Case study of switch contact failure analysis

Appearance inspection, electrical verification, and internal observation using X-rays conducted! Introduction of analysis cases.

Since a malfunction was suspected at the switch part of the appliance that would not power on, we will introduce analysis cases along with the work flow. First, we check for any shape changes such as swelling, cracking, or discoloration through visual observation. In the electrical check, we confirm whether the malfunction can be reproduced and whether it is an open or short circuit. Internal observation using X-rays revealed that the contact terminals inside the switch had melted, scattered, and disappeared, resulting in an open failure. Ultimately, we will submit a report that includes an analysis of the cause. We also welcome inquiries regarding analysis consultations after non-destructive testing, so please feel free to reach out. 【Basics of Non-Destructive Observation】 ■1: Visual Confirmation ■2: Electrical Confirmation ■3: Internal Observation with X-rays *For more details, please refer to the PDF document or feel free to contact us.

• Non-destructive testing

We undertake contract processing and manufacturing of cross-sections of various parts and materials.

At Aites, we undertake the processing of cross-sections of various components and materials, including electronic components, mounted circuit boards, semiconductors, compound semiconductors, power devices, films, resin molded products, solar panels, and LCD glass. We also conduct observations and analyses of the produced cross-sections, providing services for defect analysis and quality evaluation. 【List of Services】 ■Mechanical polishing ■CP processing ■Microtome ■FIB processing ■Analysis of semiconductor diffusion layers, etc. *For more details, please refer to the PDF document or feel free to contact us.

• Other analytical equipment

X-ray CT observation allows for the assessment of the winding condition of coil wiring! We will introduce examples of observing IC-type coils, which differ from X-ray transmission observation.

Here are some examples of observations of IC-type coils. Through X-ray observation, we can clearly capture the internal structure by using methods suited to the purpose. In transmission observation, we can quickly detect metal foreign objects, and in CT observation, we can obtain three-dimensional images of any cross-section, making it suitable for observations where positional information and shape are important. Unlike transmission observation, we can also assess the winding condition of the coil wiring. *For more details, please refer to the PDF materials or feel free to contact us.

• Analysis and prediction system

X-ray fluoroscopic observation, oblique CT observation, orthogonal CT observation, etc.! Introduction of BGA solder crack analysis cases.

We will introduce a case study of BGA solder crack analysis using X-ray imaging and CT scanning. When observing the BGA connection area of a circuit board that had become electrically open using X-ray imaging, cracks were confirmed to have occurred at the BGA connection. Additionally, we examined the cracks in the solder connection observed through X-ray imaging using oblique CT. Oblique CT provides clear planar information, but spherical shapes like solder balls and voids appear elongated in the vertical direction due to specific factors of oblique CT. While it is difficult to obtain cross-sectional information about the cracks occurring at the solder joint interface, there is the advantage of being able to observe the circuit board non-destructively. [Analysis Cases] ■ X-ray imaging observation ■ Oblique CT observation ■ Orthogonal CT observation ■ Cross-sectional observation *For more details, please refer to the PDF document or feel free to contact us.

• others

Observation of the misalignment of the internal metal plate! This is a case study of a toggle switch observed through X-ray fluoroscopy and orthogonal CT observation.

A defective toggle switch component was found where the operating lever does not switch. As a result of X-ray fluoroscopic observation, it was observed that the internal metal plate was misaligned, revealing the cause of the defect. In this case, the metal plate is supposed to move like a seesaw around the central terminal to switch the circuit, but in the defective product, the metal plate is misaligned, preventing the lever from switching to the opposite side and thus making circuit switching impossible. CT observation provides not only 3D images but also arbitrary slice cross-sectional images in the X, Y, and Z directions. [Observation Case] ■ Subject: Toggle Switch ■ Observation Method: X-ray fluoroscopic observation, orthogonal CT observation ■ Cause of Defect: Misalignment of the internal metal plate *For more details, please refer to the PDF document or feel free to contact us.

