Suresh Goyal

Improving impact tolerance of portable electronic products : Case study of cellular phones

This paper uses analysis and high-speed photography to study the impact tolerance of cellular phones. Thin-walled clamshell case construction, which is currently favored for portable products due to its size and weight advantages, may not provide sufficient rigidity to impact-induced loads, which can cause the housing to separate when dropped. A simple method for increasing case rigidity—castellation of the housing interface to prevent slipping of the case halves—that can substantially improve the products drop tolerance is presented. Implementation of variations of this technique in existing cellular phone designs allows the phones to surpass their drop survivability requirements. In addition, it is shown that the traditional construction method for cellular phone battery packs could lead to fracturing of the battery housing in a drop due to the multiple impacts that result. The authors describe a simple remedy—immobilization of the battery cells within the housing—that dramatically improves the battery packs drop performance.

Shock Protection of Portable Electronic Products: Shock Response Spectrum, Damage Boundary Approach, and Beyond

The pervasive shock response spectrum (SRS) and damage boundary methods for evaluating product fragility and designing external cushioning for shock protection are described in detail with references to the best available literature. Underlying assumptions are carefully reviewed and the central message of the SRS is highlighted, particularly as it relates to standardized drop testing. Shortcomings of these methods are discussed, and the results are extended to apply to more general systems. Finally some general packaging and shock-mounting strategies are discussed in the context of protecting a fragile disk drive in a notebook computer, although the conclusions apply to other products as well. For example, exterior only cushioning (with low restitution to reduce subsequent impacts) will provide a slenderer form factor than the next best strategy: interior cushioning with a “dead” hard outer shell.

Optical MEMS devices for telecom systems

As telecom networks increase in complexity there is a need for systems capable of manage numerous optical signals. Many of the channel-manipulation functions can be done more effectively in the optical domain. MEMS devices are especially well suited for this functions since they can offer large number of degrees of freedom in a limited space, thus providing high levels of optical integration. We have designed, fabricated and tested optical MEMS devices at the core of Optical Cross Connects, WDM spectrum equalizers and Optical Add-Drop multiplexors based on different fabrication technologies such as polySi surface micromachining, single crystal SOI and combination of both. We show specific examples of these devices, discussing design trade-offs, fabrication requirements and optical performance in each case.

The dynamics of multiple pair-wise collisions in a chain for designing optimal shock amplifiers

The major focus of this work is to examine the dynamics of velocity amplification through pair-wise collisions between multiple masses in a chain, in order to develop useful machines. For instance low-cost machines based on this principle could be used for detailed, very-high acceleration shock-testing of MEMS devices. A theoretical basis for determining the number and mass of intermediate stages in such a velocity amplifier, based on simple rigid body mechanics, is proposed. The influence of mass ratios and the coefficient of restitution on the optimisation of the system is identified and investigated. In particular, two cases are examined: in the first, the velocity of the final mass in the chain (that would have the object under test mounted on it) is maximised by defining the ratio of adjacent masses according to a power law relationship; in the second, the energy transfer efficiency of the system is maximised by choosing the mass ratios such that all masses except the final mass come to rest following impact. Comparisons are drawn between both cases and the results are used in proposing design guidelines for optimal shock amplifiers. It is shown that for most practical systems, a shock amplifier with mass ratios based on a power law relationship is optimal and can easily yield velocity amplifications of a factor 5-8 times. A prototype shock testing machine that was made using above principles is briefly introduced.

Design for reliability of MEMS/MOEMS for lightwave telecommunications

Optical Micro-Electro-Mechanical Systems (Optical MEMS, or MOEMS) comprise a disruptive technology whose application to telecommunications networks is transforming the horizon for lightwave systems. The influences of materials systems, processing subtleties, and reliability requirements on design flexibility, functionality and commercialization of MOEMS are complex. A tight inter-dependent feedback loop between Component/ Subsystem/ System Design, Fabrication, Packaging, Manufacturing and Reliability is described as a strategy for building reliability into emerging MOEMS products while accelerating their development into commercial offerings.

