Sherlock can rapidly assess all
post-assembly handling operations
o In-Circuit Test, Depaneling, Connector
Insertion, Compliant Pin, Heatsink
Attachment
Manufacturing
10
© 2004 - 2007© 2004 - 20109000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
o Sherlock performs reliability predictions previously not possible
o Commercial off-the-shelf (COTS) assemblies, wearoutof complex integrated circuits (ICs)
o Provides stronger linkage to mechanical group
o Takes results of mechanical and thermal analysis and makes a reliability prediction for thermal cycling, vibration, and shock
o Accelerates traditional design for reliability (DfR) activities
o MTBF, DFMEA, Thermal Derating
Reliability
11
© 2004 - 2007© 2004 - 20109000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
o Pass the test the first time
o Thermal cycling, Power-temperature cycling, sinusoidal
vibration, random vibration, mechanical shock
o Pre-HALT your HALT
o Make HALT an even
more powerful
activity
Test
12
9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
How Does Sherlock Work?
9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Phase 1: Data Input
• Parses standard EDA files (schematic, layout, parts list) automatically
• Uses embedded libraries (part, package, materials, solder, laminate)
• Can build box-level finite element analysis model in minutes
Phase 2: Sherlock Analysis
• Produces holistic analysis critical to develop reliable products
• Easy to assign and create standard structures and conditions
• Assessment options include: Thermal Cycling, Mechanical Shock, Natural
Frequency, Harmonic Vibration, Random Vibration, Bending, Integrated Circuit
Wearout, Thermal Derating, Failure Rate, Conductive Anodic Filament, High
Fidelity PCB Model
Phase 3: Report & Recommend
• Presents results in multiple formats: Tabular / Histogram / Life curve / Overlay
14
9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com15
• Easy-to-locate commands
• Industry terminology (parts list,
stackup, pick & place, etc.)
9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Handles very complex environments
16
9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Import Standard Design Output Files (Gerber/ODB)
17
9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Embedded / Fully Populated Libraries (Local and Global)
Parts/Package/Laminates/Materials/Solder
18
9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com19
FEA 3D Modeling
ICT and Shock/Vibration Analysis
• Fully 3D elements for the PCB,
components and mount points
• Increase simulation accuracy
• More reliable meshing algorithm
• Increased analysis flexibility
• Leads, heat-sinks, sub-
assemblies, chassis analysis
FEA Engine
• Multi-core and 64 bit support
• Faster analysis
9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com20
Leads
Coating/Potting
Traces/Vias
Heatsinks
Wirebonds
9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
• System Level Integration
– Attach one or more sub-assemblies to a
motherboard/backplane
– Supports edge connections or mezzanine
attached with standoffs
– Put it all together and model all of your
electronics and the housing in a single analysis
21
Daughter
Card
Mezzanine Card
22
Mode 1: Sherlock manages all FEA processing
Mode 2: Export model from Sherlock to FEA
Mode 3: Import FEA results into Sherlock for reliability analysis
ElectronicDesign Files
Life CycleConditions
3D Model /Analysis Steps
Pre-Processing
ReliabilityResults
3D Model /Disp Results /Strain Results
Post-Processing
PartsPackagesMaterials
FEATool
FEA
Model Results
FEAScript
SherlockDesign
Analysis
SherlockFailure
Analysis
SherlockData Store
9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Thermal Cycling Fatigue
• Cumulative Damage Index (CDI)
• Time to failure
• Thermal profile and Flowtherm results
23
9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Automated Thermal Derating• Min / Max temperature assigned to
each part (Operating and Storage)
• Sherlock automatically combines operating temperatures with thermal profiles
• Parts that exceed their ratings are flagged
24
9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Vibration/Shock/Bending
• Loading
• Mounting
• Direction
25
26
• Multi-Axis Shock and Vibration Loads
• Specify load direction and/or PCB orientation
• Specify uni-axial or tri-axial harmonic profiles
9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Board-to-Board Connector Fretting Analysis
• Stick (< 2.5 um)
• Stick-Slip (5 – 10um)
• Slip (> 10 um)
27
9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Results Summary• Results tabulated into a score
• Easy report generation– PDF Format
– Includes results and inputs
28
9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
• Only software tool that provides a complete life curve
29
Constant Failure Rate Generic Actuarial MTBF Database
PTH Thermal Cycling Fatigue
Thermal Cycling Solder Fatigue
Vibration Fatigue
Over All Module
Combined Risk
9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com30
Fully
Validated
Wirebonds
Chip ResistorsBGA
QFN
© 2004 - 2007© 2004 - 20109000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
o Global Storage Manufacturer is using Sherlock to eliminate one (1) to two (2) physical tests for EACH PCBA Design
o Ten (10) PCBAs are designed annually
o Engineering labor and hard test costs (Chambers, Samples) are approximately $750,000 per test
o Results in an Annual Savings of $7,500,000
o Sherlock also eliminates two (2) design revs for EACH PCBA
o Time-to-Market Reduced by Six (6) Months
Sherlock Software Case Study 1
31
Global Storage Manufacturer reduces
time-to-market by six (6) months
© 2004 - 2007© 2004 - 20109000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
o In 2013 American Auto Manufacturer Motors begin utilizing Sherlock for electronic module analysis in parallel with its current testing plan. o American Auto Manufacturer believed that Sherlock could accurately
simulate power temperature cycling (PTC) tests and thereby eliminate certain tests, reduce valuable senior engineering time and correspondingly reduce reliability testing costs and time to market.
