Summary of fuse testing for barrel module fuse boxes
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Summary of Fuse Testing for Barrel Module Fuse Boxes. Duke University Jack Fowler. Fuse Box Production Summary. Fuse Boxes have been in production for ~ 12 months 35 sets of each type are being produced This involves > 7500 fuses Fuses were delivered from Oct 03 until Aug 04.

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Summary of Fuse Testing for Barrel Module Fuse Boxes

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Summary of Fuse Testing for Barrel Module Fuse Boxes

Duke University

Jack Fowler


Fuse Box Production Summary

  • Fuse Boxes have been in production for ~ 12 months

  • 35 sets of each type are being produced

  • This involves > 7500 fuses

  • Fuses were delivered from Oct 03 until Aug 04


Fuse Box Production Steps

  • Assemble Fuse Box components and solder

  • Test Fuse Resistance

  • Clean Fuse boxes and dry

  • Test Fuse Resistance

  • Dry fuse boxes for minimum 3 hrs at < 55° C

  • Conformal coat fuse box components

  • Final Test Boxes - continuity at < 100 V and check for breakdown at 2 kV

  • Final assembly – add hardware and heat shrink and label cables


Fuse Boxes


Post Production Tests

  • Once fuse boxes are through the final test, we perform simple resistance test on each of the fuses.

  • In the period of time between tests, the fuse boxes are stored on a shelf in the lab.


Failed Resistance Test Post Production


Fuse Recovery

  • The recovery was performed by applying ~ 600 V through a 6 MΩ resistor to all of the fuses. This applied ~ 100 µA current. This was applied for 1 minute.

  • The fuse resistance was tested and the results recorded.


Fuse Recovery


Fuse Conditioning after Recovery

  • After recovery, all of the fuse boxes were connected in parallel and a 100 µA current was applied.

  • The fuse boxes were left in this condition.

  • After 2 weeks, half of the boxes were removed and the fuse resistance was tested. This included ~3500 fuses.


Fuse Box Conditioning


Fuse Box Connections


Fuse Tests after Two weeks of Conditioning


Summary

  • Before recovery and conditioning, fuse failures seemed to be stabilizing at ~ 0.1 % per week.

  • Recovery was successful for 60 % of previously failed fuses.

  • After 2 weeks of conditioning, 33 % of “recovered” fuses failed.

  • During 2 weeks of conditioning, an additional 8 fuses failed. This equates to ~ 0.1%/week.

  • An additional 3 of the “recovered” fuses failed 1 week later bringing the failure rate to 40 %. No new fuses failed.


Future Plans

  • Continue conditioning for the remaining half of the fuse boxes for 2 more weeks.

  • Continue testing post conditioned fuses weekly for additional failures.

  • Continue new design of fuse box without fuses. Resistors will take the place of the fuses.


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