This circuit is a relay board used to control heaters in a portable spa. The circuit failed after several years of operation. At the time of failure, the unit was operating a heating cycle. Heating water to its rated temperature. The failure was not caused by the operator. The circuit board is charred from high electrical current. The failure failed safely. Only this one circuit was damaged. The main controller circuit was not damaged. During an extended heating cycle, the relay on the left failed. The relay appears to be under rated for this application. Interestingly, the replacement circuit had been redesigned. The service technician commented, "Yeah, we've replaced a lot of these.".
When is a failure considered a design flaw?
We provide failure analysis services to product manufacturers, insurance companies and law firms. The reliability of electrical circuits is paramount in today's consumer driven world. Electronics fail by inadequate design, mishandling or inappropriate use. Large insurance claims require validation before settling. We inspect product failures to determine the initial point of failure. Secondly, we determine the root cause of the failure. And thirdly, we determine repair options or design changes to prevent future failures.