o Over the course of a twelve-month period, Sherlock identified 4 designs wherein the probability of failure during PTC exceeded the acceptable standard for American Auto Manufacturer. o Had the design moved forward, 4 additional PTC tests would have had
to be performed at a cost exceeding $346,000 each or $1,384,000 over the year
Sherlock Software Case Study 1
32
American Auto Manufacturer® Motors saves
over $1,384,000 in test costs
© 2004 - 2007© 2004 - 20109000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
o Understand the Problem You are Trying to Solve
o Understand the Process for Acquiring Software Tools
o Identify a Design
o Receive One Hour of Sherlock Training
o Complete 30-Day Trial with DfR Technical Support
How to Move Forward With Sherlock
33
© 2004 - 2007© 2004 - 20109000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com34
© 2004 - 2007© 2004 - 20109000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
o Case Study: Replacing Testing with Rapid Assessment
o Working closely with DfR, Tier 1 Automotive
Manufacturer has convinced a Major OEM to replace
elements of Product Qualification (temperature cycling,
vibration, mechanical shock) with a combination of
Sherlock and DfR-led Quality Assessment
o Initial focus on managing design changes and cost reductions
o Time-to-market reduced by 10 weeks and estimated
cost savings of $150,000
Sherlock Software Case Study 3
35
© 2004 - 2007© 2004 - 20109000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
o Case Study: Optimizing Test Conditions and Test Time
o Major HVAC manufacturer was performing extensive thermal cycling and thermal shock on all new designs
o Actual test time was in excess of seven weeks
o DfR used Sherlock ADA software to demonstrate test time was equivalent to 2X desired lifetime
o Sherlock also demonstrated that current test was not stressing the components at greatest risk of failure
o Time-to-market reduced by three weeks and test costs reduced by $50,000
Sherlock Services Case Study 4
36
© 2004 - 2007© 2004 - 20109000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
o A comparison of the performance of various solder joint
fatigue models was tested by Tom Clifford (formerly of
Lockheed Martin)
o Included chip resistors,
LCCC, QFP, and BGA
soldered to a polyimide
board
o Evaluated different
models and had some
models executed by
different users
Validation of Sherlock
37
© 2004 - 2007© 2004 - 20109000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
o “Following discussions with DfR and confirmation of the PCB material, from the supplier, I was able to refine the model for the QFN package and the PCB construction to predict the first failure of a QFN package at around 700 cycles.
It was interesting to note that the PCB material choice significantly altered Sherlock’s predicted solder joint life and choice of PCB material needs to be carefully considered from this perspective.
Subsequent real cycling of the test board has indeed produced a failure at around 770 temperature cycles and so appearing to add some (albeit limited) validation of the Sherlock prediction.
With the refined model failures of well soldered BGA joints were not predicted by Sherlock till around 3000 cycles. Our supplier has now finished the thermal cycles on the real boards seeing no BGA failures after about 1200 cycles.”
Validation – Avionics Manufacturer
38
© 2004 - 2007© 2004 - 20109000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
The cycles to failure prediction
provided by the Blattau
model (50,614 cycles) is within
5% of the observed time to
failure (53,215 cycles).