• others

From June 2025, measures against heat stroke in the workplace have become mandatory. Additionally, in December 2026, a "Support Package for Heat Wave Measures in Construction Work" was formulated, making heat stroke prevention during the summer a pressing issue, especially for those engaged in the construction industry. This time, we provide a collection of heat stroke prevention materials that can be utilized through Sysmet Co., Ltd.'s comprehensive weather platform, ZEROSAI X-AI. Examples of heat stroke prevention measures possible with ZEROSAI X-AI: - Cloud management of heat stroke information - Forecasting of the heat index (WBGT) tailored to the site with a mesh of 500m for up to 17 days ahead - Observation of the heat index (WBGT) in compliance with JIS standards using a black globe thermometer - Alerts for exceeding work standard values for the heat index (WBGT) via electronic bulletin boards, emails, and business chat tools like direct LINE WORKS We hope this will be useful at your sites as well.

The "HA-T Series" is an energy-saving automatic door sensor that opens only for those who want to enter, whether on a busy street or in a narrow passageway. The automatic door opens simply by bringing your hand close, addressing hygiene concerns even in facilities used by a large number of people. Depending on the application and installation location, you can choose between "Non-vision Mount Type/HA-T401" and "Non-vision Built-in Type/HA-T520." 【Recommended for such places!】 ☑ Entrance facing a busy passageway ☑ Presence of counters or signs near the door ☑ Buildings facing narrow passageways ☑ Buildings that prioritize aesthetics ☑ Hospitals and facilities that consider hygiene ☑ Large facilities with many doors 【Features】 ● Adaptable to various door types with four detection spot settings ● Reduces unnecessary opening and closing to minimize power consumption, contributing to energy-saving effects ● Equipped with a light touch function, allowing the door to open and close simply by waving your hand, ensuring hygiene ● Can also be used as a wide detection range non-vision infrared sensor ◎ For more details, please download the materials or contact us.

In facilities operating nurse call systems, we have made bed exit sensors wireless, allowing them to notify in conjunction with the nurse call system. By simply connecting the mat sensor "Foldable Thin Matt-kun," the body movement call "Ugo-kun," and the wheelchair body movement call "Ayumi-chan" to the transmitter HB-RS, you can make the bed exit sensor wireless. The infrared sensor "Just Place Pole-kun" has the transmitter HB-RS built-in. This helps prevent accidents caused by falls, slips, or wandering, contributing to the efficiency of medical operations. 【Features】 ○ Wireless conversion by simply connecting existing sensors to the transmitter HB-WSK. ○ Bed exit sensors notify wirelessly in conjunction with the nurse call system. ○ Up to 5 transmitters can be registered with one receiver. ○ The communication distance between the transmitter and receiver is approximately 10 meters. ◎ For more details, please contact us or download the catalog.

We have introduced Majesta Fragrance at a cabaret club located in Shizuoka Prefecture. We have selected scents tailored to each space, including the floor, VIP rooms, and restrooms, to provide a total fragrance experience within the establishment. 【Key Points of Introduction】 - Space-specific presentation: By changing the scent for each area, we create a luxurious atmosphere that remains fresh and engaging. - Branding that resonates with the five senses: We support the creation of a venue that is chosen not only for its visual appeal but also for its fragrance. - Offering an extraordinary experience: The moment customers open the door, they are invited into a special time. Majesta Fragrance is also available for free trial installation. If your company or establishment is interested in scent presentation, please feel free to contact us.

A popular garage with power supply, "EV Garage," will open in Tachikawa City. It can be conveniently used with interior lighting and power supply. The full-opening shutter and some models come with shelves for added convenience. Security is also fully equipped, allowing you to use your valuable vehicles, such as motorcycles and cars, with peace of mind. 【Notes on the Premium Type with Power Supply】 - If the electricity usage exceeds 50 kWh/month, an additional charge will be applied. - The maximum output is 20A. Restoration after a breaker trip will be handled at a later date.