When facing reliability test failures, I'll conduct a thorough investigation to understand the root causes. By analyzing test data, consulting expert engineers, and making strategic design modifications, we'll address the core issues. Our approach is systematic: diagnose problems, collaborate on solutions, implement precise improvements, and rigorously retest. The goal is to transform this setback into an opportunity for a more robust and reliable electrical design.

From my experience in the field of substations and even in low-voltage systems, one of the most successful strategies is iteration and testing. We make adjustments to meet design requirements effectively. Occasionally, we rely on the consultation with experts strategy when dealing with specialized designs or addressing issues outside our area of expertise. As for analyzing failure data, this strategy becomes essential when there are problems in the designs or in case of electrical failures.

If an innovative electrical design fails reliability tests, take these steps: 1. Analyze Test Results: Identify failure points and patterns. 2. Review Assumptions: Re-evaluate design assumptions, especially around durability and tolerance. 3. Consult Stakeholders: Gather insights from team members with practical testing experience. 4. Make Adjustments: Revise design to address weaknesses—upgrading components, refining layouts, or adjusting specifications. 5. Test Incrementally: Re-test starting with vulnerable sections to validate improvements. 6. Add Safeguards: Consider redundancies to mitigate critical failures. These steps focus on diagnosing root issues and making targeted changes to meet reliability standards before retesting.

First consider that you mush have developed either a fault tree diagram or FMEA (failure mode and effect analysis) in parallel when you started your design so that you can identify the part that could fail during the reliability test. If you did not, it is highly recommended that you make them a FTA or FMEA. However, check the quality requirements to make sure that you are between the standards and you can apply design for 6sigma that is a good approach to follow as strategy. In my experience, for Low Voltage devices, the faults are related to current transient variation that I a common issue whereas for medium and high voltage devices is the insulation.

An example you can use virtual reality to simulate the electric design under various conditions. This can help visualize potential failure points in a way that traditional testing may not reveal.

To improve a design, imitate and model existing designs to identify weaknesses before hardware testing. Refine designs based on verification findings, such as component selection and circuit robustness. Iterate prototyping to test reliability, requiring weeks of repetitions. Consider manufacturing variables and control tolerances and production methods. Keep an exhaustive record of iterations, including changes and examination techniques, and regularly review with the team and stakeholders to demonstrate progress

Revision with your team your project steps Then make test for sub loops one by one to ensure reliability If not try new strategy

I’d start by breaking down the test data to pinpoint exactly what’s failing and why. Is it a component issue, thermal stress, or something in the circuit layout? Once I know that, I’d bring in a senior reliability engineer to provide a fresh set of eyes. Their perspective might uncover subtle design flaws we overlooked. With clear insights, I’d refine the design—maybe swapping out a problematic component or adjusting our PCB trace layout—then run another set of focused tests. The key is to iterate quickly and methodically until the reliability metrics meet or exceed the required benchmarks.

Others have already covered the critical points for the next steps. I'd like to expand on that further: Revisit design assumptions, using simulation tools like SPICE or Ansys to model scenarios and pinpoint root causes. For example, investigate heat dissipation, material choices, or circuit layout if a power supply overheats. Incorporate advanced components like SiC or GaN for better performance and explore adaptive systems such as real-time thermal monitoring to enhance resilience. Iterative prototyping, collaborating across disciplines, and employing HALT testing can uncover hidden vulnerabilities and refine the design.