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

―― Is attendance management becoming a "burden" without you realizing it? A seminar to quickly learn about common issues and their solutions ―― We will be holding our attendance management web seminar in October, which takes place several times a year! The content is new, so whether you have participated in our webinars before or not, please feel free to join us. Date and Time: October 15 (Wednesday) 13:00- October 22 (Wednesday) 11:00- *Both days will cover the same content *Please check the link below for registration. In this seminar, we will recreate common situations in the workplace in a short drama format for easy understanding, and introduce specific solutions to each issue. This content is especially recommended for those who think, "I'm not struggling now, but I want to know information for the future." Common workplace "situations" can be a trigger for improvement. We will clearly present the challenges and countermeasures of attendance management. Recommended for: ❏ Those who take a long time to compile monthly attendance ❏ Those who tend to postpone compliance with legal revisions ❏ Those who currently have no major complaints but want to know hints for improvement ❏ Those who want to refer to initiatives and examples from other companies

On Monday, September 22, the Japan Meteorological Agency announced its three-month forecast for October to December. Due to the continued influence of conditions similar to the La Niña phenomenon until around December, the westerly winds are expected to flow more to the north than usual from October to early November, making it likely that warm air will cover the entire country. From late November to December, the westerly winds are expected to meander southward near Japan, and there may be periods when the winter pressure pattern strengthens. In December, the region is likely to be affected by cold air, and temperatures in western and eastern Japan are expected to be around or lower than the average for the season. For more details, please visit our website.

PTC Japan will support the CAR and DRIVER team, a car magazine founded in 1978, which will participate in the 36th "Media Challenge Roadster Endurance Race" held at Fuji Speedway on Saturday, October 4, 2025, continuing from last year.

PTC announced today the release of an AI assistant that supports Arena's Product Lifecycle Management (PLM) and Quality Management System (QMS). The Arena AI Assistant provides context-specific expertise and optimal operational methods in a conversational format in real-time for tasks related to Product Lifecycle Management (PLM) and Quality Management (QMS). This enables user teams to realize value in a shorter amount of time.

The seventh installment of the beginner-friendly 3D CAD Creo Parametric tutorial series focuses on features suitable for designs using frames, such as aluminum and sheet metal. It allows for easy realization of 3D solid structures.