summary of fuse testing for barrel module fuse boxes
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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.

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fuse box production summary
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
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
post production tests
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.
fuse recovery
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 conditioning after 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.
summary
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
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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