Validation – Advanced Energy (AEI)
39
© 2004 - 2007© 2004 - 20109000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Thermo King (the customer)
now requires Watlow
(the supplier) to perform a Sherlock analysis
on every new design
Validation – Watlow
40
© 2004 - 2007© 2004 - 20109000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
o With all material and design information
received, Sherlock predicted failure of
I200 (Actel Microcontroller) in just over
300 thermal cycles of -55C to 125C
Validation – GPS Manufacturer
41
© 2004 - 2007© 2004 - 20109000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
o The Atmel device has two die
o This information is in the Atmel datasheet
o Results in a ball grid array (BGA) with a low coefficient of
thermal expansion (CTE)
o The PCB was constructed with TU-622-5 laminate
o This material has a high coefficient of thermal expansion (CTE)
o This material is in the Sherlock laminate library
o Certain part packages (e.g., BGAs) are very sensitive
to differences in CTE
Validation – GPS Manufacturer (cont.)
42
© 2004 - 2007© 2004 - 20109000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Validation – HVAC Manufacturer
43
Summary• Both Test and Sherlock
Simulation results are well
correlated
• Random profile pertaining to
Qualmark HALT chamber is
used for the simulation
© 2004 - 2007© 2004 - 20109000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
o DfR created an ad-hoc Sherlock project using only a
picture and a component
Validation – Satellite Manufacturer
44
o DfR predicted 1016 cycles to first failure and 1693 cycles to characteristic life
o Test data showed 750 cycles to first failure
o No stackup info
o Polyimide board
o Solder fatigue calculator was also used as a standalone tool
© 2004 - 2007© 2004 - 20109000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
o “The Sherlock analysis that DfR solutions did last year predicted that the QFN would fail first during thermal cycling <sic>. At the time last year we did not agree with what Sherlock was telling us, but after lots of $$$ and thermal cycles, Sherlock was right.
It was a very important lesson learned about thermal cycling life of large QFN packages on boards that are epoxy laminated to aluminum chassis<sic>. This is something that we would not have guessed to be a problem. But it was.
Sherlock now has added merit for us to consider using on other new product reliability analyses”
- John DeCamp, Manufacturing Engineer
Validation – ViaSat
45
© 2004 - 2007© 2004 - 20109000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Perfect correlation to testing
Validation – Consumer Electronics Manufacturer
46
Mode1
experimental
Mode2
experimental
Frequency Simulation Experiment Difference
Homogenous
Layered Model
Mode1 307.4 Hz 307 -0.13%
Mode2 439 Hz 456 -3.7%
Mode3 796 Hz - -
© 2004 - 2007© 2004 - 20109000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Validation – GPU Manufacturer
47
© 2004 - 2007© 2004 - 20109000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
o Solder joint cracking was
occurring during In-Circuit Testing
(ICT)
o Customer asked if Sherlock could
be used to predict the cracking
since it had an internal FEA tool
o Customer supplied ODB++ files
and test point information of the
assembly with cracks.
o Sherlock predicted all cracks plus
hairline cracks
Validation – Plexus (In-Circuit Testing)
9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Sherlock Automated Design Analysis™ software is the go-to
electronics reliability tool used by designers and engineers across
every major industry.
Sherlock can help you design more reliable products faster and
more efficiently!
Reduced NPI time
Lower Development Costs
Better Decisions
Faster Time to Market
49
9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
Back Up Slides
50
9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com
DFMEA
• The only Design Failure Mode Effects Analysis (DFMEA) software dedicated to electronics
51
Current DFMEA Tools (cont)
Sherlock – DFMEA module
– Module in Design Reliability Assessment tool
– Imports data from BOM or ODB++ design files (generated by PADS / Expedition)
» Later in design cycle than desired
» Earlier than typically being done today
» Facilitates integrating Reuse into DFMEA
– Highest level of automation – Standardized but customizable
– Common formatting – Can import / export to Excel
– Generates DFMEA by “Subcircuit” (Reuse Function)
– SEV / DET based on Standard Practices (Design Standards, etc.)
– OCC (Occurrence Rating)
» Based on component Reliability Predictions
Delphi Warranty Database
Multiple Industry databases
» Future:
Mission profile will drive reliability predictions / OCC
BaselineComponent Level DFMEA Generation
Schematic
Parts List
• Circuit Function / SubFunction / Sub-SubFunction
• Reference Designator
• Part Number
SherlockDesign Assistant
Delphi
Component
Database
(DMS)
Failure Rate ClassDelphi
DFMEA
Data Source
Failure Rate Class
• Failure Rate
• Failure Modes
• Fail Mode Distribution
Default:
• SEV, OCC, DET
• Failure Cause
• Failure Effects
• Preventions
• DetectionsBaseline DFMEA Assumes:
• Typical Application
• Not Safety Related
Description, properties