A predictive model for impact response of viscoelastic polymers in drop tests

We show for the first time that a classical Hookean viscoelastic constitutive law for rubbery materials can predict the impact forces and deflections measured with a commercial drop tester when a mass, or “tup” with a flat impacting surface is dropped onto a flat pad of commercial impact-absorbing rubber. The viscoelastic properties of the rubber, namely the relaxation times and strengths, are obtained by a standard rheological linear-oscillatory test, and the equation of momentum transfer is then solved, using these measured parameters, assuming a uniaxial deflection of the pad during the impact. Good agreement between measured and predicted forces and deflections is obtained for a series of various drop heights, tup masses, impact areas, and pad thicknesses, as long as the deflection of the pad relative to its thickness is small or modest (<50% or so), and as long as the area of the pad is less than or equal to that of the tup. When the pad area is greater than the tup, forces are higher than predicted, unless an empirical factor is introduced to account for the nonuniaxial stretching of the ring of material that extends outside of the impact area. These results imply that the impact-absorbing properties of a rubbery polymeric material can be assessed by simply examining the materials linear viscoelastic spectrum.

Piecewise analysis and modeling of circuit pack temperature cycling data

Temperature cycling environmental stress testing (EST) of circuit packs is a standard test procedure for the precipitation of latent defects in order to minimize early product lifecycle customer returns. EST is an expensive, energy-intensive bottleneck in the manufacturing process, one that is based on empiricisms that may be out of date. This presents great opportunity for optimization and test cost reduction. This paper describes the characterization of temperature cycling through analysis and modeling of process data in order to optimize the test parameters — ramp rate, temperature extremes, dwell times, and number of cycles. Failure data from circuit packs tested at a Lucent facility is analyzed using a regression technique and graphical inspection. The dwell and ramp periods of the test are considered in a piecewise manner. A cost model is applied based on distributions fitted to the failure data. The analysis yields a methodology for the dynamic, value-based optimization of temperature cycling EST.

Quantitative Prediction of Impact Forces In Elastomers

We measure the impact forces and deflections resulting from drop tests of a mass with a flat impact surface onto flat pads of various elastomeric materials, and show that the forces can be predicted quantitatively with no adjustable parameters by using a theory whose only inputs are the linear viscoelastic characteristics of the material, measured in small-amplitude oscillatory deformations. The theory, which models the elastomer as a nonlinear neo-Hookean material, is accurate for several elastomeric solids including polyurethanes, polynorbornene, and poly-vinyl-chlorides (PVCs), over a wide range of impact velocities, masses, temperatures and pad thicknesses. Some steps are taken to extend the model to surfaces which are not flat. The application in mind is the rational design of elastomeric components in impact-tolerant portable electronic equipment.

Thermal test scheduling using constraint programming

Abstract Temperature cycling test is one of the key stages in the process of testing circuit packs in telecommunications. To obtain a good overall test schedule requires that the thermal test is carried out efficiently i.e. with the minimum number of runs and valid configurations of packs at each run. However, finding valid configurations and building them into a minimal thermal test schedule is a difficult combinatorial problem. Constraint Programming allows both a way of modelling the rules of configuration and formulating a model to derive an optimal number of runs. We describe this model and the results obtained from it for a large multi-national telecommunications manufacturer.

Safe zones for shock-protection of fragile components during impact-induced clatter

Clattering motion that occurs when flat objects strike the ground at an oblique angle is studied through a simple, tractable, model of a rigid bar with arbitrary, but symmetric, mass distribution and coefficient of restitution. The maximum velocity changes, or velocity shocks, that occur at various locations of the bar as it clatters to rest, are presented. It is shown that different parts of the bar can be subjected to sequences of velocity changes that are both higher, and lower, than those encountered in a single clatter-free impact. The implication that the drop-tolerance of an electronic product can be increased by configuring it to have ‘safe zones’ – where the velocity shocks are lower – for the placement of fragile components, is analysed. It is shown, through example, that a significant safe zone can be created in the center of the product by configuring it to have a low moment of inertia and by minimizing coefficient of restitution.