We all know that the reliability of power modules directly determines the operational stability of the entire system. However, this critical component often faces various failure risks. Below, we briefly analyze the five most common power module failures and their causes.

I. No Output Voltage

— Typical Symptoms: Equipment fails to start completely or suddenly stops working

— Primary Causes:

1. Abnormal input power (overvoltage/undervoltage, wiring errors)

2. Internal fuse blown

3. Power device failure (e.g., MOSFET breakdown)

4. Output short circuit triggering protection circuit

II. Voltage Instability

— Typical Symptoms: Unstable device operation, random reboots, or data anomalies

— Primary Causes:

1. Input voltage fluctuations exceeding the module's regulation range

2. Load changes too abrupt for the module's dynamic response capability

3. Aging feedback loop components (e.g., capacitor capacitance decay)

4. PCB layout flaws causing noise interference

III. Overheating Failure

— Typical Symptoms: Hot housing, derated performance, reduced lifespan

— Primary Causes:

1. Inadequate thermal design (insufficient heatsink size, lack of air cooling)

2. Excessively high ambient temperature or poor ventilation

3. Efficiency degradation leading to increased losses (e.g., capacitor ESR rise)

4. Overloaded operation exceeding rated power

IV. Abnormal Noise

— Typical Manifestations: High-frequency whistling, crackling, or other unusual sounds

— Primary Causes:

1. Loose or saturated transformer/inductor cores

2. Piezoelectric effect in ceramic capacitors

3. Switching frequencies entering audible range

4. Mechanical resonance in components

V. Intermittent Failures

— Typical Manifestations: Intermittent operation, failure under specific conditions

— Primary Causes:

1. Poor solder joints or connector contact issues

2. Degradation of temperature-sensitive components (e.g., electrolytic capacitors)

3. Partial discharge due to aged insulation materials

4. Crack propagation caused by mechanical stress

      By thoroughly understanding common failure modes, implementing systematic preventive measures, and establishing scientific maintenance strategies, equipment reliability can be significantly enhanced. Selecting high-quality power module suppliers and building long-term technical partnerships often yields more professional application support and more reliable quality assurance.